In this study, a set of thermodynamic, kinetic, and microstructure data is presented to simulate the non-equilibrium solidification of Fe-Al-Mn-Si-C alloys. The data were further validated with the experimental measurements and then used in a thermodynamic–kinetic software, IDS, to establish the effect of the alloying and cooling rate on the solidification behavior of high-AlMnSi (Al ≥ 0.5 wt pct, Mn ≥ 2 wt pct, Si ≥ 1 wt pct) steels. The modeling results were additionally validated by conducting electron probe microanalysis (EPMA) measurements. The results reveal that (1) solidification in high-AlMnSi steels occurs at much lower temperatures than in carbon steels; (2) increasing the cooling rate marginally lowers the solidus; (3) the microsegregation of Mn in austenite is much stronger than that of Si and Al due to the tendency of Al and Si to deplete from the liquid phase; (4) the residual delta ferrite content may be influenced by a proper heat treatment but not to the extent that could be expected solely from thermodynamic calculations; (5) in high-AlMnSi steels containing less than 0.2 wt pct carbon, the cracking tendency related to the strengthening above the solidus and the shell growth below the solidus may be much lower than in carbon steels.

New CCT equations have been developed and optimized to simulate the start temperatures of the austenite decomposition process in low-alloyed steels using experimental CCT data published in the literature. Exceptionally, this optimization does not apply the nominal compositions of the steels, but the corresponding soluble compositions of the grain boundaries calculated using IDS software, depending on the reported austenitization treatments of the steels. These compositions, rather than the nominal ones, are expected to control the start of the austenite decomposition, which usually initiates at the grain boundaries. The new optimization treatment takes into account the solute microsegregation and the possible precipitate formation. Using IDS software, the new equations were validated with new experimental CCT data. Agreement was good not only for the austenite decomposition start temperatures, but also for the final phase fractions, indicating fairly reasonable predictions of phase transformation kinetics by the IDS. In addition, IDS simulations were compared with the experimental CCT data of five high-carbon steels, applying both the new equations based on grain boundary soluble compositions as well as the equations based on the nominal compositions. With the same experimental CCT data used in optimization, better agreement was obtained with the new equations, indicating the importance of determining the soluble compositions at the grain boundaries where the austenite decomposition process is likely to begin.

Although the formation of defects in continuous casting has been studied for several decades, a deeper understanding and improved quality prediction concepts are needed to correlate the defects with the actual steel compositions, machine data and casting parameters. The aim of this work was to derive new quality criteria based on steel composition and cooling pattern for continuous casting and for the subsequent cooling and reheating processes. The criteria were devised based on the outputs of multiphysics simulation tools for online casting applications. The developed criteria were found to be good predictors of whether a steel grade combined with a given cooling pattern is prone to a specific defect. The criteria useful in providing a theoretical justification as to why certain defects form or would form, and can be used for devising practical solutions to avoid them. In practice, the final determination of whether a defect will form depends on the cumulative impact of various single quality criteria combined with the models/data describing the mechanical and thermal stresses forming. The criteria proposed are applicable as part of online quality prediction systems in casting machines. In this paper, new quality criteria were proposed for different kind of cracking-related and gas defects along with case examples. In further work, the criteria will be used to develop rule-based online control systems, in which cumulative effects of individual quality criteria are combined with data from mechanical and thermal stress calculations.

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InterDendritic Solidification (IDS) is a thermodynamic-kinetic software combined with a microstructure tool developed to simulate the nonequilibrium solidification (non-EQS) of steels. Herein, its main calculation module, solidification (SOL), is introduced, and some essential results of that module, such as the formation of ferrite and austenite in different types of steels during their solidification, and the formation and dissolution of precipitates during subsequent cooling and heating processes, respectively, following solidification, are presented. The non-EQS is compared with equilibrium and poor-kinetics solidification to demonstrate the effect of kinetics on the results using finite solute diffusion and microstructure data. The poor-kinetics solidification is comparable with the modified Scheil simulation ignoring the solid-state diffusion of slowly moving metallic elements. A particular emphasis is made on demonstrating how to use a postprocessing treatment to control the residual ferrite amounts in stainless steels and the extent of precipitation in particular steel. In this context, the phenomena occurring behind the results are discussed. Finally, to validate the simulations of the SOL module, its calculations are compared with numerous solidification measurements, such as the liquidus and solidus temperatures of different steels and the residual ferrite amounts in stainless steels.