Continuous casting simulator

Simulator creates complete overview of continuous casting

Although extensive research concerning the behaviour of molten steel in the mould during casting has been conducted, not all flow relations can be described. Swerim has developed a simulator for studying important relations during continuous casting. The simulator provides an overall view of the casting process.

 It is difficult to study the metal in a real casting machine or to build one in pilot scale. Often, water models are used; but molten steel and water do not behave similarly when it comes to pressure and flow.

Physical model simulate continuous casting

Swerim has therefore created a full-scale physical model of a continuous casting machine complete with a stopper rod, casting tube and mould. Only the tundish has been reduced in size as compared to that of a real casting machine. An alloy with a low melting point (137 degrees Celsius) has been selected as a suitable medium for simulating steel flow. The model is equipped for gas injection via the stopper rod, which corresponds to normal practice in industry.

The alloy's properties are similar to that of steel and it is non-toxic. Its electrical properties make it ideal for studying devices such as electromagnetic stirring or braking. In addition, an oil layer can be applied to simulate how slag behaves in a real casting machine. Metal flow rate is measured with various sensors, while a video camera monitors the surface of the mould.

Complete overview of continuous casting

The equipment enables better understanding of the importance of the multiphase flow (steel, slag and argon) in continuous casting. The model provides a clear overall view of the continuous casting process. Studies with the model have also resulted in two patent-pending methods.