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A Unified Mechanism for the Formation of Oscillation Marks

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Abstract

Oscillation marks (OMs) are regular, transverse indentations formed on the surface of continuously cast (CC) steel products. OMs are widely considered defects because these are associated with segregation and transverse cracking. A variety of mechanisms for their formation has been proposed (e.g., overflow, folding, and meniscus freezing), whereas different mark types have also been described (e.g., folded, hooks, and depressions). The current work uses numerical modeling to formulate a unified theory for the onset of OMs. The initial formation mechanism is demonstrated to be caused by fluctuations in the metal and slag flow near the meniscus, which in turn causes thermal fluctuations and successive thickening and thinning of the shell, matching the thermal fluctuations observed experimentally in a mold simulator. This multiphysics modeling of the transient shell growth and explicit prediction of OMs morphology was possible for the first time through a model for heat transfer, fluid flow, and solidification coupled with mold oscillation, including the slag phase. Strategies for reducing OMs in the industrial practice fit with the proposed mechanism. Furthermore, the model provides quantitative results regarding the influence of slag infiltration on shell solidification and OM morphology. Control of the precise moment when infiltration occurs during the cycle could lead to enhanced mold powder consumption and decreased OM depth, thereby reducing the probability for transverse cracking and related casting problems.

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Abbreviations

d liquid :

liquid slag film thickness

d OM :

oscillation mark depth

d solid :

liquid slag film thickness

f :

frequency (cycles/min)

k :

thermal conductivity (W/m-K)

m disp :

mold displacement (m)

\( q^{\prime} \) :

fluctuating heat flux (W/m2)

\( \bar{q} \) :

mean heat flux (W/m2)

q peak :

peak heat flux (W/m2)

Q c :

mass flow rate (kg/s)

Q s :

powder consumption (kg/m2)

r int :

interfacial resistance (m2-K/W)

s :

stroke (m)

T br :

break temperature (K)

t n :

negative strip time

t p :

positive strip time

v c :

casting speed (m/min or m/s)

v m :

mold velocity (m/s)

v slag :

slag velocity in the gap (m/s)

∆T :

superheat (K)

η :

slag viscosity at 1573 K (100 °C) (dPa-s)

OM:

oscillation mark

SEN:

submerged entry nozzle

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Acknowledgments

The authors would like to thank Tata Steel and EPSRC (GR/T26344) for financial support and facilities. P.R.L. thanks CONACYT and SEP (Mexico) for financial assistance to attend the PhD program at Imperial College London. P.R.L. also acknowledges Swerea MEFOS (Sweden) for further support.

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Author notes

  1. Peter D. Lee (Professor, Co-Director)

    Present address: Manchester X-Ray Imaging Facility, School of Materials, The University of Manchester, Research Complex at Harwell, Rutherford Appleton Laboratory, Didcot, Oxon, OX11 OFA, United Kingdom

Authors and Affiliations

  1. Casting and Flow Simulation Group, Process Metallurgy Department, Swerea MEFOS, SE97 437, Luleå, Sweden

    Pavel E. Ramirez Lopez (Research Engineer)

  2. Department of Materials, Imperial College London, London, SW7 2AZ, United Kingdom

    Kenneth C. Mills (Professor) & Peter D. Lee (Professor, Co-Director)

  3. Casting Metallurgy Flat Products, Steelmaking & Continuous Casting Department, Tata Steel Research Development & Technology, 1970 CA, IJmuiden, The Netherlands

    Begoña Santillana (Group Leader)

Authors
  1. Pavel E. Ramirez Lopez
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Corresponding author

Correspondence to Pavel E. Ramirez Lopez.

Additional information

Manuscript Submitted December 8, 2010.

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Ramirez Lopez, P.E., Mills, K.C., Lee, P.D. et al. A Unified Mechanism for the Formation of Oscillation Marks. Metall Mater Trans B 43, 109–122 (2012). https://doi.org/10.1007/s11663-011-9583-5

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