Mathematical modeling of solidification in continuous cast low carbon steel billets

A continuous increase in demand for steel usage exists in modernized nations; new production techniques, such as the Continuous Casting process emerged to meet present requirements. The intent of the Continuous Casting process lies in overcoming the disadvantages in ingot casting: product quality, optimal energy usage, and cost. The microstructure formed during the solidification defines the quality of the steel. Therefore, the prediction of microstructural features becomes essential in the Continuous Casting process (Chakraborty and Dutta 2000).;Present research work establishes a relationship between the Secondary Dendrite Arm Spacing (SDAS), the Area of Mushy Zone, and the Continuous Casting variables in Low Carbon Steels during the solidification process in the mold zone. A Finite Element analysis of the heat flow equation, coupled with the solute distribution model and the dendrite growth model, enable the determination of the temperature profiles and dendrite growth.;The results from the mathematical model enable the determination of the local solidification time from the temperature profiles which in turn, enables determination of the Secondary Dendrite Arm Spacing (SDAS).;The CONBCAST.FOR program is the software developed in this work to analyze the effects of process variables on the Secondary Dendrite Arm Spacing ( SDAS) and Volume of the Bleed in Continuous Cast Low Carbon Steel billets. Analysis of the results indicates that lower casting speed yields lower Secondary Dendrite Arm Spacing (SDAS).;A new concept introduced in this work analyzes the relationship between the Area of Mushy Zone with the Volume of the Bleed and Secondary Dendrite Arm Spacing (SDAS). A qualitative analysis performed in three different cases concludes that lower pouring temperature and lower casting speed produce a better quality of billets by way of reduction in Secondary Dendrite Arm Spacing (SDAS) and Volume of the Bleed.