Multiphase fluid flow involving solidification is common in many industrial processes such as extrusion, continuous casting, drawing, etc. The present study concentrates on the study of air gap formation due to metal shrinkage on the interfacial heat transfer of a continuous casting mold. Enthalpy method was employed to model the solidification of continuously moving metal. The effect of basic process parameters mainly superheat, withdrawal velocity, mold cooling rate and the post mold cooling rate on the heat transfer was studied. The results of cases run with air gap formation were also compared with those without air gap formation to understand the phenomenon comprehensively. The current study shows that there exists a limiting value of Pe above which the effect of air gap formation on the overall heat transfer is negligible.
Issue Section:
Melting and Solidification
1.
Namburu
, R. R.
, and Tamma
, K. R.
, 1990
, “Recent Advances, Trends and New Perspectives via Enthalpy-Based Finite Element Formulations for Applications to Solidification Problems
,” Int. J. Numer. Methods Eng.
, 30
, pp. 803
–820
.2.
Ho
, K.
, and Pehlke
, R. D.
, 1984
, “Mechanisms of Heat Transfer at a Metal-Mold Interface
,” AFS Transactions
, 92
, pp. 587
–598
.3.
Beck
, J. V.
, 1970
, “Nonlinear Estimation Applied to the Non-Linear Inverse Heat Conduction Problem
,” Int. J. Heat Mass Transf.
, 13
, pp. 703
–716
.4.
Huang
, C. H.
, Ozisik
, M. N.
, and Sawaf
, B.
, 1992
, “Conjugate Gradient Method for Determining Unknown Contact Conductance During Metal Casting
,” Int. J. Heat Mass Transf.
, 35
(7
), pp. 1779
–1786
.5.
Ho, B., 1992, “Characterization of Interfacial Heat Transfer in the Continuous Slab Casting Process,” M.S. thesis, University of Illinois, Urbana, IL.
6.
Isaac
, J.
, Reddy
, G. P.
, and Sharma
, G. K.
, 1985
, “Variations of Heat Transfer Coefficients During Solidification of Castings in Metallic Moulds
,” The British Foundryman
, 78
, pp. 465
–468
.7.
Blackwell
, J. H.
, and Ockendon
, J. R.
, 1982
, “Exact Solution of a Stephan Problem Relevant to Continuous Casting
,” Int. J. Heat Mass Transf.
, 25
(7
), pp. 1059
–1060
.8.
Chidiac, S. E., Samarasekera, I. V., and Brimacombe, J. K., 1989, “A Numerical Method for Analysis of Phase Change in the Continuous Casting Process,” Proceedings of Numiform 89, E. C. Thompson, R. D. Wood, O. C. Zienkiewick, A. Samuelson, and A. A. Balkema, eds., The Netherlands, pp. 121–128.
9.
DeBellis, C. L., and LeBeau, S. E., 1989, “A Verified Thermal Model for Continuous Casting Process,” Heat Transfer in Manufacturing and Materials Processing, R. K. Shah ed., ASME 1989 National Heat Transfer Conference, NY, pp. 105–111.
10.
Kang
, B. H.
, and Jaluria
, Y.
, 1993
, “Thermal Modeling of the Continuous Casting Process
,” J. Thermophys. Heat Transfer
, 7
(1
), pp. 139
–147
.11.
Kim, W. S., Ozisik, M. N., and Hector Jr., L. G., 1990, “Inverse Problem of 1D Solidification for Determining Air-Gap Resistance to Heat Flow During Metal Casting,” XXII ICHMT International Symposium on Manufacturing and Material Processing, Dubrovnik, Yugoslavia.
12.
Piwonka, T. S., and Berry, J. T., 1993, “Heat Transfer at the Mold/Metal Interface in Investment Castings,” Proceedings of the 41st Annual Technical Meeting—Investment Casting Institute, pp. 15:1–15:17.
13.
Ho
, K.
, and Pehlke
, R. D.
, 1985
, “Metal-Mold Interfacial Heat Transfer
,” Metall. Trans. B
, 16B
, pp. 585
–594
.14.
Droste
, W.
, Engler
, S.
, and Nishida
, Y.
, 1986
, “The Air Gap Formation Process at the Casting Mold Interface and the Heat Transfer Mechanism Through the Gap
,” Metall. Trans. B
, 17B
, pp. 833
–844
.15.
Holzhauser
, J.-F.
, Spitzer
, K.-H.
, and Schwerdtfeger
, K.
, 2001
, “Correction on: Laboratory Study of Heat Transfer Through Thin Layers of Casting Slag—Minimization of the Slag/Probe Contact Resistance
,” Steel Res.
, 72
(7
), pp. 281
–282
.16.
Stone
, D. T.
, and Thomas
, B. G.
, 1999
, “Measurement and Modeling of Heat Transfer Across Interfacial Mold Flux Layers
,” Can. Metall. Q.
, 38
(5
), pp. 363
–375
.17.
Cho
, J. W.
, Emi
, T.
, Shibata
, H.
, and Suzuki
, M.
, 1998
, “Heat Transfer Across Mold Flux Film in Mold During Initial Solidification in Continuous Casting of Steel
,” ISIJ International
, 38
(8
), pp. 834
–842
.18.
Brimacombe
, J. K.
, Muojekwu
, C. A.
, and Samarasekera
, I. V.
, 1995
, “Heat Transfer and Microstructure During Early Stages of Solidification
,” Metall. Mater. Trans. B
, 26B
, pp. 361
–382
.19.
Ansys, 1999, Commands Reference Manual, Version 5.6, Eight Edition, SAS IP Inc.
20.
Gawas, N. L., 2001, “Numerical Modeling of Solidification Process During Continuous Casting Including the Effects of Interface Heat Flux,” M.S. thesis, Montana State University, Bozeman, MT.
21.
Siegel
, R.
, 1984
, “Two-Region Analysis of Interface Shape in Continuous Casting With Superheated Liquid
,” ASME J. Heat Transfer
, 106
, pp. 506
–511
.22.
Wolff
, F.
, and Viskanta
, R.
, 1988
, “Solidification of a Pure Metal at a Vertical Wall in Presence of Liquid Superheat
,” Int. J. Heat Mass Transf.
, 31
(8
), pp. 1735
–1744
.23.
Greif, D., 1998, “Numerical Study of Conjugate Heat Transfer in a Continuously Moving Metal During Solidification,” M.S. thesis, Montana State University, Bozeman MT.
Copyright © 2003
by ASME
You do not currently have access to this content.
