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Study of Transient Flow Structures in the Continuous Casting of Steel
Brian G.Thomas and S. Pratap Vanka, Principal Investigators
Hua Bai, Sivaraj Sivaramakrishnan, Shanker Subramanian, David Creech, Tiebiao Shi, Student Researchers
National Science Foundation # DMI-98-00274 and
Continuous Casting Consortium
Quick Links:
Project Overview
National Science Foundation Support
Industry Support
Summary of Activities
Overview of Findings
Training and Development
Outreach Activities
NSF Publications Describing This Work
Journal Publications
Book(s) or other one-time publication(s)
Software Products
Teaching Aids
Contributions
Project Overview:
Plant observations have found that many serious quality problems are directly associated with the flow pattern in the mold. Previous studies have generated understanding mainly through numerical simulations using time-averaged turbulence models. However, many problems are intermittent and the essential transient nature of the flow may be important to their formation. To obtain further understanding of these important transient turbulence processes, this project developed and applied computational models to directly compute the evolution and dynamics of the large-scale turbulence structures. Accurate numerical schemes and parallel computers are used to solve the governing fluid flow equations using a Large Eddy Simulation (LES) approach. The insights into how costly defects form are being used to find improvements in design and operating conditions in continuous casting that can avoid them.
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National Science Foundation Support:
DMI-98-00274; Jan. 1998 - Jan. 2001
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Industry Support (Continuous Casting Consortium members):
Provided: Financial Support (CCC membership); In-kind Support; Facilities (water models and plant measurements); and Research direction, were provided by:
LTV Steel (Cleveland,OH)
AK Steel Company (Middletown, OH)
Inland Steel, (East Chicago IN)
Allegheny Ludlum (Brackenridge, PA)
Columbus Stainless Steel (Middleburg, SA),
Stolberg, (Niagara Falls, NY),
Hatch Associates, (Buffalo, NY),
Accumold, (Huron Park, Ontario),.
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Summary of Activities (download 173KB .pdf)
Research and Education Activities:
The attached pdf document briefly summarizes the research activities of each of the student projects funded directly by this project. The results of each project were presented by each student to steel industry representatives at the annual meetings of the Continuous Casting Consortium at the University of Illinois in Fall 1999, 2000, and 2001. In addition, the results formed the basis for several reports, conference presentations, journal papers, book chapters, and short courses to industry.
Activities on this project began with development of computational models of steady and transient models of flow in the continuous casting nozzle and mold. The relative accuracy of these models is investigated through extensive comparison with laboratory measurements
in water models, including particle image velocimetry, and with plant measurements conducted on continuous casting machines at the supporting steel companies. Next, extensive steady simulations are conducted to characterize multiphase fluid flow through the nozzle as a function of nozzle geometry and casting conditions. With the help of fundamental studies of bubble formation, the nozzle model is further applied to optimize argon injection to suggest guidelines to avoid nozzle clogging and to measure it using a “clogging
index”. Fully transient models of flow in the caster using Large Eddy Simulation are developed, evaluated, and applied to simulate flow in the mold. Then, the accuracy and relative advantages of the different models of fluid flow are compared with flow measurements in both water models and operating casters. Next, the models are applied to simulate three different phenomena associated with fluid flow in the mold: inclusion transport, heat transfer, and multiphase flow due to argon bubble injection. Guidelines are
developed to predict optimal gas flow rates that should assist in designing better mold flow patterns to improve steel quality.
In addition to working on the research projects (and communicating the results through publishing book chapters, journal articles, conference presentations, online electronic articles and animations on two websites), semi-annual day-long meetings were held with industry representatives from the steel-related companies in the Continuous Casting Consortium (usually about 10 researchers from 7 different companies) to discuss the results of the individual projects, and to obtain feedback to benefit the students. Finally, the results from this work are incorporated into the short course to the steel industry (Brimacombe Continuous Casting Course, in Vancouver, Canada) which is presented annually by a team of 5 instructors including the PI of this project.
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Overview of Findings
Text (111 KB .pdf)
Figures (2231KB .pdf)
The attached pdf document summarizes findings for the entire 3 years of the project on all of the individual student projects. The pdf file containing the sample results figures referred to in this report is given above. The following is a brief overview of significant findings:
Several different computational models of turbulent fluid flow and heat transfer have been developed to simulate flow phenomena in the nozzle and mold regions of the continuous casting of steel slabs. The models have been calibrated, validated, and tested quantitatively
through comparisons with water model experiments, steel plant trials, and metallographic measurements at LTV Steel and several other steel companies who are cosponsoring this research. Next, this work has revealed many specific insights into multiphase flow through nozzles, which are important to designing nozzle geometry to avoid clogging andflow-related problems in the mold, which may generate defects in thefinal steel product. Contributions in three different areas include:
1) characterizing flow conditions exiting a typical slide-gate nozzleas a function of casting conditions,
2) developing a clogging index toreveal when clogging has occurred and
3) providing guidelines tooptimize argon injection to avoid clogging due to air aspiration in
the nozzle.
Through extensive comparisons of steady and transient models,particle-image velocimetry measurements in water models, and plantmeasurements, all taken under similar conditions, this work hasquantified how simple K-e flow models can reasonably predicttime-averaged multiphase flow of molten steel under the conditions ofinterest. Provided that the inlet conditions are accurate, large-eddysimulations of transient flow can further reveal important transient flow structures and accurately predict time-dependent signals, such as RMS velocity, at least for single phase flow. Further application of this model to inclusion transport has revealed its ability to matchthe distribution and flotation removal of inclusion particles in thetransient flow field with water model measurements, both qualitatively and quantitatively. In addition to the inlet velocity and direction the turbulence and swirl at the inlet ports has been shown to be very important to both the fluid flow and inclusion motion.
Secondly, transient LES simulations of impinging jets are performed and applied to predict heat transfer to the surface. This is important for theprediction of shell thinning and breakouts. The angle of jetimpingement against the narrow face also appears to have an important influence on the fraction of inclusion particles transported down deepinto the caster, where they may become entrapped to form defects.
Thirdly, steady, multiphase flow computations are compared with flow patterns observed in both a 0.4-scale water model and an operatingsteel caster with argon gas injection. For the same conditions, the water model and steel caster produced very different flow behavior.The computational model was able to match the measured flow patterns in both systems. The model is extended to predict the flow pattern as a function of operating conditions, which can be used as guidelines tooptimize gas injection practice in the real process.
In addition to its contributions to the continuous casting of steel, this work has demonstrated the potential of computational flow modeling to match real industrial processes. Moreover, computationalmodels are shown to be as accurate or better than water models, especially when complex related phenomena such as particle motion and multiphase flow are involved. The models will be further improved and applied in the current NSF project.
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Training and Development:
This NSF grant, together with the matching industrial funds, supported the education of two doctoral students, and five Masters students. The research performed by these students was (or will be) reported in the theses submitted by the students towards partial fulfillment of their degrees. In addition to learning how to conduct research on acommercial process such as the continuous casting of steel, these students learn numerical techniques and fundamental skills to solve flow and heat transfer problems encountered in other industries. The students also visit the plant facilities to learn of the process, and also to conduct experiments. The results of this research are presented by the students at least once a year at meetings with industrial participants of the Continuous Casting Consortium, thus leading to the development of their presentation skills.
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Outreach Activities:
The results of the research conducted under this NSF project is presented at semi-annual meetings of the Continuous Casting Consortium at which personnel from all six industrial member companies are present. Thus, the industry is exposed to this state of the art research as it is conducted. In addition, the results of this and other research is presented to the steel industry as part of the Brimacombe Continuous Casting Short Course, held every year in Vancouver, British Columbia, (with over 100 industry participants each year for more than a decade).
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NSF Publications Describing This Work:
Thomas, B.G. and P. Vanka; "Study of Transient Flow Structures in the Continuous Casting of Steel", 1999 NSF Design & Manufacturing Grantees Conference, Long Beach, CA, Jan. 5-8 1999.
(view html) (download 198KB .pdf).
Thomas, B.G. and S.P. Vanka; "Study of Transient Flow Structures in the Continuous Casting of Steel", Proceedings of the 2000 NSF Design & Manufacturing Grantees Conference, Vancouver, Canada, Jan. 3-6 2000, NSF, Washington, D.C.,14p. (download 638KB .pdf)
Vanka, S.P., and B.G. Thomas; “Study of Transient Flow Structures in the Continuous Casting of Steel”, Proceedings of the 2001 NSF Design & Manufacturing Grantees Conference, Tampa, Florida, Jan. 7-10 2001, NSF, Washington, D.C.,14p. (download 498KB .pdf)
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Journal Publications:
Miki, Y Thomas, B.G., "Modeling of Inclusion Removal in a Tundish", Metallurgical and Materials Transactions B, vol. 30B (4), (1999), p. 639. (download 944KB .pdf)
Stone, D. Thomas, B.G., "Measurement and Modeling of Heat Transfer Across Interfacial Mold Flux Layers", Canadian Metallurgical Quarterly, vol. 38 (5), (1999), p. 363. (download 1.14MB .pdf)
Bai, H. Thomas, B.G., "Turbulent Flow of Liquid Steel and Argon Bubbles in Slide-Gate Tundish Nozzles, Part I, Model Development and Validation", Metallurgical and Materials Transactions B, vol. 32B (2), (2001), p. 253. (download 1.26MB .pdf)
Bai, H. Thomas, B.G., "Turbulent Flow of Liquid Steel and Argon Bubbles in Slide-Gate Tundish Nozzles, Part II, Effect of Operation Conditions and Nozzle Design", Metallurgical and Materials Transactions B, vol. 32B (2), (2001), p. 269. (download 1.94MB .pdf)
Bai, H. Thomas, B.G., "Effects of Clogging, Argon Injection and Continuous Casting Conditions on Flow and Air Aspiration in Submerged Entry Nozzles", Metallurgical and Materials Transactions B, vol. 32B (4), (2001), p. 707. (download 0.99MB .pdf)
Thomas, B.G. Yuan, Q. Sivaramakrishnan,S. Shi, T. Vanka,S.P. Assar, M.B., "Comparison of Four Methods to Evaluate Fluid Velocities in a Continuous Slab Casting Mold", ISIJ International, vol. 41 (10), (2001), p. 1266. (download 776KB .pdf)
Thomas, B.G. Zhang, L., "Mathematical Modeling of Fluid Flow in Continuous Casting of Steel: a Review", ISIJ International, vol. 41 (10), (2001), p. 1185. (download 1.33MB .pdf)
Bai, H. Thomas, B.G., "Bubble Formation During Horizontal Gas Injection into Downward Flowing Liquid", Metallurgical and Materials Transactions B, vol. 32B (6), (2001), p. 1143. (download 784KB .pdf)
Yuan, Q. Sivaramakrishnan, S. Vanka, S.P. Thomas, B.G., "Large Eddy Simulations of Transient Flow Structures in Continuous Casting of Steel", Metallurgical and Materials Transactions B, vol. , (2002), p.
Thomas. B.G., "Casting Profess Simulation and Visualization: A JOM-e perspective", Journal of Metals (Also in http://www.tms.org/pubs/journals/JOM/0201/Thomas/Thomas-0201-commentary.html), vol. 54 (1), (2002), p. 20.
Thomas, B.G. Yuan, Q. Sivaramakrishnan, S. Vanka, S.P. , "Transient Fluid Flow in the Continuous Steel-Slab Casting Mold", JOM-e (Also in http://www.tms.org/pubs/journals/JOM/0201/Thomas/Thomas-0201.html), vol. 54, (2002), p. 1. online publication
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Book(s) or other one-time publication(s):
Thomas, B.G. Vanka, S.P., "Study of Transient Flow Structures in the Continuous Casting of Steel" , bibl. Long Beach, CA, Jan. 5-8 1999, (1999). Conference Proceedings Published
of Collection: , "Proceedings of the 1999 NSF Design & Manufacturing Grantees Conference"
Creech, D. Thomas, B.G., "3-D Turbulent Multiphase Modeling of Molten Steel Flow and Heat Transfer in a Continuous Slab Caster" , bibl. CFX User Meeting, Wilmington, DE, Oct. 1, 1998, (1998).
Bai, H., "Argon Bubble Behavior in Tundish Nozzles During Continuous Casting of Steel Slabs (Summary of work to April 1999)" , bibl. Continuous Casting Consortium Report, University of Illinois, August 19, 1999, (1999). Report
Subramanian, S. Thomas, B.G. Vanka, S.P., "Heat Transfer From an Impinging Steel Jet Using LES Models" , bibl. Continuous Casting Consortium Report,University of Illinois, August 19, 1999, (1999). Report
Sivaramakrishnan, S. Thomas, B.G. Vanka, S.P., "Investigation of Transient Turbulent Flow in a Water Model using LES Calculations and PIV Experiments" , bibl. Continuous Casting Consortium Report, University of Illinois, August 5, 1999, (1999). Report
Thomas, B.G., "Mathematical Models of Continuous Casting of Steel Slabs" , bibl. Annual Report to Continuous Casting Consortium, University of Illinois, August 19, 1999, (1999). Report
Thomas, B.G., "Mathematical Models of Continuous Casting of Steel Slabs" , bibl. Annual Report to Continuous Casting Consortium, University of Illinois, August 21, 1998, (1998). Report
Thomas, B.G. Vanka, S.P., "Study of Transient Flow Structures in the Continuous Casting of Steel" , bibl. Vancouver, Canada, Jan. 3-6 2000, (2000)., "Proceedings of the 2000 NSF Design & Manufacturing Grantees Conference, NSF, Washington, D.C.,14p."
Sivaramakrishnan, S. Thomas, B.G. Vanka, S.P., "Large Eddy Simulation of Turbulent Flow in Continuous Casting of Steel" , bibl. TMS Annual Meeting, Nashville, TN, March 12-16, 2000, (2000), V. Voller and H. Henein, "Materials Processing in the Computer Age III, pp. 189-198."
Bai, H. Thomas, B.G., "Two Phase Flow in Tundish Nozzles during Continuous Casting of Steel" , bibl. TMS Annual Meeting, Nashville, TN, March 12-16, 2000, (2000). ,V. Voller and H. Henein, "Materials Processing in the Computer Age III, pp. 85-99."
Sivaramakrishnan, S. Bai, H. Thomas, B.G. Vanka, S.P. Dauby, P. Assar, M., "Transient Flow Structures in Continuous Cast Steel" , bibl. Pittsburgh, PA, March 26-29, 2000, (2000), "59th Ironmaking Conference Proceedings, Vol. 59, Iron and Steel Society, Warrendale, PA, 2000, pp. 541-557."
Bai, H. Thomas, B.G., "Effect of Clogging, Argon Injection and Casting Conditions on Flow Rate and Air Aspiration in Submerged Entry Nozzles" , bibl. Pittsburgh, PA, March 26-29, 2000, (2000), "83rd Steelmaking Conference Proceedings, Vol. 83, Iron and Steel Society, Warrendale, PA, 2000, 183-197."
Thomas, B.G. R. O'Malley Shi, T. Meng,Y. Creech, D. Stone, D., "Validation of Fluid Flow and Solidification Simulation of a Continuous Thin Slab Caster" , bibl. Aachen, Germany, August 20-25, 2000, (2000), P. Sahm, "Modeling of Casting, Welding, and Advanced Solidification Processes - IX, Shaker Verlag GmbH, Aachen, Germany, 2000, pp. 769-776
Thomas, B.G., "The Importance of Numerical Simulations for Further Improvements of the Continuous Casting Process" , bibl. Linz, Austria, June 5 - 7, 2000, (2000), "The 8th International Continuous Casting Conference, Voest Alpine I., pp. 7.1-7.11. "
Yuan, Quan Vanka, S.P. Thomas, B.G., "Large Eddy Simulation of Turbulent Flow and Inclusion Transport in Continuous Casting of Steel" , bibl. APS/DFD 2000 (American Physical Society, Division of Fluid Dynamics 2000), Washington D.C, Nov. 19 - 21, 2000, (2000). Unpublished Presentation
Thomas, B.G., "Mathematical Models of Continuous Casting of Steel Slabs" , bibl. Annual Report to Continuous Casting Consortium, University of Illinois, September 25, 2000. , (2000). Report
Vanka, S.P. Thomas, B.G., "Study of Transient Flow Structures in the Continuous Casting of Steel" , bibl. Tampa, Florida, Jan. 7-10 2001, (2001), "Proceedings of the 2001 NSF Design & Manufacturing Grantees Conference, NSF, Washington, D.C.,14p."
Thomas, B.G., "Continuous Casting: Complex Models" , bibl. Elsevier Science Ltd., Oxford, UK, Vol. 2, 2001, pp. 1599-1609; and online at http://www.elsevier.com/mrwclus/15/show/Main.htt., (2001).
of Collection: Buschow, K.H.J., Cahn, R., Flemings, M., Ilschner, B., Kramer E.J., Mahajan, S., eds., (Dantzig, J., subject ed.), "The Encyclopedia of Materials: Science and Technology"
Thomas, B.G., "Continuous Casting of Steel" , bibl. Marcel Dekker, New York, NY, 2001, (2001), Yu, O., "Chapter 15 in Modeling for Casting and Solidification Processing, pp. 499-540"
Thomas, B.G., "Continuous Casting" , bibl. Elsevier Science Ltd., Oxford, UK, Vol. 2, 2001, pp. 1595-1599; and online at http://www.elsevier.com/mrwclus/15/show/Main.htt., (2001).
of Collection: Buschow, K.H.J., Cahn, R., Flemings, M., Ilschner, B., Kramer E.J., Mahajan, S., eds., (Apelian, D., subject ed.), "The Encyclopedia of Materials: Science and Technology"
Thomas, B.G., "Modeling of Continuous Casting" , bibl. AISE Steel Foundation, Pittsburgh, PA, (2001)., A. Cramb, editor, "Chapter 6 in Making, Shaping and Treating of Steel, 11th Edition, Vol. 5, Continuous Casting." Submitted
Thomas, B.G., "Continuous Casting Operation: Fluid Flow" , bibl. AISE Steel Foundation, Pittsburgh, PA, (2001), A. Cramb, editor, "Chapter 4.3 in Making, Shaping and Treating of Steel, 11th Edition, Vol. 5, Continuous Casting." Submitted
Thomas, B.G. Bai, H., "Tundish Nozzle Clogging - Application of Computational Models" , bibl. 18th PTD Conf., Baltimore, MD, March 25-28, 2001, (2001), "84th Steelmaking Conference Proceedings, Vol. 84, Iron and Steel Society, Warrendale, PA, 2001, pp. 895-912"
Yuan, Q. Vanka, S. P. Thomas, B. G., "Large Eddy Simulations of Turbulent Flow and Inclusion Transport in Continuous Casting of Steel" , bibl. 2nd International Symposium on Turbulent and Shear Flow Phenomena, Royal Insitute of Technology(KTH), Stockholm, Sweden, June 27 - 29, 2001. 6p., (2001).
Yuan, Q. Shi, T. Thomas, B. G. Vanka, S.P., "Simulation of Fluid Flow in the Continuous Casting of Steel" , bibl. Seattle, WA, Feb.18-20, 2002, (2002), "Computational Modeling of Materials, Minerals and Metals Processing, TMS(The Materials, Minerals, and Metals Society, Warrendale, PA) , pp. 491-500."
Thomas, B.G., "University - Steel Industry Interaction" , bibl. Buenos Aires, Inst. Argentino de Siderurgia (in Spanish), September 12-15, 1999, (1999), "R&D in the Steel Industry, 40th Congreso Latinoamericano de Siderurgia (ILAFA 40 Congress Proceedings), pp.65-67"
Thomas, B.G. Bai, H. Sivaramakrishnan, S. Vanka, S.P., "Detailed Simulation of Flow in Continuous Casting of Steel Using K-epsilon, LES and PIV" , bibl. Osaka, Japan, Nov. 14-16, 1999, (1999), "International Symposium on Cutting Edge of Computer Simulation of Solidification and Processes, pp. 113-128"
Thomas, B.G., "Modeling of the Continuous Casting of Steel: Past, Present and Future" , bibl. Pheonix AZ, (2001), "59th Electric Furnace Conference, 2001, ISS, Warrendale, PA, pp.3-30. [Dr. J. Keith Brimacombe Lecture, 2001, Iron and Steel Society"
Shi, T. Thomas. B.G., "Argon Injection Optimization in Continuous Slab Casting" , bibl. Annual Report to Continuous Casting Consortium, University of Illinois, October 18, 2001, (2001). Report
Thomas, B.G., "Mathematical Models of Continuous Casting of Steel Slabs" , bibl. Annual Report to Continuous Casting Consortium, University of Illinois, October 18, 2001., (2001). Report
Thomas, B.G. Vanka, S.P. , "Study of Transient Flow Structure in the Continuous Casting of Steel" , bibl. San Juan, Puerto Rico, Jan. 7-10 2002, (2002)., "Proceedings of the 2002 NSF Design, Service, Manufacturing and Industrial Innovation Research Conf., NSF, Washington, D.C., 22p."
Rani, S.L. Vanka, S.P., "Two-way Coupling Effects in a Particle-laden Turbulent Pipe Flow" , bibl. The 54th APS/DFD (American Physical Society/Division of Fluid Dynamics) meeting, San Diego, CA, Nov 18-20, 2001, (2001), "Bulletin American Physical Society, DFD 2001, Abstract JA-3"
Luo, G. Vanka, S.P., "Rayleigh-Benard Convection in a Vertical Cylinder Heated from Below with Nonuniform Temperature" , bibl. The 54th APS/DFD (American Physical Society/Division of Fluid Dynamics) meeting, San Diego, CA, Nov 18-20, 2001, (2001), "Bulletin American Physical Society, DFD 2001, Abstract EG-7"
Winkler, C.M. Vanka, S.P., "Turbulent Particle Dispersion in a Square Duct" , bibl. The 54th APS/DFD (American Physical Society/Division of Fluid Dynamics) meeting, San Diego, CA, Nov 18-20, 2001, (2001), "Bulletin American Physical Society, DFD 2001, Abstract EG-7"
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Software Products:
The computer program, LES3D, was developed under this grant. This is a general purpose program for solving turbulent fluid flow and heat transfer problems with particle transport using Large Eddy Simulation techniques.
A computer program to predict a clogging index (to predict clogging) has been developed as an outcome of this work and was tested at LTV Steel.
The LES3D and clogging index programs are both available on request. The LES3D program is being enhanced and actively used by students in ongoing research on related projects.
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Teaching aids
Video presentations visualizing the flow in the casting mold and slides of the important findings on transient phenomena have been developed as part of this project.
This educational material is being presented as part of a 1-week long course on continuous casting of steel, presented by the PI (and 4 others) every year to steel-industry personel and operators (enrolment in this short course has been 75-150 per year for the past 10 years).
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Contributions:
Contributions within Discipline:
This project has made significant contributions within the several different disciplines concerned in this project.
Towards the modeling of flow phenomena, this project has demonstrated both how to develop computational models, and the accuracy of their predictions. This was done by comparing, for the first time, results from four different flow methodologies: large eddy simulation, conventional time-averaged models, particle image velocimetry measurements, and plant measurements. It has demonstrated the feasibility and accuracy of applying Large Eddy Simulation to study transient flow structures during complex flow processes, such as the continuous casting of steel, but has shown its limitations in computational speed. It has also quantified the extent to which conventional models can reasonably approximate the time-averaged flow field. It has demonstrated the importance of accurate inlet conditions. Perhaps of greatest interest, it has shown that computational models are as accurate or better than water models, especially when complex related phenomena such as particle motion or multiphase flow are involved.
Towards fundamental understanding and study of the continuous casting process, this project has revealed many important new insights. It has created a database of jet characteristics exiting the nozzle for different conditions, which are needed for future optimization of nozzle geometry to control flow in the mold to avoid quality problems. It has revealed the detailed flow structures created during transient flow, including a staircase flow pattern associated with swirl from the inlet ports, and short circuiting flow in the mold. For the same conditions, the water model and steel caster sometimes produce very different flow behavior, and the computational model is able to match both. This contribution suggests that great care is needed in the use of physical water model experiments, at least for scale models involving multiphase flow. Towards the measurement of flow in the real process using electromagnetic sensors, this work has shown that such sensors are indeed capable of accurate velocity prediction, (based on the offset in time signals), but only in regions of horizontal flow, such as found at the center of the top surface.
Towards the industrial practice of continuous casting of steel, this project has made several practical contributions. Perhaps of greatest significance, separate sets of guidelines have been developed for the optimization of argon gas injection practice with respect to 1) pressurizing the nozzle to avoid air aspiration and reoxidation defects and 2) control of the flow pattern in the mold. In addition, a model has been developed to infer the extent of nozzle clogging, based on the drop in flow rate relative to the theoretical results.
Finally, this work has developed computational tools and knowledge, which can be applied to make further contributions in subsequent projects currently underway.
Contributions to Other Disciplines:
The LES computer program developed in this project has wide applicability to a variety of other industrial flows, such as aluminum casting, bulk crystal growth, welding, etc. Currently, we are applying the same computer program for study of particle transport in continuous casting, evaluating sub-grid scale models, and for study of heat transfer in impinging jets. The CFX and FLUENT computer programs used for the Reynolds averaged calculations are commercial programs widely used by a number of industries. Our results comparing and developing LES and Reynolds averaged CFD models will provide information on turbulence modeling that will benefit modelers working on a wide range of applications.
Contributions to Education and Human Resources:
This project has helped to develop the careers of six young researchers through direct funding of their graduate student research (through both the NSF and Continuous Casting Consortium matching funds).
To date, two students supported by this project (Sivaraj Sivaramkrishnan, and David Creech), have graduated with Master's Degrees in Mechanical Engineering; one student (Tiebiao Shi) has graduated with a Masters Degree in Materials Science and Engineering, and one student (Hua Bai) has graduated with a PhD in Mechanical Engineering. All are working on technical carreers in the U.S. applying their knowledge gained with support of this project. We expect that several more students (including Quan Yuan and Bin Zhao) will graduate soon.
Finally, a Post-Doctoral Researcher, (Lifeng Zhang) benefited by partial support from the matching funds to this project. Partial support of the PIs has enabled them to work to develop other human resources, including undergraduates students and people working in the steel industry.
Contributions to Resources for Science and Technology:
This research effort has produced a general purpose computer program (LES3D) for Large Eddy simulations of turbulent flows, heat transfer, and particle motion, which could simulate a wide variety of industrial processes in addition to continuous casting of steel. This tool will not only aid in research, but also will serve as an educational tool for students to learn fluid flow and process modelling.
The numerous publications developed through this research will provide education on many levels, ranging from general introductary knowledge (contained in several book chapters), to detailed knowledge (archived in many peer-reviewed journal articles, conference proceedings, and online publications) for improving continuous casting operation and modeling of flow phenomena.
Contributions Beyond Science and Engineering:
The results of this research will help the steel industry to modify the continuous casting process to avoid defects that arise as a consequence of flow-related problems. Maintaining a stature of cutting-edge research into steel technology in the U.S. will help to encourage open knowledge exchange with other research centers around the world, and lessen the chance of this country lagging behind in this important manufacturing technology. Improving domestic steel quality and technology in these ways could help to reduce the need to import steel from overseas, and maintain the viability of the domestic steel industry, thus increasing economic security of the nation.
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