Coupled turbulent flow, heat, and solute transport in continuous casting processes

Aboutalebi, M.R.; Hasan, Mainul; Guthrie, R. I. L.

doi:10.1007/bf02651719

Cited by 189 publications

(127 citation statements)

References 21 publications

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“…[1][2][3][4][5][6][7][8][9][10] Fewer publications related with fluid flow in billet molds and particle image velocimetry (PIV) measurements are available, [11][12][13][14][15] probably because the conventional straight nozzles employed in this field work in a much more confined space, inducing what would be called standard flows with small variations of fluid flow patterns. However, the study presented here made clear that the complex nature of turbulent flows prevails even under the conditions of very stable flows, such as those expected in billet molds.…”

Section: Introductionmentioning

confidence: 99%

Influence of Straight Nozzles on Fluid Flow in Mold and Billet Quality

Torres-Alonso

Morales

Garcia-Hernandez

et al. 2008

Metall Mater Trans B

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Flux entrainment defects in a billet mold with two straight nozzles (outer radius of 60 mm, S60, and 73 mm, S73, and same interior radius of 36 mm) are studied using mathematical simulations and experimental techniques including particle image velocimetry (PIV), tracer injection, and water-oil modeling. Experimental findings indicated that using either of these nozzles at the deepest position of 135 mm (measured from the nozzle tip to the meniscus level) induces a flow near the meniscus, characterized by low turbulence yielding very stable water-oil interfaces. Simultaneously, owing to the mold radius, the entry jet induces a nonsymmetric flow downstream in the mold. At the shallow position of 90 mm, nozzle S73 induces a flow characterized by cyclic velocity spikes of low frequency and short duration close to the meniscus making the metal-flux interface highly instable. As the gap between the nozzle outer wall and the mold face is narrower and the nozzle position is shallower, the fluid close to the meniscus develops zones of high vorticity gradients leading to rotating flows, which are responsible for that instability. Water-oil experiments indicated that during the generation of this phenomenon, water flow entrains oil droplets in the side of the mold inner radius. Instability of metal-flux interface is then a consequence of the fluctuating nature of the recirculating flows in the mold, which induce upper rotating flows with large vorticity gradients. This mechanism explains actual flux entrainment defects in a billet caster.

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Section: Introductionmentioning

confidence: 99%

Influence of Straight Nozzles on Fluid Flow in Mold and Billet Quality

Torres-Alonso

Morales

Garcia-Hernandez

et al. 2008

Metall Mater Trans B

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“…[20] Because of its low computational cost, the Reynolds-averaged approach, typically with the two-equation (k-) turbulence model, has been extensively adopted in previous studies and has produced valuable insights about the flow in continuous casting nozzles [21][22][23][24] and molds. [10,[25][26][27][28][29] However, this approach, limited by its nature, is not suited for studying the time evolution of unsteady flow structures triggered by flow instabilities. Plant observations suggest that flow transients under the nominally steady operating conditions are very important.…”

Section: Introductionmentioning

confidence: 99%

Computational and experimental study of turbulent flow in a 0.4-scale water model of a continuous steel caster

Yuan

Sivaramakrishnan

Vanka

et al. 2004

Metall Mater Trans B

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Single-phase turbulent flow in a 0.4-scale water model of a continuous steel caster is investigated using large eddy simulations (LES) and particle image velocimetry (PIV). The computational domain includes the entire submerged entry nozzle (SEN) starting from the tundish exit and the complete mold region. The results show a large, elongated recirculation zone in the SEN below the slide gate. The simulation also shows that the flow exiting the nozzle ports has a complex time-evolving pattern with strong cross-stream velocities, which is also seen in the experiments. With a few exceptions, which are probably due to uncertainties in the measurements, the computed flow field agrees with the measurements. The instantaneous jet is seen to have two typical patterns: a wobbling "stair-step" downward jet and a jet that bends upward midway between the SEN and the narrow face. A 51-second time average suppressed the asymmetries between the two halves of the upper mold region. However, the instantaneous velocity fields can be very different in the two halves. Long-term flow asymmetry is observed in the lower region. Interactions between the two halves cause large velocity fluctuations near the top surface. The effects of simplifying the computational domain and approximating the inlet conditions are presented.

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“…Moreover, this approach could be physically more realistic for alloy solidification in a dendritic columnar crystal growth than the mushy approach. The equilibrial mushy model (6) , in which the solid fraction of a cell is the function of only local temperature and its constituents, is the most popular model for continuous casting simulation. However, when the mushy approach is applied to cases of physically sharp S.F., most of the liquid domain could be occupied with mushiness because of the relatively low supply temperature and possible stirring flow induced through the casting process.…”

Section: Resultsmentioning

confidence: 99%

“…a spatially fixed velocity field is given beforehand) and/or the mushy model (i.e. an intermediate material between solid and liquid is assumed) (6) (7) . The permeability model is not appropriate for deforming solids because there is no physically plausible rule to give a fixed velocity field in advance.…”

Section: Introductionmentioning

confidence: 99%

Numerical Method for Deforming Solidification Fronts in Continuous Casting

Ito

2006

JTST

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Pressure and velocity are generally discontinuous at the solidification front when the solid domain is deformed. This discontinuity, which has been ignored in most conventional solidification models for continuous casting processes, could cause significant numerical error around the solidification front in numerical simulations. To overcome error, a solidification front-tracking model in which the liquid-solid interface is discontinuous for pressure and velocity was developed. Assuming a sharp solidification front at the solidification front, the liquid and the solid domains are weakly coupled for momentum transport equations. The present model was proved to be more effective in cases of higher solidification rate such as in twin roll rapid cooling casting.

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Coupled turbulent flow, heat, and solute transport in continuous casting processes

Cited by 189 publications

References 21 publications

Influence of Straight Nozzles on Fluid Flow in Mold and Billet Quality

Influence of Straight Nozzles on Fluid Flow in Mold and Billet Quality

Computational and experimental study of turbulent flow in a 0.4-scale water model of a continuous steel caster

Numerical Method for Deforming Solidification Fronts in Continuous Casting

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