Molten Steel Flow Research Articles

Features of real-time modeling of steelmaking processes using unreal engine 5

This paper explores the features of real-time modeling of steelmaking processes using Unreal Engine 5, focusing on the visualization and simulation of continuous casting machine (CCM) operations. The study highlights the advantages of interactive and virtual reality (VR) technologies in the training and optimization of metallurgical processes, providing a safer and more cost-effective alternative to traditional training methods. A detailed approach to 3D modeling of CCM components is presented, including the tundish, mold, secondary cooling system, and roller sections, with a focus on their realistic visualization and optimization for real-time performance. The implementation of physical simulations using Chaos Physics and Niagara in Unreal Engine 5 allows for an accurate rep-resentation of molten steel flow, solidification dynamics, and temperature gradients. Addi-tionally, gamification elements have been integrated to enhance user interaction, enabling students and engineers to explore various operational parameters in a controlled virtual envi-ronment. The research also assesses the efficiency of digital simulation techniques compared to conventional learning methods in metallurgical training programs. The use of VR-based in-teractive learning modules improves engagement and comprehension by allowing users to manipulate casting parameters and observe the impact on the final product in real-time. The paper concludes that Unreal Engine 5 provides an effective platform for modeling complex industrial processes, offering high-quality visual representation, dynamic interaction, and immersive training experiences for metallurgical professionals. Future work will focus on enhancing AI-driven adaptive learning, expanding the simu-lation scope to include additional steelmaking stages, and integrating augmented reality (AR) tools to bridge the gap between virtual training and real-world applications.

Numerical Simulation of the Influence Mechanism of Melt Rate Variation on the Macrosegregation of 8Cr4Mo4V-Bearing Steel During Vacuum Arc Remelting

In this study, 8Cr4Mo4V steel was selected as the research material to develop a numerical model of the macrosegregation phenomenon during vacuum arc remelting (VAR). The accuracy of the model was validated by comparing it with the literature and experimental results. According to the simulation results, molten steel flows down along the solidification front, resulting in positive segregation at the center and negative segregation close to the edge of the ingot. Solute enrichment reduces the undercooling of the alloy system, which in turn decreases the local solidification rate and causes a slight increase in steady-state molten pool depth. Notably, as the molten pool depth increases, the temperature gradient decreases, while the local cooling rate remains nearly constant, which leads to an increase in the local solidification rate again. Consequently, the positive segregation degree at the ingot’s center is gradually alleviated, and the depth of the molten pool gradually decreases. Furthermore, macrosegregation in VAR ingots becomes pronounced with an increase in melt rate. The main reason for this is due to the increased molten pool depth when the melt rate is increasing, which strengthens fluid flow and accelerates the migration of solute elements to the center. Additionally, due to the increase in the extent of solute enrichment when the melt rate is increasing, the degree of fluctuation in both the steady-state molten pool depth and positive segregation increases.

Flow Behavior and Solute Distribution in the Second Cooling Zone of Continuous Casting of GCr15 Bearing Steel Regulated by Combined Magnetic Fields

GCr15 bearing steel is prone to center segregation and center crack during continuous casting, which is caused by irregular flow behavior and uneven distribution of solute. In this article, two‐stage combined magnetic fields of high‐frequency and low‐current and low‐frequency and high‐current are used to regulate the flow behavior of 30% solid phase ratio and 60% solid phase ratio in the secondary cooling zone, respectively. The distribution of solute in the final solidified structure can be homogenized by the fine control of macroscopic flow and microscopic inter‐dendrite flow under the combined magnetic field. The results show that the rotational flow of molten steel is accelerated with lower solidification rate by the first stage of electromagnetic stirring. Therefore, the solute concentration in the liquid phase increases with the increase of magnetic induction intensity. In the second stage of electromagnetic stirring, the dendrites are broken by micromagnetohydrodynamic effect and the solute segregation decreases.

Influence of Processing Parameters on Flow Behaviour of Ultra-Large-Section Beam Blank Continuous Casting Mould.

The complex cross-sectional shape of oversized beam blanks and the size effect of ultra-large-section beam blanks create severe issues related to the surface and internal quality of the castings. To ensure quality and control in the production of ultra-large-section beam blanks, a numerical and physical model of molten steel flow in the three-port submerged entrance nozzle (SEN) mould, with section dimensions of 1300 × 510 × 140 mm, was established. This model was created using numerical simulations and NSGA-II genetic algorithm optimisation, and the impact of the casting speed and SEN immersion depth on the mould's flow behaviour was investigated. The results showed that a deeper SEN immersion depth resulted in, a greater impact depth of the molten steel, and the surface flow velocity decreased. Both the impact depth and the surface flow velocity of the molten steel increased with increasing casting speed. The physical simulation and numerical simulation of the molten steel flow form and flow velocity distribution in the mould were in good agreement with each other, thus verifying the accuracy of the numerical simulation. The process parameters derived from this study were all within an appropriate range, which can help to improve the quality of continuously cast beam blanks. This also provides guidance for selecting optimal parameters for actual continuous casting production processes.

Inclusion Transfer Phenomenon under Unsteady Multiphase Flow during Rheinstahl–Heraeus Vacuum Treatment Process

Inclusion particles are extremely harmful to the quality of steel products, and Rheinstahl–Heraeus (RH) vacuum treatment is the key process to remove the inclusions from molten steel. By coupling analyzing the unsteady gas–liquid flow and decarbonization reaction, the inclusion mass/population conservation model is developed to explore the inclusion particles transfer phenomenon during RH vacuum treatment process. The coupling mathematical models are validated by the metallurgical experimental data. The results show that the predicted inclusion mass concentration in unsteady CO–Ar–molten steel multiphase system has significantly smaller relative error than that in steady Ar–molten steel flow. CO bubble plays a key role in the inclusion transfer phenomenon, which prompts the inclusion transport, the collision‐aggregation, and the removal process. At the 4th minute of vacuum treatment, the average inclusion volume concentration and the average inclusion number density in CO–Ar–molten steel are 72.75% and 64.62% of those in Ar–molten steel, respectively. The average inclusion characteristic radius in CO–Ar–molten steel is 7.33% larger than that in Ar–molten steel.

Enhancement of mass transfer in converter by improving the flow of slag and molten steel

Enhancement of mass transfer in converter by improving the flow of slag and molten steel

Removal and distribution behaviors of inclusion particles in the steel melt under different rotation modes during continuous casting

This work investigated the removal and distribution behaviors of non-metallic inclusion particles caused by the flow of molten steel under two rotational modes, i.e. from edge to center (E-C) and from center to edge (C-E). Three-dimensional mathematical models discovering the relation between fluid flow, temperature distribution, solidified shell growth of large round bloom, and the movement of inclusions were established to investigate the mechanism of the differences. The obtained results show that under the C-E rotational mode, the removal rate of inclusions is 7 times and the highest local agglomeration number density of inclusions is reduced by 38.4 % compared to the E-C rotational mode. The current work proposes that the C-E rotating flow of molten steel can effectively raise the removal and uniform distribution of inclusions, thereby providing a new strategy for effective control of inclusion during the continuous casting process utilizing the novel electromagnetic metallurgy.

Optimization Design of Submerged-Entry-Nozzle Structure Using NSGA-II Genetic Algorithm in Ultra-Large Beam-Blank Continuous-Casting Molds.

To achieve uniform cooling and effective homogenization control in ultra-large beam-blank molds necessitates the optimization of submerged-entry-nozzle (SEN) structures. This study employed computational fluid dynamic (CFD) modeling to investigate the impact of two-port and three-port SEN configurations on fluid flow characteristics, free-surface velocities, temperature fields, and solidification behaviors. Subsequently, integrating numerical simulations with the non-dominated sorting genetic algorithm II (NSGA-II) and metallurgical quality-control expertise facilitated the multi-objective optimization of a three-port SEN structure suitable for beam-blank molds. The optimized parameters enabled the three-port SEN to deliver molten steel to the meniscus at an appropriate velocity while mitigating harmful effects such as SEN port backflow, excessive surface temperature differences, and shell thickness reduction due to fluid flow. The results indicated that the three-port SEN enhanced the molten-steel flow pattern and mitigated localized shell thinning compared with the two-port SEN. Additionally, the optimized design (op2) of the three-port SEN exhibited reduced boundary layer separation and superior fluid dynamics performance over the initial three-port SEN configuration.

Numerical Simulation of Molten Steel Flow Field in a Ladle Induced by Low‐Frequency High‐Power Ultrasound

Numerical Simulation of Molten Steel Flow Field in a Ladle Induced by Low‐Frequency High‐Power Ultrasound

Influence of Different Submerged Entry Nozzles for Continuous Casting of Ultrathick Slab

Controlling the flow activity at the meniscus in the mold during the continuous casting of ultrathick slab is challenging due to the complex flow behavior, which is not extensively documented. Herein, a multiphase transient model of the ultrathick slab mold has been developed to describe the flow of molten steel, velocity distribution, and stream pattern at different submerged entry nozzle (SEN) outlets. The position of impact points and the fluctuation of liquid level are discussed as well. After ejecting from the port, the stream of the S‐shaped SEN splits into upper and lower streams. The upper stream moves to the liquid level, which improves the liquid level activity near the SEN. However, the reduced mainstream momentum alleviates the occurrence of slag layer exposure. Industrial application of the S‐shaped SEN results in uniform slag distribution and smooth casting operations.

Flow and fluctuation of molten steel under permanent magnet flow control-mold in continuous casting process

Flow and fluctuation of molten steel under permanent magnet flow control-mold in continuous casting process

Large Eddy Simulation of Molten Steel Flow and Inclusion Transport in a New Butterfly-Type Induction Heating Tundish

Large Eddy Simulation of Molten Steel Flow and Inclusion Transport in a New Butterfly-Type Induction Heating Tundish

Numerical and experimental studies on the effects of molten steel viscosity on fluid flow, inclusion motion, and temperature distribution in a tundish

Tundishes are refractory vessels that are used to control the flow of molten steel, promote the removal of inclusions, and increase the homogeneity of temperature and composition during continuous casting processes by optimizing their geometric shape. The flow of molten steel in tundishes is a high-temperature process, and the optimization of the tundish structure is carried out by numerical and physical simulations. In numerical simulations, the viscosity of molten steel is generally set to a constant value; however, in industrial scenarios, the molten steel viscosity is variable with temperature. In the present work, the effects of molten steel viscosity varying with temperature on fluid flow, inclusion motion, and temperature distribution in a tundish were investigated by numerical simulations based on the modification of the top heat flux of the tundish, and the results were further verified by an industrial experiment. The removal rate of inclusions obtained from the industrial experiment was 40.40%. In numerical simulations, the inclusion removal rates were 50.85% and 40.67% when the fluid viscosity was constant and variable, respectively. Hence, when the molten steel viscosity was variable, the numerical simulation result was closer to the experimental one. The industrial experiment revealed that the temperature difference between the edge flow and the middle flow on the tundish liquid surface was 0 K. In numerical simulations, when the top heat fluxes of the tundish were 15 000 and 100 W/m2, the temperature differences on the tundish liquid surface were 5.95 and 0.16 K, respectively.

Research on the Relative Placement Angle of the Induction Heater and the Channel in a Four-Channel Induction-Heating Tundish.

In order to optimize the application effect of induction heating (IH) tundishes, a four-channel IH tundish is taken as the research object. Based on numerical simulation methods, the influence of different relative placement angles of induction heaters and channels on the electromagnetic field, flow field and temperature field of the tundish is investigated. We focus on comparing the magnetic flux density (B) and electromagnetic force (EMF) distribution of the channel. The results show that regardless of the relative placement angle between the heater and the channel, the distribution of B in the central circular cross-section of the channel is eccentric. When the heater rotates around channel 1 towards the bottom of the tundish, the distribution of B in the central circular cross-section of the channel changes from a horizontal eccentricity to a vertical one. Through the analysis of the B contour in the longitudinal section of the channel, the difference in effective magnetic flux density area (ΔAB) between the upper and lower parts of the channel can be obtained, thereby quantitatively analyzing the distribution of B in this section. The distribution pattern of ΔAB is consistent with the distribution pattern of the electromagnetic force in the vertical direction (FZ) of the channel centerline. The ΔAB and FZ of channel 1 gradually increase as the heater rotates downwards, while those of channel 2 reach their maximum value at a rotation angle of 60°. Compared to the conventional placement, when the heater rotation angle is 60°, the outlet flow velocities at channel 1 and channel 2 decrease by 15% and 12%, respectively. However, the outlet temperature at channel 2 increases by 1.96 K, and the molten steel flow at the outlet of channel 1 and channel 2 no longer exhibits significant downward flow. This shows that when the heater rotation angle is 60°, it has a dual advantage. On the one hand, it is helpful to reduce the erosion of the molten steel on the channel and the bottom of the discharging chamber, and on the other hand, it can more effectively exert the heating effect of the induction heater on the molten steel in the channel. This presents a new approach to enhance the application effectiveness of IH tundish.

Carbon Macrosegregation Pattern in 30Cr15Mo1N Ingot: Impact of Pouring Rate

The effect of the pouring rate on the carbon macrosegregation in 30Cr15Mo1N ingots has been clarified by investigating changes in the content of carbon‐containing precipitated phases, cooling rate, secondary dendrite arm spacing (SDAS) and the flow characteristics of molten steel. During the solidification process, the solute‐enriched liquid steel migrates toward the center of the ingot under the action of convection, resulting in an increasing segregation ratio from the edge to the center. However, the growth of equiaxed grains partially restricts the flow of solute‐enriched liquid steel, which leads to a maximum segregation ratio not at the center but at approximately a quarter radius from the center. Furthermore, due to the upward flow of molten steel in the center, positive segregation occurs at the top. An increment in the pouring rate reduces the SDAS by enhancing the cooling rate, and thus the permeability decreases. It aggravates the carbon macrosegregation horizontally. However, increasing the pouring rate decreases the carbon macrosegregation vertically. This is due to the more intense flow of molten steel and the larger liquid phase region at higher pouring rate, which reduces the solute enrichment degree and promotes compositional homogeneity above and below the ingot.

Numerical Simulation of the Density Effect on the Macroscopic Transport Process of Tracer in the Ruhrstahl–Heraeus (RH) Vacuum Degasser

Silicon steel (electrical steel) has been used in electric motors that are important components in sustainable new energy Electrical Vehicles (EVs). The Ruhrstahl–Heraeus process is commonly used in the refining process of silicon steel. The refining effect inside the RH degasser is closely related to the flow and mixing of molten steel. In this study, a 260 t RH was used as the prototype, and the transport process of the passive scalar tracer (virtual tracer) and salt tracer (considering density effect) was studied using numerical simulation and water model research methods. The results indicate that the tracer transports from the up snorkel of the down snorkel to the bottom of the ladle, and then upwards from the bottom of the ladle to the top of the ladle. Density and gravity, respectively, play a promoting and hindering role in these two stages. In different areas of the ladle, density and gravity play a different degree of promotion and obstruction. Moreover, in different regions of the ladle, the different circulation strength leads to the different promotion degrees and obstruction degrees of the density. This results in the difference between the concentration growth rate of the salt tracer and the passive scalar in different regions of the ladle top. From the perspective of mixing time, density and gravity have no effect on the mixing time at the bottom of the ladle, and the difference between the passive scalar and NaCl solution tracer is within the range of 1–5%. For a larger dosage of tracer case, the difference range is reduced. However, at the top of the ladle, the average mixing time for the NaCl solution case is significantly longer than that of the passive scalar case, within the range of 3–14.7%. For a larger dosage of tracer case, the difference range is increased to 17.4–41.1%. It indicates that density and gravity delay the mixing of substances at the top area of the ladle, and this should be paid more attention when adding denser alloys in RH degasser.

Effects of Submerged Entry Nozzle Bottom Shape on the Size Distribution of Argon Bubbles in a Steel Continuous Casting Slab Strand Using Multiple‐Size‐Group Approach

Herein, the effects of the bottom shape of the submerged entry nozzle (SEN) on the molten steel flow and size distribution of argon bubbles are analyzed in a steel continuous casting slab strand using multiple‐size‐group approach. The type of nozzle bottom includes the well bottom, flat bottom, and mountain bottom. Most of argon bubbles are larger than 4.5 mm inside the SEN and the mold at the three types of nozzles. The frequency distribution of bubbles inside the SEN increases from 28.29% to 32.65% and 35.74% for 5.0–5.5 mm bubbles and decreases from 53.71–50.49% and 47.38% for 5.5–6.0 mm bubbles with the nozzle bottom varied from the flat to mountain and well shape, respectively. The number density of argon bubbles with 4.0–5.5 mm diameter in the mold decreases and increases for 5.5–6.0 mm bubbles with the nozzle bottom varying from the well to flat and mountain shape, respectively. In addition, the results of the industrial trials show that inclusions adhesion and aggregation at the bottom of the nozzle are eliminated using the flat bottom SEN casting. Meanwhile, the mechanism of SEN clogging under the different types of nozzle bottoms is analyzed.

Corrosion mechanism and microstructure evolution of industrial used Al2O3-ZrO2-C slide plates

Slide plates are one of the most important functional refractories that control the flow of molten steel from the steel ladle to the tundish. In order to improve the service performance of slide plates and accelerate continuous production of the steel industry, a detailed post-mortem analysis was necessary. In this study, the corrosion behaviors of the high-temperature heated Al2O3-ZrO2-C slide plate used one heat for a 200 tons steel ladle in industry were investigated. The results showed that the thermo-mechanical properties' mismatch led the formation of radial cracks, which was the main factor limiting the service life of the slide plates. Besides, corrosion microstructure revealed the dissociation of mullite-zirconia aggregates and the loss of graphite provided a channel for the penetration of molten steel. The penetration of molten steel could react with Al2O3 in the slide plates, which accelerated corrosion in the early stage and formed a composite spinel layer in the later stage to block corrosion. Also, acicular CaAl12O19 was formed behind the composite spinel layer, further blocking the penetration of molten steel. Furthermore, the ZrO2 from mullite-zirconia had an interlocking structure to prevent corrosion. Finally, the content and viscosity of the liquid phase at different positions of the used slide plates were calculated, which indicated that the area near the casting hole had more liquid phase and lower viscosity. This would further optimize the service performance of the slide plates.

Numerical Study on Characteristic Positions and Transition of Flow Patterns in a Slab Continuous Casting Mold

The flow pattern in an opaque mold cannot be readily visible, and worker experience plays a major role in controlling it, even though it has a significant impact on slab quality in a continuous casting (CC) mold. An Eulerian–Eulerian two‐fluid model is used to comprehensively study the two‐phase flow of argon and molten steel in a slab CC mold. The positions of vortex centers in upper/lower recirculation zones and the impingement point of jet flow on the narrow face of mold are identified and their distribution is analyzed. The interactive effects of casting speed, argon flow rate, and immersion depth of the submerged entry nozzle (SEN) on the flow pattern inside the mold are revealed. 2D and 3D flow pattern regimes are plotted and the boundary lines and boundary surfaces are fit with exponential functions and ternary functions, respectively. To obtain a double roll flow in the slab CC mold investigated, the relation among argon flow rate (), casting speed (), and the immersion depth of the SEN () should satisfy, .

Channel parameter optimization of one-strand slab induction heating tundish with double channels

Abstract A generalized three-dimensional mathematical model is built to study the influences of channel parameters (channel angle, channel section diameter, and channel distance) on the molten steel flow, heat transfer, and inclusion removal in the induction heating tundish. The results demonstrate that as the channel angle increases, the flow of molten steel in the discharging chamber gradually slows down. When the channel angle is 6°, the temperature of the discharging chamber is slightly lower than when the channel angles are 2° and 4°. When the channel angle is 2°, the inclusion removal rate is lower than when the channel angles are 4° and 6°, while the latter two have little difference. As the channel section diameter increases, the flow of molten steel in the discharging chamber gradually slows down. When the channel section diameter is 100 mm, the temperature distribution in the discharging chamber is uneven. While the temperature distributions of the discharging chamber are even and similar, when the channel section diameters are 150 and 200 mm. As the channel section diameter increases, the removal rate of inclusion gradually decreases. The variation of channel distance has little effect on the temperature distribution of the discharging chamber. When the channel distance is 600 mm, the removal rate of inclusion is lower than when the channel distances are 1,000 and 1,400 mm. Moreover, for the latter two, the removal rates of inclusions have little difference. For this model, the best channel angle is 4°, the best channel section diameter is 150 mm, and the best channel distance is 1,000 mm.