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New method for determining contact resistance through variable heat transfer coefficient is introduced which
takes into account physical properties of the casting material, process parameters and contact time/length bet-
ween molten material (melt puddle) and chilling wheel and enables cooling rate prediction before experiment
execution. From the results can be concluded, that those process parameters which determine the thickness of
the melt puddle in the downstream and consequently the ribbon thickness have major influence on cooling
rate of the ribbon. In the case of continuous casting, heat balance of the wheel is calculated and influence of
the chill wheel cooling mode on cooling rate of metallic ribbon is analyzed.
Key words: continuous casting, rapid solidification, metallic materials, heat transfer balance, heat transfer co-
efficient, numerical modeling
Analiza prijelaza topline tijekom kontinuiranog lijevanja ure|ajem za brzo skru}ivanje. Uvedena je
nova metoda za odre|ivanje kontaktne toplinske otpornosti pomo}u varijabilnog koeficijenta prijelaza topline,
koji uzima u obzir fizikalna svojstva lijevanog materijala, procesne parametre i vrijeme kontakta/duljine izme|u
rastaljenog djela materijala i rashladnog valjka, omogu}avaju}i predvi|anje brzine hla|enja prije provo|enja ek-
sperimenta. Iz navedenih se rezultata mo`e se zaklju~iti, da oni procesni parametri koji odre|uju debljinu rastalje-
nog djela materijala u donjem toku, a posljedi~no i debljinu trake, imaju najve}i utjecaj na brzinu hla|enja trake.
U slu~aju kontinuiranog lijevanja izra~unata je toplinska bilanca valjka i analiziran je utjecaj na~ina hla|enja valjka
na brzinu hla|enja metalne trake.
Klju~ne rije~i: kontinuirano ljevanje, brzo skru}ivanje, metalni materijali, toplinska bilanca, koeficijent prijelaza
topline, numeri~ko modeliranje
Figure 4 Steel and copper wheel temperature profile un- Figure 5 Cooling curves for 66 mm thick Al ribbon as a
der melt puddle as a function of contact time function of initial wheel temperature and con-
(uw = 18,9m/s, ribbon thickness 66mm, contact tact time (uw = 18,9 m/s, a = f(x))
time 0,923 msec, a =106W/(m2·K))
– No radiation from the crucible is taken into ac-
face temperature is about 200 °C and penetration depth count.
twice as much. Nevertheless, after reaching its maxi- Internally water cooled wheel will reach the periodic
mum the wheel surface temperature decreases, although steady state after few hundred of revolutions. But if the
it is in contact with hotter ribbon. This seems unlikely, wheel casing is too thick, internal cooling will have no
but considering the wheel as a whole, its enthalpy rises practical influence on wheel surface temperature, which
constantly, since temperature of more than 0,3mm under can still increase significantly when high melting-point
the surface increases the entire contact time. alloys are cast.
When materials with higher melting point are cast, External gas convective cooling has also no signifi-
surface temperature will increase much higher. Obvi- cant influence on the wheel surface temperature even
ously, such a large deviation in surface temperature under assumption of exaggerated value of convective
should not be neglected in calculation of cooling and so- heat transfer coefficient aair = 1000 W/(m2·K), because
lidification rate of the melt. Importance of wheel mate- duration of one revolution is too short. Conducting of
rial selection is evident. Pure deoxidized copper has the heat into the wheel is much higher than external convec-
highest thermal diffusivity between all commercially tive cooling with surrounding atmosphere.
useful materials and therefore it is the best choice for the If the wheel casing thickness is reduced down to
wheel material. 2 mm, internal water cooling will be more effective.
During continuous casting process, the wheel is not Wheel surface temperature that melt will actually “see”
subjected only to heat transfer from the solidifying ma- at the beginning of the next pass of the wheel under the
terial, but also to radiation and convection heat transfer melt puddle, will be practically the same as at the first
from the crucible. In that case, significant “long term” revolution, even if high melting temperature materials
surface temperature increase may take place, if the are cast. But with further reduction of the wheel casing,
wheel in not externally or internally cooled. Figure 5 even beneath the heat penetration depth (Figure 6), con-
shows the effect of the initial wheel temperature on the
temperature profiles calculated in the Al ribbon. Initial
wheel temperature has considerable influence on ribbon
free surface solidification time, which have further in-
fluence on puddle dynamic stability. When relatively
thicker (> 60 mm) ribbons or materials with low thermal
conductivity are cast, puddle instability prevent casting
of ribbon with uniform thickness.
For continuous casting heat balance calculations, the
following assumptions were considered:
– Wheel is cooled by convection heat transfer from
the outside with surrounding atmosphere, and
from the inside with water stream. Convective
heat transfer coefficients were taken as constants
and represents the average values calculated from Figure 6 Internally cooled copper wheel surface tempera-
ture increase as a function of contact time and
forced convection correlation equations thickness of wheel casing for aluminum casting
(awater = 5000 W/(m2·K), aair = 50 W/(m2·K) or (Rw = 0,2 m, uw = 18,9 m/s, ribbon thickness
limited value of 1000 W/(m2·K)). 66 mm, contact time 0,923 ms)
vective heat resistance on the inner side (wheel – water casing of the wheel is too thin, thermal resistance on the
interface) becomes significant. Even if the heat transfer cooling side (wheel-water interface) becomes the limit-
coefficient value on inner side of a casing is assumed as ing factor, which reduces the heat transfer from the melt
high as 100000 W/(m2·K), which can be reached with and consequently its cooling and solidifying rate. Internal
high pressure impingement water jets[9], heat removal wheel cooling with liquids of room temperature does not
from the melt will be slower as in the case of bulk wheel. increase cooling and solidifying rate of the ribbon, but
Reducing the thickness of the wheel casing under the only assures constant wheel surface temperature.
heat penetration depth is unsuitable, because of rapid so-
lidification and because steadiness point of view [10]. REFERENCES
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thickness is correctly selected. When too thick casing is
applied, water cooling will have no considerable influ- Note: The responsible translator for English language is Ur{ka Letonja,
ence on wheel surface temperature decrease. When the University of Ljubljana, Slovenia