Heat Transfer with Change of

Phase in Continuous Casting

Ernesto Gutierrez-Miravete
Rensselaer at Hartford
ANSYS Users Group Meeting
September 28, 2010
Outline
Continuous Casting Processes
Physics and Mathematics of Heat
Conduction with Change of Phase
and Mass Transport
Finite Element Formulations
Illustrative Examples
Continuous Casting Processes
Metal Processing often involves Molten
Metals
Molten Metals must be Solidified to produce
Bulk Solid Specimens
Metal Solidification for the Production of
Bulk Specimens is carried out in Practice
either in Batches (Ingot or Shape Casting) or
Continuosly (Continuous Casting)

Mathematical Formulation of
Heat Conduction with Change of Phase Problems
Differential Thermal Energy Balance Equation
Inside the Bulk Phases (Energy Conservation)
Heat Flux-Temperature Gradient Relationships
Inside the Bulk Phases (Fourier Law)
Differential Thermal Energy Balance Equation
at the Interface between Phases accounting
for the Latent Heat of Phase Change (Stefan
Condition)
Boundary Conditions on External Boundaries

Latent Heat of Phase Change
Enthalpy
(H)
Temperature (T)
H
f
DT
f
H/T = C
p
Critical Issues in Numerical Solution of
Heat Conduction problems with Change of Phase in CC
Stefan Condition makes problem Non-
Linear even for Constant Properties
T(x,t) x(t) T(x,t)
Interface Motion driven by Physics,
unrelated to Position of Mesh Nodes
x(t) = f(t)
Grid Peclet Number Constraint
V L r C
p
/2k < 1
Finite Element Formulation of
Heat Conduction with Change of Phase Problems in CC
Variational Statement of the Problem
Galerkins Method
Time Stepping
Handling of the Stefan Condition
Enthalpy Method
Effective Specific Heat Method
Effect of Mass Transport

Illustrative Examples
Continuous Casting in 2D (a Useful
Toy Model)
Direct Chill Continuous Casting Model
Thin Slab Continuous Casting Model

Continuous Casting in 2D
Effect of M (kg/min) and q (W/m2)
on T-z Curve along Slab Centerline
400
500
600
700
800
900
1000
1100
1200
0 0.2 0.4 0.6 0.8 1
T (C)
z (m)
Effect of M
400
500
600
700
800
900
1000
1100
1200
0 0.2 0.4 0.6 0.8 1
T (C)
z (m)
Effect of q
Predicted Metallurgical Length z
m

2D Model
M (kg/min) Z
m
(m)
24 0.52
27 0.63
30 0.72
33 0.83
36 0.98
Q (W/m
2
) Z
m
(m)
-0.8e5 1.10
-0.9e5 0.84
-1.0e5 0.72
-1.1e5 0.66
-1.2e5 0.57
Direct Chill Continuous Casting
2D DC CC Model (Slab Detail)

2D DC CC Model (Mold Detail)

3D DC CC Square Bar Model
(Slab and Mold Temperatures)

3D DC CC Model (Slab CL Detail)

3D DC CC Model
(Full Slab View from CL)

3D DC CC Model
(Full Slab View from Narrow Face)

Thin Slab Continuous Casting
Thin Slab Continuous Casting Mold
This Slab CC Mold Heat Flux
(Measured)
Thin Slab CC Mold Model (Mesh)
Thin Slab CC Mold Model
(Predicted Temperature and Displacements)

In Closing
Heat Conduction with Change of Phase is the Simplest Model
of a Solidifying System
Additional Important Issues and Future Goals
Thermo-Mechanical Effects
Liquid Metal Flow Effects
Solidified Microstructure Development
Solid State Phase Changes
Optimal Heat Extraction Practices
Comprehensive, Push-Button Models
Partial support from CCAT for the performance and
presentation of this work is gratefully acknowledged