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A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: closed (31 January 2021) | Viewed by 41655

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Prof. Dr. Markéta Tkadlečková

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Technology and Research/TŘINECKÉ ŽELEZÁRNY, a.s., Průmyslová 1000, Staré Město, 739 61 Třinec, Czech Republic
Interests: fundamentals of steelmaking processes; technology of steelmaking; steelmaking optimization using numerical modelling; steel refining in ladle; optimization of steel flow in tundish; steel ingot casting; continuous casting of steel; prediction of volume defects; such as porosity; hot tears; cracks
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Dear Colleagues,

Steel production represents a complex process which is accompanied by a series of physical-chemical processes from melting, through the multiphase flow of steel and chemical reactions (processes taking place between the slag, metal, and an inert gas) after solidification. A frequent problem in steel production is setting the correct conditions, e.g., in blowing argon for the steel processing in a ladle, the vacuum degassing of steel, optimising the nature of flow in individual reactors (ladle, tundish, nozzles, moulds), or the conditions for casting and the solidification of steel. Understanding these mechanisms requires knowledge from the technology of steel production, metallurgical thermodynamics, and kinetics. The other two mutually dependent requirements, which help to understand the production of steel, are experimental measurements and the modelling of processes. Especially in demanding metallurgical conditions, where it is very difficult to obtain information about the steel flows in the metallurgical plants, or on the solidification point and the macrostructure of solidified metal, the method of numerical modelling plays an irreplaceable role.

The results of numerical modelling are highly dependent on the selected parameters of calculation from the determination of the modelled area, through the generation of a computational mesh, up to the very definition of a mathematical model, the selected type of flow or set thermodynamic conditions of materials, which often require interdisciplinary cooperation with other workplaces.

The main aim of Special Issue “Numerical Modelling in Steel Metallurgy” is to present new knowledge and trends in the optimization of steel production using numerical modelling. Articles on the numerical modelling of steel refining in ladle, vacuum processing, steel flow optimization in tundish or mould, slag emulsification into steel, steel ingot casting and continuous casting, are welcome.

Assoc. Prof. Markéta Tkadlečková
Guest Editor

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Keywords

Steelmaking Optimization
Numerical modelling
Steel Refining
Steel Flow in Tundish
Steel Flow in Mould
Non – Metallic Inclusions Removal
Steel Ingot Casting
Steel Continuous Casting
Porosity
Hot Tears
Cracks

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Published Papers (13 papers)

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Editorial

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3 pages, 180 KiB

Open AccessEditorial

Numerical Modelling in Steel Metallurgy

by Markéta Tkadlečková

Metals 2021, 11(6), 885; https://doi.org/10.3390/met11060885 - 28 May 2021

Cited by 3 | Viewed by 2036

Abstract

Steel production represents a complex process which is accompanied by a series of physical–chemical processes from melting, through the multiphase flow of steel and chemical reactions (processes taking place between the slag, metal, and an inert gas) after solidification [...] Full article

(This article belongs to the Special Issue Numerical Modelling in Steel Metallurgy)

Research

Jump to: Editorial

17 pages, 9685 KiB

Open AccessArticle

Development of Universal Mould Geometry for the Teeming of Cylindrical Iron-Base Alloy Ingots

by Josef Odehnal, Pavel Ludvík, Tomáš Studecký and Pavel Michálek

Metals 2021, 11(3), 471; https://doi.org/10.3390/met11030471 - 12 Mar 2021

Cited by 1 | Viewed by 1846

Abstract

The presented work is aimed at developing a mould geometry suitable for casting both low- and high-alloy steel grades into 500 kg experimental ingots. The high Height-to-Diameter (H/D)-ratio mould currently used in COMTES FHT Inc. served as a reference and for finite element method simulations (FEM) of the filling and solidification process. The optimized mould geometry, balancing the porosity and segregations, was determined using MAGMA software. Four different steel grades were defined for the simulation. Case studies were carried out for 34CrNiMo6 (W.Nr. 1.6582), DHQ8, CB2 and borated stainless steel grades ranging from low-alloy steel to high-alloy steel. Extended user-defined criteria and verified boundary conditions were used to predict the formation of A-segregations in cast steel. Both primary (PDAS) and secondary (SDAS) arm spacings were modelled as well. The optimized mould shape and the casting assembly were designed based on the simulation results. Full article

(This article belongs to the Special Issue Numerical Modelling in Steel Metallurgy)

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16 pages, 9957 KiB

Open AccessArticle

The Effect of Forging Conditions on Final Macrostructure of Slab Ingot from the 55NiCrMoV7 Tool Steel

by Petr Jonšta, Vladislav Kurka, Marek Vindyš and Ladislav Kander

Metals 2021, 11(3), 435; https://doi.org/10.3390/met11030435 - 6 Mar 2021

Cited by 2 | Viewed by 3082

Abstract

The paper presents numerical modelling and an operational experiment to forge a slab ingot P40N from 55NiCrMoV7 tool steel and the procedure for the optimization of its production. The aim of the numerical simulation of forging was to verify the existing procedure of forging a plate from a conventional polygonal 8K forging ingot and a slab ingot with a polygonal shape of P40N surfaces. The effect of the shape of the ingot on the achievement of the required forging reduction and strain after the cross section of the forging of the plate, with final dimensions of approximately 1010 mm width × 310 mm thickness × 5350 mm length, was studied. The results obtained in the operational experiment showed satisfactory qualitative parameters of the steel forging from the slab P40N ingot which were in accordance with the predicted results of numerical simulations. The results indicated that in selected cases the use of a slab P40N ingot instead of the conventional polygonal 8K forging ingot can be considered in the production of certain plate-type forgings. Full article

(This article belongs to the Special Issue Numerical Modelling in Steel Metallurgy)

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17 pages, 7087 KiB

Open AccessArticle

Control of Shrinkage Porosity and Spot Segregation in Ø195 mm Continuously Cast Round Bloom of Oil Pipe Steel by Soft Reduction

by Liang Li, Zhonghua Zhang, Ming Luo, Bo Li, Peng Lan and Jiaquan Zhang

Metals 2021, 11(1), 9; https://doi.org/10.3390/met11010009 - 23 Dec 2020

Cited by 23 | Viewed by 3452

Abstract

Based on the Ø195 mm round bloom continuous casting of oil pipe steel, a two dimensional thermal-mechanical coupled model has been developed to investigate the deformation behavior of round bloom during soft reduction (SR) in the reduction force mode. Good agreement was achieved in surface temperature, shell thickness and contact zone width from modeling and measurement. Under the same reduction force, the reduction amount of round bloom at the front unit is much larger than back unit. Moreover, due to its higher temperature and lower center solid fraction, the deformation penetration before solidification is much stronger than that after solidification. Considering the limitation of the round bloom ovality, the maximum allowable force in reduction unit is calculated. According to the simulation results, a multi-unit soft reduction plan was proposed and carried out on the Ø195 mm round bloom. After the reduction process of No.1 to No.3 withdrawal units, the shrinkage porosity in the center of the round bloom was almost vanished, while the number and size of spot segregation were significantly reduced. Moreover, the oil pipe produced by the round bloom with SR got a better resistance to sulfide stress corrosion (SSC). It indicates that SR is an effective technology for the round bloom to control the shrinkage porosity and spot segregation in the continuous casting. Full article

(This article belongs to the Special Issue Numerical Modelling in Steel Metallurgy)

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13 pages, 3940 KiB

Open AccessArticle

A Numerical and Experimental Study on the Solidification Structure of Fe–Cr–Ni Steel Slab Casting by Roller Electromagnetic Stirring

by Hong Xiao, Pu Wang, Bing Yi, Xiqing Chen, Aiwu Li, Haiyan Tang, Weihong Li and Jiaquan Zhang

Metals 2021, 11(1), 6; https://doi.org/10.3390/met11010006 - 22 Dec 2020

Cited by 9 | Viewed by 2420

Abstract

We present a segmented coupling model for slab casting by roller electromagnetic stirring (R-EMS) of electromagnetic, flow, heat transfer, and solidification behavior based on magnetohydrodynamics and solidification theory. A three-dimensional (3-D) segmented coupling model that included electromagnetic, flow, and heat transfer elements was established using Ansoft Maxwell and ANSYS Fluent software. The effects of the roller sleeve, magnetic shielding ring, coil, core, molten steel, and air domain on the electromagnetic, thermal and flow fields were studied numerically. The accuracy of the model was verified by measuring the magnetic flux density at the centerline in a pair of rollers and the electromagnetic force of the copper plate. Based on the numerical results of the optimal technical parameters, the effect of the R-EMS on the solidification of Fe–17 wt% Cr–0.6 wt% Ni stainless steel was explored. The results indicated that with each additional pair of electromagnetic rollers, the average electromagnetic force increased by 2969 N/m³ in the casting direction, and 5600 N/m³ in the central section of the rollers. With increasing number of pairs of rollers, the effective stirring region increased, and the velocity of molten steel at the solidification front first increased but then decreased. The strong electromagnetic swirling washing effect reduced the solidification rate of the slab shell and promoted the superheated dissipation of molten steel in the center of the strand. The center equiaxed crystal ratio of the slab was improved to 69% with two pairs of R-EMS rollers and electromagnetic parameters of 400 A/7 Hz, which was beneficial for obtaining a uniform and dense solidified structure to improve the subsequent hot working performance and product quality. Full article

(This article belongs to the Special Issue Numerical Modelling in Steel Metallurgy)

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22 pages, 4238 KiB

Open AccessArticle

Design Optimization of a Single-Strand Tundish Based on CFD-Taguchi-Grey Relational Analysis Combined Method

by Dong-Yuan Sheng

Metals 2020, 10(11), 1539; https://doi.org/10.3390/met10111539 - 19 Nov 2020

Cited by 21 | Viewed by 3330

Abstract

A novel digital design methodology that combines computational fluid dynamics (CFD) modelling and Taguchi-Grey relational analysis method was presented for a single-strand tundish. The present study aimed at optimizing the flow control device in the tundish with an emphasis on maximizing the inclusion removal rate and minimizing the dead volume fraction. A CFD model was employed to calculate the fluid flow and the residence-time distribution of liquid steel in the tundish. The Lagrangian approach was applied to investigate the behavior of non-metallic inclusions in the system. The calculated residence-time distribution curves were used to analyze the dead volume fraction in the tundish. A Taguchi orthogonal array L9(3^4) was used to analyze the effects of design factors on both single and multiple responses. Moreover, for the purpose of meeting the multi-objective target functions, grey relational analysis and analysis of variance were used. The optimum positions of the weir and the dam were obtained based on the design targets. A special focus of this study was to demonstrate the capabilities of the Taguchi-Grey relational analysis method as a powerful means of increasing the effectiveness of CFD simulation. Full article

(This article belongs to the Special Issue Numerical Modelling in Steel Metallurgy)

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18 pages, 6477 KiB

Open AccessArticle

Mathematical Modelling of Multiphase Flow and Inclusion Behavior in a Single-Strand Tundish

by Dong-Yuan Sheng

Metals 2020, 10(9), 1213; https://doi.org/10.3390/met10091213 - 9 Sep 2020

Cited by 27 | Viewed by 3935

Abstract

A mathematical model was developed to study the effects of the flow control devices and the gas curtain on the steel cleanness in a single-strand tundish. The Eulerian–Lagrangian approach was applied to investigate the bubble flow and the behavior of the non-metallic inclusions in the system. Two modelling approaches were considered: (i) one-way coupling, where the influence of the micro-inclusion on the molten steel flow is neglected; and (ii) two-way coupling, where the momentum exchange between the molten steel and the bubbles is modelled. The model verification and validation (V&V) were carried out in order to establish confidence in the model predictions. Four different tundish configurations and the effect of various parameters, such as the inclusion size, the inclusion density and the gas flow rate, were investigated at the normal casting conditions. The results show that the flow control devices and the gas curtain reduce the extent of the dead volumes in the tundish and thus enhance the removal efficiency of the inclusions. Controlling the gas stirring intensity is important for tundish operation with the aim of removing the inclusions. Theoretical analysis suggests that small bubbles are preferable to increase the inclusion removal rate in industrial operations. Full article

(This article belongs to the Special Issue Numerical Modelling in Steel Metallurgy)

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17 pages, 5980 KiB

Open AccessArticle

Modeling of Fluid Flow and Residence-Time Distribution in a Five-Strand Tundish

by Dong-Yuan Sheng and Qiang Yue

Metals 2020, 10(8), 1084; https://doi.org/10.3390/met10081084 - 11 Aug 2020

Cited by 23 | Viewed by 4720

Abstract

Quantified residence-time distribution (RTD) provides a numerical characterization of mixing in the continuous casting tundish-thus allowing the engineer to better understand the metallurgical performance of the reactor. This study describes a computational fluid dynamic (CFD) modeling study for analyzing the flow pattern and the residence-time distribution in a five-strand tundish. Two passive scalar-transport equations were applied to separately calculate the E-curve and F-curve in the tundish. The numeric modeling result were compared to water-modeling results to validate the mathematical model. The volume fraction of different flow regions (plug, mixed and dead) and the intermixing time during the ladle changeover were calculated to study the effects of the flow control device (FCD) on the tundish performance. From the results of CFD calculations, it can be stated that a combination of the U-baffle with deflector holes and the turbulence inhibitor had three major effects on the flow characteristics in the tundish: (i) to reduce the extent of the dead volume; (ii) to evenly distribute the liquid streams to each strand and (iii) to shorten the intermixing time during the ladle changeover operation. Full article

(This article belongs to the Special Issue Numerical Modelling in Steel Metallurgy)

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14 pages, 5043 KiB

Open AccessArticle

Splashing Simulation of Liquid Steel Drops during the Ruhrstahl Heraeus Vacuum Process

by Zhi-jian Zhao, Min Wang, Lei Song and Yan-ping Bao

Metals 2020, 10(8), 1070; https://doi.org/10.3390/met10081070 - 7 Aug 2020

Cited by 5 | Viewed by 3696

Abstract

In view of the serious splashing problem in the 120 ton Ruhrstahl Heraeus (RH) refining process of a special steel company, a coupling model of volume of fluid + discrete phase model was established to study the influence of the vacuum pressure drop mode on the RH vacuum splashing. Three different pressure drop modes were simulated, and the splash situation was described by the fluctuation of the liquid level and the velocity field in the vacuum chamber in this model. The model predicted that the most serious splashing situation of liquid drops would happen at the early stage of vacuum treatment, which was consistent with that found in industrial production. The liquid level in the vacuum chamber maintained a low fluctuation at the late stage of the RH vacuum process. The vacuum pressure drop mode was closely relevant with the splashing situation. The splashing of liquid steel can be effectively improved by controlling the vacuum pressure drop mode, and it can be used in the industrial production situation. Full article

(This article belongs to the Special Issue Numerical Modelling in Steel Metallurgy)

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19 pages, 6330 KiB

Open AccessArticle

Numerical Analysis of Radiative Heat Transfer and Direct Reduction of Three-Dimensional Multilayer Ellipsoidal Carbon-Containing Pellet Unit in the Rotary Hearth Furnace

by Nan Li and Feng Wang

Metals 2020, 10(8), 994; https://doi.org/10.3390/met10080994 - 23 Jul 2020

Cited by 5 | Viewed by 2664

Abstract

It is very important for a multilayer pellet bed to have a proper description of the radiant heat transfer and direct reduction process in the rotary hearth furnace. Ellipsoidal pellets may also be used in industrial production. The research on this ellipsoidal pellet bed will provide comprehensive data support for the production process. Besides, the view factor is one of the important factors affecting the heat transfer of the multilayer pellet bed. It is of great significance to study its value and distribution. In this study, the effects of the gas field and the bottom of the furnace on the direct reduction of multilayer ellipsoidal pellets were considered. The local environmental viewing angle coefficient in the model was obtained through the mechanism calculation method, which is more accurate than the calculation through the radiation exchange network. Furthermore, the porosity variation in the pellet during the direct reduction process was also considered. According to the calculation, it was found that the higher initial temperature at the furnace bottom is beneficial to increase the degree of metallization (DOM) and zinc removal rate (ZRR) for all pellets, and is more advantageous to the lower pellets in the material bed. Nevertheless, the reduction degree of the lower pellets is still smaller than that of the upper pellets. The results also show that increasing the offset

ξ

has a greater effect on increasing the ambient view factor and each position reduction degree in the ellipsoidal pellets layer. Results can be applied for the optimization of pellets distribution in a rotary hearth furnace. Full article

(This article belongs to the Special Issue Numerical Modelling in Steel Metallurgy)

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20 pages, 8651 KiB

Open AccessFeature PaperArticle

Numerical Analysis of RTD Curves and Inclusions Removal in a Multi-Strand Asymmetric Tundish with Different Configuration of Impact Pad

by Markéta Tkadlečková, Josef Walek, Karel Michalek and Tomáš Huczala

Metals 2020, 10(7), 849; https://doi.org/10.3390/met10070849 - 27 Jun 2020

Cited by 33 | Viewed by 3191

Abstract

To effectively remove non-metallic inclusions from the steel during the flowing in a five-strand asymmetric tundish, the novel configuration of the impact pad was developed. For analysis, complex numerical modelling in the programme ANSYS Fluent was used. The Lagrangian Discrete Phase Model of inclusion tracking was applied. The distribution of inclusions, with sizes ranging from 2 µm to 100 µm and density from 2500 to 3500 kg·m⁻³, was considered only through the shroud tube. The residence time distribution (RTD) curves and inclusion removal efficiency were used for evaluation of steady state steel flow character depending on internal configuration of a tundish with an impact pad in two design modifications (Modification 1—M1, Modification 2—M2). The preliminary results showed that in the case of asymmetric geometry plays a role the computational mesh independency. The assembly method with cut cell approach was satisfactory even when the tundish geometry was changed. The RTD curves with an M1 showed a huge dead volume in the tundish. In the case with an M2, the RTD curves are more or less uniform for all casting strands, and the removal of inclusions to slag increased from about 55% up to 70% in comparison with M1. Full article

(This article belongs to the Special Issue Numerical Modelling in Steel Metallurgy)

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14 pages, 3782 KiB

Open AccessArticle

Numerical Simulation of the Melting Behavior of Steel Scrap in Hot Metal

by Nanyang Deng, Xiaobin Zhou, Moer Zhou and Shiheng Peng

Metals 2020, 10(5), 678; https://doi.org/10.3390/met10050678 - 21 May 2020

Cited by 8 | Viewed by 3413

Abstract

The current study focuses on the melting behavior of a scrap bar with low carbon content in hot metal which contains high carbon concentration by applying experiments and mathematical modelings. The experiments suggest that higher temperature is favorable for the melting of the bar and the melting rate of the bar is initially high while decreased to a relative stable level after 90 s in the current conditions. It can be found from the mathematical results that the bar temperature is increased near to bath temperature in about 20 s after it was immersed into the bath, and the temperature in the axis of the bar is not distributed evenly during the temperature increase stage. Moreover, the mathematical results shows that a bath circulation flow would be formed in the bath under the effects of temperature and carbon distribution during the melting process. The bath flow near the melting interface would influence the carbon concentration of the molten phase, in turn, affects the melting rate of the bar in the vertical direction. Both the experimental and mathematical results show that the melting rate in the upper part, which is in the upstream of the bath flow, is higher than that of the middle part, followed by the down part of the bar in the downstream of the flow, in which the carbon concentration is much lower than that of the bath. At this period, the main factor that dominate the bar melting is not the temperature but the carbon distribution at the melting interface after the bar temperature is increased to the bath temperature. Full article

(This article belongs to the Special Issue Numerical Modelling in Steel Metallurgy)

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9 pages, 4275 KiB

Open AccessArticle

Measurement of Surface Velocity in a 150 mm × 1270 mm Slab Continuous-Casting Mold

by Yang Wang, Jie Feng, Shufeng Yang and Jingshe Li

Metals 2020, 10(4), 428; https://doi.org/10.3390/met10040428 - 25 Mar 2020

Cited by 4 | Viewed by 2264

Abstract

Surface velocity in the continuous-casting mold needs to be studied to better control the quality of steel products. In this paper, the measurement of surface velocity in a 150 mm × 1270 mm slab continuous-casting mold was investigated. Taking the slag layer into consideration, a numerical simulation was performed which was validated by a particle image velocimetry test. A nail-board experiment was also conducted to measure surface velocity in the continuous-casting mold. The effect of nail diameter used in nail-board experiment on the measurement of the surface velocity was also discussed to improve the precision of nail-board experiment result. The results showed that the maximum surface velocity was 0.739 m/s around the mid-section of the free surface, and the results of nail-board experiments were more accurate when the steel nail diameter was 10 mm. Full article

(This article belongs to the Special Issue Numerical Modelling in Steel Metallurgy)

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