The present article is a sequel to the previous review on the history of near net shape strip casting facilities. The present review focuses on technical progress made in strip casting over the last three decades. Strip casting is a revolutionary technology that promises the hope for an efficient, economical and environmentally-friendly process to produce hot-rolled, steel sheets. This review provides a summary of the theory, recent research, and progress, in the developments of strip casting operations for steels, along with technical discussions regarding the characteristics and design features of steel strip casting machines. Two strip casting processes are discussed in detail; the Twin-Roll Casting (TRC) process and the Horizontal Single-Belt Casting (HSBC) process. Particular emphasis is placed on topics such as the commercial potential for strip casting technology in the steel industry, and the economic and environmental advantages of direct strip production, versus current continuous casting, fixed mold technologies.
With increasing competition in the global steel market, strip casting technology potentially offers an efficient, economical and environmentally-friendly approach to the production of hot-rolled, coiled steel. This review provides a summary of the basic theory and history in the developments of strip casting operations of steels, along with technical discussions regarding various strip casting initiatives that have been carried out in the past, as well as present. Two strip casting processes are discussed in detail; Twin-Roll Casting (TRC) and Horizontal Single-Belt Casting (HSBC). With its inevitable logic, the emergence of strip casting technology could have an enormous impact on the world's steel industry. This present paper reviews the progress of strip casting technology for steel from a historical perspective, and this will be followed by a sequel, reviewing recent technical developments in the field.
Horizontal Single Belt Casting (HSBC) is a near net shape strip casting technology that will probably gain significant prominence in the coming years. Fluid mechanics and associated heat and mass transfer are important aspects of any continuous casting process, and the HSBC process is no exception.In this study, mathematical models have been developed, using ANSYS FLUENT 14, to assess various aspects of the HSBC process for the Al-Mg-Sc-Zr system. Specific emphasis is placed on a) the effects of substrate surface properties on strip quality, b) liquid metal-air two-phase interactions and meniscus behavior, c) heat fluxes between the metal and substrate, and d) solidification behavior during strip casting.These predictions are validated against experimental casting results. A 5000 series Al-Mg alloy, with added Sc and Zr, shows exceptional potential as a structural material for aerospace and transportation applications. It is also a suitable material to be produced via the HSBC process. Optical microscopy, SEM and EBSD analyses were conducted to compare the potential advantages of casting this alloy via the HSBC process versus conventionally produced Direct Chill Casting.
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