Numerical Simulation of Macro-Segregation Phenomena in Transition Blooms with Various Carbon Contents

Abstract

This paper presents a numerical simulation of the steel grade transition from the ladle nozzle to the solidification end of the bloom. The simulation is based on models encompassing fluid flow, solidification, heat transfer, an electromagnetic field, and solute transport. To validate the accuracy of the steel grade transition model, transition blooms of high-carbon steel are sampled. Subsequently, the model is applied to investigating the steel grade transition between medium-carbon steel and low-carbon steel. The findings indicate that the regions exhibiting significant differences between their molten steel flow velocity and bloom casting speed in the strand model are primarily concentrated within 1 m below the meniscus. Additionally, the mushy zone in the strand model possesses a substantial volume. Solute elements continuously permeate the liquid phase from the solid phase through the mushy zone. Consequently, the distribution of solute elements in the transition bloom is primarily influenced by the molten steel flow in the tundish and macro-segregation in the casting process. The segregation degree of each solute element varies among grades with different carbon contents. In the austenite phase, the segregation degree of each element follows the order C > Si > Mo > Mn > Cr > Ni, while in the ferrite phase, the segregation degree is ordered as C > Si = Mn. Considering macro-segregation, the transition bloom partition model proves to be more stringent than the original partition method. This results in longer transition blooms when a significant difference exists between the new and old grades. For example, in Scheme 1, the original plan transition bloom length is 8.88 m, whereas the new plan transition bloom length is 10.88 m. Similarly, in Scheme 2, the original plan transition bloom length is 34.64 m, and the new plan transition bloom length is 35.16 m. Conversely, shorter partition intervals occur when there is an overlap in the composition of the new and old grades. In Scheme 3, the original plan partition interval for the new and old grades is 4.08 m, while the new plan partition interval is reduced to 0.94 m.