Computational modeling is an important tool to understand and stabilize transient turbulent fluid flow in the continuous casting of steel to minimize defects. The current work combines the predictions of two steady Reynolds-averaged Navier-Stokes (RANS) models, a ''filtered'' unsteady RANS model, and two large eddy simulation (LES) models with ultrasonic Doppler velocimetry (UDV) measurements in a small-scale liquid GaInSn model of the continuous casting mold region fed by a bifurcated well-bottom nozzle with horizontal ports. Both mean and transient features of the turbulent flow are investigated. LES outperformed all models while matching the measurements, except in locations where measurement problems are suspected. The LES model also captured high-frequency fluctuations, which the measurements could not detect. Steady RANS models were the least accurate methods. Turbulent velocity variation frequencies and energies decreased with distance from the nozzle port regions. Proper orthogonal decomposition analysis, instantaneous velocity patterns, and Reynolds stresses reveal that velocity fluctuations and flow structures associated with the alternating-direction swirl in the nozzle bottom lead to a wobbling jet exiting the ports into the mold. These turbulent flow structures are responsible for patterns observed in both the time average flow and the statistics of their fluctuations.

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The evolution of macro inclusions during continuous casting was investigated by large-area inclusion characterization using ASPEX and analysis of nozzle blockage deposits. Six kinds of inclusions over 5 μm were observed in samples taken from the tundish and the slabs: single alumina particles, alumina dendrites, refractory-related alumina, alumina associated with bubbles, alumina clusters and Al-Ti complex oxides. By examining the morphology of the nozzle blockage deposit, it was concluded that the refractory-related alumina in the slabs came from the decarburization layer washed away by the steel stream. Some of the alumina clusters that came from the nozzle blockage deposit dislodged by the steel flow, were formed by the agglomeration and sintering of 5-20 μm inclusions that were carried over from the tundish. Two kinds of Al-Ti oxides were found in the tundish, and their evolution mechanisms during the casting process were proposed.

Full-scale water modelling studies combined with nail-dipping industrial trials at Shougang Jingtang (SGJT) Works were carried out in order to investigate the parameters that influence flow patterns in the continuous slab casting mould. The effects of casting speed/mould width combinations, argon bubbling flow rates, submerged entry nozzle (SEN) immersion depths and SEN geometries (port angle and bottom shape) on the flow patterns were examined. A CMI factor defined as casting speed/mould width ratio index is put forward to describe the combined effect of these parameters on the fluid flow patterns in the mould. The results show that the CMI and argon injection rates are the dominant factors that determine the flow pattern. On the basis of the results from this study, critical argon flow rates for different casting combinations have been evaluated. These findings provide operating guidelines for generating optimal flow patterns based on double roll flow with appropriate surface velocities in continuous slab casting moulds. On the basis of these considerations, slab quality at SGJT Works was substantially improved and the percentage of flow pattern-related sliver defects in cold rolled products was decreased from 4.5 to 2.3%.

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