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The objectives of this collaborative multinational project aimed to improve the surface and sub-surface quality of as-cast billets were achieved through the establishment of the effect of process variables on surface defects on industrial casters producing carbon and stainless steels, optimisation of the casting process via physical and mathematical modelling and the development of a numerical understanding of the development of the shell and meniscus and its effects on oscillation mark and inclusion/powder entrapment. Within the framework of the project, BFI carried out basic investigations related to the physical phenomena in the multiphase melt/slag/inclusions/bubbles system of continuous billet casting moulds and their influence on solidification, steel cleanness and surface quality via both physical and numerical modelling. The numerical modelling undertaken by Politecnico di Milano was an attempt to structure a computational approach to billet surface quality and was complimentary to that of BFI. The models were used to aid the interpretation of the results of Corus and, especially, Mittal Steel. In the latter respect, observations made during the industrial trials at Mittal Steel on M-EMS intensity and oscillation parameters were explained easily using the model. Casting process conditions were optimised to enable billet surface quality improvement for carbon (Mittal Steel) and stainless (Corus) steels through an investigation of the effects of M-EMS stirring intensity, mould oscillation parameters, mould powder composition and feeding, steel composition, primary mould water flow rate, casting superheat, mould geometry, variation in meniscus level, lubricant oil composition and secondary cooling. The detection on-line of surface defects in hot billets was also progressed via a CSM successful development and installation on the Ori-Martin Billet Mill of an optical system able to detect defects 1 mm across in the rolling surface of a square billet.

Additional information

Authors: LUDLOW V, Corus UK, Middlesborough (GB);RIAZ S, Corus UK, Middlesborough (GB);STRIEDINGER R, BFI, Düsseldorf (DE);STERCKEN K, Mittal Steel Hamburger, Hamburg (DE);FALESSI R, CSM, Rome (IT);MAPELLI C, Politechnico di Milano, Milano (IT);DE MIRANDA R, ORI Martin, Brescia (IT);GERBINO G, Riva Acciaio, Lesegno (IT)
Bibliographic Reference: EUR 22440 EN (2007), 340 pp. Euro: 45
Availability: Katalogue Number: KI-NA-22440-EN-S The paper version can be ordered online and the PDF version downloaded at:
ISBN: ISBN: 978-92-79-04601-8
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