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Insight into the Common W-Shaped Uneven Solidification Profile in Slab Casting: From Mechanisms to Targeted
Hao Geng1, Feifei Yang2, Shuaikang Xia1
1School of Metallurgical and Ecological Engineering, University of Science and Technology Beijing, No. 30 Xueyuan Road, Haidian District, Beijing 100083, China.
Materials (Basel, Switzerland)
|May 7, 2025
Summary
W-shaped solidification profiles in continuous casting are caused by shell erosion from steel flow and uneven cooling. Localized cooling in the secondary zone improves shell uniformity and reduces segregation.
Area of Science:
- Materials Science
- Metallurgical Engineering
- Process Engineering
Background:
- The W-shaped solidification profile in slab continuous casting presents challenges for product quality.
- Uneven shell thickness can lead to defects such as centerline segregation.
Purpose of the Study:
- To elucidate the formation mechanisms of the W-shaped solidification profile.
- To investigate mitigation strategies for achieving uniform shell thickness.
- To provide guidance for optimizing continuous casting parameters.
Main Methods:
- Development of a multiphysics coupling numerical model.
- Integration of measured nozzle cooling data from the secondary cooling zone.
- Systematic study of steel flow patterns in the mold and cooling conditions.
Main Results:
- Wide-face shell erosion, driven by radial jet and recirculation, is the primary cause of uneven shell thickness.
- Increased nozzle side-hole immersion depth and inclination angle worsen shell non-uniformity.
- Non-uniform secondary cooling amplifies shell thickness differences, creating dumbbell-shaped geometry.
Conclusions:
- Localized enhanced cooling on the wide face in the secondary cooling zone effectively improves shell uniformity.
- The efficacy of enhanced cooling is dependent on a critical process window (Segments 1-6).
- Findings provide mechanistic understanding and practical strategies to minimize centerline segregation in continuous casting.
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