Abstract
Horizontal Single Belt Casting of strips is a green strip casting technology, potentially capable of replacing current DC and slab caster operations. As-cast strip bottom surface quality is a key factor for the near-net shape casting operations. The meniscus behavior at the triple point of gas, substrate, and liquid metal, where the melt first touches the moving belt is important to surface quality, as is the way in which the melt behaves while in subsequent contact with the chill substrate. In this paper, meniscus behavior and fluid flow mechanisms were analyzed and predicted through mathematical modeling, using COMSOL software. It was found that the backwall gap, combined with melt vertical inlet velocity through the tundish nozzle slot, and the belt speed, dominated meniscus behavior. The backwall gap must be pre-set to be less than the critical gap size in order to prevent melt “back flows” and leaking accidents. The mathematical modeling of meniscus behavior and fluid flow was further supported by physical water modeling, and was validated through HSBC simulator tests using aluminum alloys.
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