连铸初始凝固过程若干动力学问题研究
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摘要
连铸坯凝固是包含流动、传热、传质的动力学过程,也是具有高温、多相及相互影响特征的复杂体系,控制连铸坯初始凝固对铸坯质量至关重要。连铸生产中,大部分铸坯缺陷是在凝固初期形成,随凝固进程而发展,严重时会形成质量事故。本文围绕连铸中结晶器振动和水口吹氩浇注工艺,研究其动力学过程(如金属熔体及其温度的动力学响应、气泡的动力学行为和运动过程等),及其对铸坯质量的影响,进而揭示部分凝固缺陷形成的动力学过程。这有助于从问题的本源或动因的定量角度,进行工艺设计、分析、优化,为改善铸坯质量提供内在依据和理论指导。
目前,冶金研究者对连铸坯凝固的研究主要是围绕流动、传热、相变中的“力”和“热”的作用展开的,而连铸中的流动和传热受众多因素影响,尤其在结晶器振动、水口注入氩气等工艺条件下,流动和传热的情况更为复杂,直接通过实验观察和测量,以及理论计算都存在许多困难,因此结晶器振动等因素往往被忽略或做简化处理,这就会丢失一些重要的影响信息,使连铸过程深层次的一些动力学行为难以展示,进而影响了工艺设计和优化的准确性。对此,本文考虑结晶器振动和拉坯过程,建立包含结晶器振动的非稳态传热模型,定量地揭示铸坯初始凝壳的传热特点,进而提出一种新的振痕形成机理。
另一方面,水口吹氩工艺使用不当,也会对铸坯带来质量缺陷。为了降低钢水中气泡对铸坯质量的影响,弄清气泡在结晶器内的动力学行为和运动过程十分重要。这里,气泡在结晶器内的运动是涉及钢(液)-渣(液、固)-气三相的多相流问题,通过数值模拟的方法再现气泡运动的整个过程难度极大,而水模拟实验也难以真实反映气泡在金属液中的运动特点。因此,本文采用物理模拟和数值模拟相结合的方法,测量气泡在液态金属(水银)条件下的运动特点和数量分布,计算气泡上浮中的变形、破裂/聚合等行为和对钢渣界面的影响,观察气泡被坯壳(固液界面)所俘获的情况,从而相对完整地反映气泡在结晶器内的动力学行为和过程。
文中首先建立了结晶器振动条件下的传热和凝固模型,通过传热方程中对流项的特殊处理将结晶器振动和拉坯过程同时考虑进来,在算法上实现了结晶器振动和拉坯作用的计算。在此基础上,模拟了结晶器振动条件下的锡液初始凝固传热行为,发现锡连铸中,初始凝固区域温度随结晶器振动而发生周期性变化。频谱分析显示,该温度变化的频率与结晶器振动的频率一致。同时,为验证数值模拟结果的正确性,文中设计了实验室的小型连铸实验,并以锡为模拟介质,采用热电偶序列对初始凝固区域温度进行测量。实验结果显示,结晶器振动导致初始凝固区域温度发生变化,温度变化幅度在4～11℃,变化频率与结晶器振动基本一致。将数值结果与实测结果进行对比,发现上述结果数值接近,趋势吻合,这表明本文所建立的数学模型适用于结晶器振动条件下的传热计算。
由此,利用上述数学模型对实际生产中的钢连铸传热进行了数值模拟,从理论上证实了“温度波动”现象的存在,并且针对不同的连铸工艺参数下的传热模拟,得到了不同工艺参数对铸坯初凝壳区域温度波动的影响规律。结果显示,温度波动峰值往往出现在初始凝固点附近,提高结晶器振动频率或减小结晶器振动幅度,均可减小温度波动。
其次,文中基于对结晶器振动条件下的传热计算,结合包晶钢相转变解析计算方法,建立了温度波动条件下的相转变模型,分析温度波动对微观枝晶组织生长的影响。结果显示,温度波动使得包晶钢凝固过程中L/δ和δ/γ界面发生变化,当温度波动幅度较大时,已凝固的γ相会发生重熔,就本文所计算的不同化学成分对包晶钢相变的影响来看,碳含量在0.1%～0.14%的亚包晶钢受温度波动影响尤甚,这解释了包晶钢和不锈钢难以连铸的原因。
再者,文中基于宏观温度场分析和微观枝晶生长计算,并对实际生产的铸坯进行取样分析,观察铸坯表面形貌、振痕特征,以及振痕附近的组织特点等,提出了铸坯表面振痕和微裂纹形成的一种可能机理。
从本文对铸坯表面振痕的观察可见,除了传统的“凹陷”型和“皱折”型振痕,还有一种新的、被称之为“熔断溢流”型振痕。这类振痕可能是初始凝固区域的温度波动导致弯月面(初始凝固点)温度探底到零强温度和零韧温度,此时任何外力都可能破坏枝晶组织,从而显现为熔断溢流型振痕或其它裂纹缺陷。基于温度波动计算和实验分析,可解释目前所有类型振痕的形成机理。笔者认为,温度波动是振痕形成的一个重要原因,并由此提出温度波动因子(Index of temperature fluctuation)概念,以此衡量温度波动对铸坯表面形成振痕的影响。同时,不同位置温度波动因子的变化还揭示铸坯凝固坯壳厚度的不均匀状态,表明铸坯表面一定范围内的力学性能会有较大差异,易形成表面缺陷。在生产中,采取适当的工艺措施抑制温度波动因子大小和变化幅度,有利于改善铸坯表面质量。
最后,本文针对连铸浇注时水口吹氩,以及其对对铸坯质量的影响问题,进行了物理和数值模拟,由此分析气泡在上浮过程中的拓扑变化和对钢渣界面局部流场的影响,再通过现场取样对比,提出了气泡被铸坯捕获的可能机理。文中设计了水口吹氩的实验装置,采用水银作为模拟介质进行水口吹氩的物理模拟实验,并用电阻探针组对结晶器内的气泡分布进行统计测量。结果表明,进入结晶器的大部分气泡上浮逸出,小部分气泡在固液界面处被铸坯捕获而凝入铸坯。对于气泡在液面处的上浮行为和凝固前沿被铸坯捕获的过程,本文分别采用数值模拟和实验观察方法进行研究。为研究结晶器内气泡上浮时穿过钢渣界面的运动行为及其拓扑变化,笔者用水平集法对钢-渣-气三相体系进行了数值模拟,以此研究不同尺寸的气泡在上浮过程中的变形行为,以及气泡穿过钢渣界面时对界面流场(分布)的影响规律(变化特点),进而考察气泡与卷渣现象的关联性等问题。另外,本文通过水冷插针凝固耦合钢液内气体喷吹实验,还观察了气泡在固液界面处的运动和被凝固坯壳俘获的动力学行为,发现部分气泡在固液界面处被捕获,而有些气泡却在到达固液界面处后被微液流推开。另从铸坯试样观察发现,铸坯振痕底部存在气泡,且四周被枝晶所包围,据此认为弯月面处的枝晶阻碍了气泡上浮,这会是气泡被铸坯捕获的一个重要原因。
通过对连铸过程上述关键问题的动力学研究,揭示结晶器振动条件下连铸坯初始凝固区域温度场分布及变化情况和规律,分析其对振痕形成的作用机理;同时全面准确地描述气泡在结晶器内的运动、变形、逸出/被俘获的动力学过程,为确定合理的吹氩工艺和制度提供理论指导。
纵观全文,笔者的研究工作由两部分组成,(1)结晶器振动对连铸坯质量的影响(第二～五章),(2)水口吹氩对铸坯缺陷产生的影响(第六章)。前者首先建立结晶器振动条件下连铸初始凝固区域传热数学模型,并采用低熔点金属对模型进行验证(第二章),再利用该模型模拟了钢坯连铸中初始凝固区域的传热特点(第三章),并在此基础上对连铸中包晶钢的相变过程进行模拟(第四章),同时,为研究结晶器振动对表面振痕的影响,对实际生产的铸坯进行取样分析并与理论计算结果相互对比,得出结晶器振动所导致的弯月面区域温度波动是铸坯表面振痕的形成动因之一的结论(第五章);后者则设计了以液态金属汞为工质的物理模拟实验,测量气泡在结晶器不同部位的分布特点和规律,同时用数值模拟方法,分析气泡上浮过程中的变形、破碎/聚合等动力学行为和特征,以及其对钢渣界面的影响,并分别采用水力学模拟(用冰-水界面模拟凝固前沿)和水冷插针凝固实验方法展现和观察结晶器内气泡被凝固坯壳所捕获的情况和过程,最后再通过生产现场的取样,观察铸坯内气泡周围的组织特征,分析气泡被铸坯捕获的机理,并与理论和模拟实验的研究结果相互印证(第六章)。
It is important to control the initial solidification in continuous casting, during this period, not only the fluid flow, heat transfer and mass transfer were involved, but also the complex system, such as high temperature and multi-phase, was concerned. Most of billet defects were formed in the initial solidification stage, and would get worse during later process. Based on the mold oscillation and argon blowing techniques, the dynamic process and its influence on the billet qualities were investigated, then the dynamic formation process of billet defects were analyzed. It was helpful to improve the billet quality.
Up to the present, metallurgists payed attention to the fluid flow, heat transfer, and the force in the phase transfer, however, most of them were affected by many factors, it was difficult to study directly through experiments or numerical simulation, thus some important information was lost. In this paper, mold oscillation and billet withdrawing were considered, and the transient heat transfer mathematical model was established, with which the heat transfer character was quantitatively revealed, then a new formation mechanism of oscillation marks was proposed.
Besides, improper application of argon blowing would lead to the billet defeats. In order to reduce the influence of gas bubble on the billet quality, it was very important to investigate the dynamic behavior of gas bubble in the mold. The motion of bubble in mold was a three phase flow problem, it was extremely difficult to calculate this process by numerical simulation. Meanwhile, the water modeling experiment was hard to reflect the real motion characteristics of gas bubble in the liquid metal. In this paper, combing with physical modeling and numerical simulation, bubbles distribution in the liquid metal (mercury) was measured, and bubble deformation during floating was calculated, its influence on the steel-slag interface was analyzed. On the other hand, bubble behavior in solidifying front was observed in the experiments. With which the dynamic behavior of gas bubble in the mold was comprehensively described.
This paper is composed of four parts. In the first part, a mathematical model was established to calculated the heat transfer under mold oscillation, the mold oscillation and billet withdrawing were considered through convection term in the governing equations. The heat transfer in continuous casting of Tin was calculated with this model, it was found that temperature of initial solidification area was varied periodically along with mold oscillation. The frequency spectrum analysis of temperature data showed that the frequency was the same as mold oscillation. In order to verify the mathematical model, experiments were carried out on a small-scale caster. Thermocouples column were adopted to measure the temperature of initial solidification area. Repeat experiments results showed that mold oscillation leads to temperature fluctuation, the amplitude was about 4 to 10℃, and the frequency of temperature variety was almost the same as mold oscillation. Compared with calculation and experiment results, it was found that calculation temperature was agreed with measured data, the mathematical model was suitable to calculate the heat transfer under mold oscillation during continuous casting.
The heat transfer of steel continuous casting was simulated with above model, the temperature fluctuation phenomenon was confirmed theoretically. Different continuous casting operation parameters were considered, and its influence on temperature fluctuation was analyzed. The results showed that the maximum temperature fluctuation appeared in vicinity of the initial solidification point, both increasing mold oscillation frequency and decreasing the oscillation amplitude would helpful to reduce the temperature fluctuation.
In the second part of the paper, combined with heat transfer simulation and analytical calculation of peritectic phase transformation, a special mathematical model was proposed to investigate the effect of temperature fluctuation on the initial solidification during continuous casting of peritectic steel. Pretectic phase transfer with different temperature fluctuation was calculated with above mathematical model, the interface of L/δandδ/γwere changed along with temperature fluctuation. While the temperature fluctuation amplitude was larger, part of theγ-phase would be re-melted . Different chemical compositions with different carbon content were calculated, and it was found that the peritectic steel with carbon content of 0.1-0.17% was most sensitive to the temperature fluctuation, it maybe the reason why some of peritectic steels and stainless steels were difficult to continuous cast in industry production. In the third part of the paper, the samples were cut from the industrial billet, and the surface morphology was observed, solidified microstructures in the oscillation marks area were analyzed, the possible formation mechanism of oscillation marks and cracks were proposed.
Besides the depression type and hook type oscillation marks, a new type of oscillation marks was found on the billet surface, we called it as "melt-overflow" type oscillation marks. The temperature in meniscus area may changed near the ZST ( Zero Strength Temperature) or ZDT ( Zero Ductility Temperature) because of temperature fluctuation in initial solidification area, and lead to the formation of "melt-overflow" type oscillation marks. And in this situation, any force exert on the shell might brake the dendrite, then the new type oscillation marks formed.
Based on the analysis of calculation and experiment results, the formation mechanism of all kinds of oscillation marks could be explained, and the temperature fluctuation was considered to be a key factor to the formation of oscillation marks. The ITF( Index of Temperature Fluctuation) was proposed to evaluate the effect of temperature fluctuation on billet surface defects, the variation of ITF lead to the non-uniform shell thickness, and then the billet mechanical properties was heterogeneous, furthermore lead to the formation of surface defects. So, it was useful to improve the billet quality by depressing the ITF as low as possible.
In the fourth part of this paper, the impact of argon blowing on the slab quality was studied in experiment and numerical simulation respectively, the deformation of bubbles during floating and its influence on the velocity field in the area of steel-slag interface were calculated, and the mechanism of bubble entrapment in the solidification front was proposed.
The experiment device of argon blowing was designed, mercy was used in the experiment, and a resistance probe was developed to measure the quantity of bubbles. The results showed that most of bubbles were escaped form liquid surface, some of the bubbles which moved to the solid-liquid interface were captured and then entrapped by the solidified shell. The level set method was used to simulate the three phase flow, and the shape deformation of bubbles with different diameter was calculated, vertical velocity in the steel-slag interface was analyzed, also the possible influence on slag entrapment was discussed. The dip test was carried to observe bubble behavior in front of solid-liquid interface, it was found that some bubbles were captured, while other bubbles could escape form the interface. Observation on the slab specimens, it was found that bubbles were existed at the bottom of oscillation marks, and the bubble was surrounded by dendrites, maybe the floating bubbles were blocked by the dendrites in the meniscus ,it might to be an important reason why bubbles were entrapped in the solidified shell.
Based on the investigation of above key dynamic issues, the temperature distribution and variation in initial solidification area under mold oscillation was revealed, and then the formation mechanism of oscillation marks was proposed. Also, the dynamic behavior of gas bubble in the liquid metal and in solidification front was described comprehensively, and it would be used to determine the reasonable argon blowing parameters.
目前,冶金研究者对连铸坯凝固的研究主要是围绕流动、传热、相变中的“力”和“热”的作用展开的,而连铸中的流动和传热受众多因素影响,尤其在结晶器振动、水口注入氩气等工艺条件下,流动和传热的情况更为复杂,直接通过实验观察和测量,以及理论计算都存在许多困难,因此结晶器振动等因素往往被忽略或做简化处理,这就会丢失一些重要的影响信息,使连铸过程深层次的一些动力学行为难以展示,进而影响了工艺设计和优化的准确性。对此,本文考虑结晶器振动和拉坯过程,建立包含结晶器振动的非稳态传热模型,定量地揭示铸坯初始凝壳的传热特点,进而提出一种新的振痕形成机理。
另一方面,水口吹氩工艺使用不当,也会对铸坯带来质量缺陷。为了降低钢水中气泡对铸坯质量的影响,弄清气泡在结晶器内的动力学行为和运动过程十分重要。这里,气泡在结晶器内的运动是涉及钢(液)-渣(液、固)-气三相的多相流问题,通过数值模拟的方法再现气泡运动的整个过程难度极大,而水模拟实验也难以真实反映气泡在金属液中的运动特点。因此,本文采用物理模拟和数值模拟相结合的方法,测量气泡在液态金属(水银)条件下的运动特点和数量分布,计算气泡上浮中的变形、破裂/聚合等行为和对钢渣界面的影响,观察气泡被坯壳(固液界面)所俘获的情况,从而相对完整地反映气泡在结晶器内的动力学行为和过程。
文中首先建立了结晶器振动条件下的传热和凝固模型,通过传热方程中对流项的特殊处理将结晶器振动和拉坯过程同时考虑进来,在算法上实现了结晶器振动和拉坯作用的计算。在此基础上,模拟了结晶器振动条件下的锡液初始凝固传热行为,发现锡连铸中,初始凝固区域温度随结晶器振动而发生周期性变化。频谱分析显示,该温度变化的频率与结晶器振动的频率一致。同时,为验证数值模拟结果的正确性,文中设计了实验室的小型连铸实验,并以锡为模拟介质,采用热电偶序列对初始凝固区域温度进行测量。实验结果显示,结晶器振动导致初始凝固区域温度发生变化,温度变化幅度在4～11℃,变化频率与结晶器振动基本一致。将数值结果与实测结果进行对比,发现上述结果数值接近,趋势吻合,这表明本文所建立的数学模型适用于结晶器振动条件下的传热计算。
由此,利用上述数学模型对实际生产中的钢连铸传热进行了数值模拟,从理论上证实了“温度波动”现象的存在,并且针对不同的连铸工艺参数下的传热模拟,得到了不同工艺参数对铸坯初凝壳区域温度波动的影响规律。结果显示,温度波动峰值往往出现在初始凝固点附近,提高结晶器振动频率或减小结晶器振动幅度,均可减小温度波动。
其次,文中基于对结晶器振动条件下的传热计算,结合包晶钢相转变解析计算方法,建立了温度波动条件下的相转变模型,分析温度波动对微观枝晶组织生长的影响。结果显示,温度波动使得包晶钢凝固过程中L/δ和δ/γ界面发生变化,当温度波动幅度较大时,已凝固的γ相会发生重熔,就本文所计算的不同化学成分对包晶钢相变的影响来看,碳含量在0.1%～0.14%的亚包晶钢受温度波动影响尤甚,这解释了包晶钢和不锈钢难以连铸的原因。
再者,文中基于宏观温度场分析和微观枝晶生长计算,并对实际生产的铸坯进行取样分析,观察铸坯表面形貌、振痕特征,以及振痕附近的组织特点等,提出了铸坯表面振痕和微裂纹形成的一种可能机理。
从本文对铸坯表面振痕的观察可见,除了传统的“凹陷”型和“皱折”型振痕,还有一种新的、被称之为“熔断溢流”型振痕。这类振痕可能是初始凝固区域的温度波动导致弯月面(初始凝固点)温度探底到零强温度和零韧温度,此时任何外力都可能破坏枝晶组织,从而显现为熔断溢流型振痕或其它裂纹缺陷。基于温度波动计算和实验分析,可解释目前所有类型振痕的形成机理。笔者认为,温度波动是振痕形成的一个重要原因,并由此提出温度波动因子(Index of temperature fluctuation)概念,以此衡量温度波动对铸坯表面形成振痕的影响。同时,不同位置温度波动因子的变化还揭示铸坯凝固坯壳厚度的不均匀状态,表明铸坯表面一定范围内的力学性能会有较大差异,易形成表面缺陷。在生产中,采取适当的工艺措施抑制温度波动因子大小和变化幅度,有利于改善铸坯表面质量。
最后,本文针对连铸浇注时水口吹氩,以及其对对铸坯质量的影响问题,进行了物理和数值模拟,由此分析气泡在上浮过程中的拓扑变化和对钢渣界面局部流场的影响,再通过现场取样对比,提出了气泡被铸坯捕获的可能机理。文中设计了水口吹氩的实验装置,采用水银作为模拟介质进行水口吹氩的物理模拟实验,并用电阻探针组对结晶器内的气泡分布进行统计测量。结果表明,进入结晶器的大部分气泡上浮逸出,小部分气泡在固液界面处被铸坯捕获而凝入铸坯。对于气泡在液面处的上浮行为和凝固前沿被铸坯捕获的过程,本文分别采用数值模拟和实验观察方法进行研究。为研究结晶器内气泡上浮时穿过钢渣界面的运动行为及其拓扑变化,笔者用水平集法对钢-渣-气三相体系进行了数值模拟,以此研究不同尺寸的气泡在上浮过程中的变形行为,以及气泡穿过钢渣界面时对界面流场(分布)的影响规律(变化特点),进而考察气泡与卷渣现象的关联性等问题。另外,本文通过水冷插针凝固耦合钢液内气体喷吹实验,还观察了气泡在固液界面处的运动和被凝固坯壳俘获的动力学行为,发现部分气泡在固液界面处被捕获,而有些气泡却在到达固液界面处后被微液流推开。另从铸坯试样观察发现,铸坯振痕底部存在气泡,且四周被枝晶所包围,据此认为弯月面处的枝晶阻碍了气泡上浮,这会是气泡被铸坯捕获的一个重要原因。
通过对连铸过程上述关键问题的动力学研究,揭示结晶器振动条件下连铸坯初始凝固区域温度场分布及变化情况和规律,分析其对振痕形成的作用机理;同时全面准确地描述气泡在结晶器内的运动、变形、逸出/被俘获的动力学过程,为确定合理的吹氩工艺和制度提供理论指导。
纵观全文,笔者的研究工作由两部分组成,(1)结晶器振动对连铸坯质量的影响(第二～五章),(2)水口吹氩对铸坯缺陷产生的影响(第六章)。前者首先建立结晶器振动条件下连铸初始凝固区域传热数学模型,并采用低熔点金属对模型进行验证(第二章),再利用该模型模拟了钢坯连铸中初始凝固区域的传热特点(第三章),并在此基础上对连铸中包晶钢的相变过程进行模拟(第四章),同时,为研究结晶器振动对表面振痕的影响,对实际生产的铸坯进行取样分析并与理论计算结果相互对比,得出结晶器振动所导致的弯月面区域温度波动是铸坯表面振痕的形成动因之一的结论(第五章);后者则设计了以液态金属汞为工质的物理模拟实验,测量气泡在结晶器不同部位的分布特点和规律,同时用数值模拟方法,分析气泡上浮过程中的变形、破碎/聚合等动力学行为和特征,以及其对钢渣界面的影响,并分别采用水力学模拟(用冰-水界面模拟凝固前沿)和水冷插针凝固实验方法展现和观察结晶器内气泡被凝固坯壳所捕获的情况和过程,最后再通过生产现场的取样,观察铸坯内气泡周围的组织特征,分析气泡被铸坯捕获的机理,并与理论和模拟实验的研究结果相互印证(第六章)。
It is important to control the initial solidification in continuous casting, during this period, not only the fluid flow, heat transfer and mass transfer were involved, but also the complex system, such as high temperature and multi-phase, was concerned. Most of billet defects were formed in the initial solidification stage, and would get worse during later process. Based on the mold oscillation and argon blowing techniques, the dynamic process and its influence on the billet qualities were investigated, then the dynamic formation process of billet defects were analyzed. It was helpful to improve the billet quality.
Up to the present, metallurgists payed attention to the fluid flow, heat transfer, and the force in the phase transfer, however, most of them were affected by many factors, it was difficult to study directly through experiments or numerical simulation, thus some important information was lost. In this paper, mold oscillation and billet withdrawing were considered, and the transient heat transfer mathematical model was established, with which the heat transfer character was quantitatively revealed, then a new formation mechanism of oscillation marks was proposed.
Besides, improper application of argon blowing would lead to the billet defeats. In order to reduce the influence of gas bubble on the billet quality, it was very important to investigate the dynamic behavior of gas bubble in the mold. The motion of bubble in mold was a three phase flow problem, it was extremely difficult to calculate this process by numerical simulation. Meanwhile, the water modeling experiment was hard to reflect the real motion characteristics of gas bubble in the liquid metal. In this paper, combing with physical modeling and numerical simulation, bubbles distribution in the liquid metal (mercury) was measured, and bubble deformation during floating was calculated, its influence on the steel-slag interface was analyzed. On the other hand, bubble behavior in solidifying front was observed in the experiments. With which the dynamic behavior of gas bubble in the mold was comprehensively described.
This paper is composed of four parts. In the first part, a mathematical model was established to calculated the heat transfer under mold oscillation, the mold oscillation and billet withdrawing were considered through convection term in the governing equations. The heat transfer in continuous casting of Tin was calculated with this model, it was found that temperature of initial solidification area was varied periodically along with mold oscillation. The frequency spectrum analysis of temperature data showed that the frequency was the same as mold oscillation. In order to verify the mathematical model, experiments were carried out on a small-scale caster. Thermocouples column were adopted to measure the temperature of initial solidification area. Repeat experiments results showed that mold oscillation leads to temperature fluctuation, the amplitude was about 4 to 10℃, and the frequency of temperature variety was almost the same as mold oscillation. Compared with calculation and experiment results, it was found that calculation temperature was agreed with measured data, the mathematical model was suitable to calculate the heat transfer under mold oscillation during continuous casting.
The heat transfer of steel continuous casting was simulated with above model, the temperature fluctuation phenomenon was confirmed theoretically. Different continuous casting operation parameters were considered, and its influence on temperature fluctuation was analyzed. The results showed that the maximum temperature fluctuation appeared in vicinity of the initial solidification point, both increasing mold oscillation frequency and decreasing the oscillation amplitude would helpful to reduce the temperature fluctuation.
In the second part of the paper, combined with heat transfer simulation and analytical calculation of peritectic phase transformation, a special mathematical model was proposed to investigate the effect of temperature fluctuation on the initial solidification during continuous casting of peritectic steel. Pretectic phase transfer with different temperature fluctuation was calculated with above mathematical model, the interface of L/δandδ/γwere changed along with temperature fluctuation. While the temperature fluctuation amplitude was larger, part of theγ-phase would be re-melted . Different chemical compositions with different carbon content were calculated, and it was found that the peritectic steel with carbon content of 0.1-0.17% was most sensitive to the temperature fluctuation, it maybe the reason why some of peritectic steels and stainless steels were difficult to continuous cast in industry production. In the third part of the paper, the samples were cut from the industrial billet, and the surface morphology was observed, solidified microstructures in the oscillation marks area were analyzed, the possible formation mechanism of oscillation marks and cracks were proposed.
Besides the depression type and hook type oscillation marks, a new type of oscillation marks was found on the billet surface, we called it as "melt-overflow" type oscillation marks. The temperature in meniscus area may changed near the ZST ( Zero Strength Temperature) or ZDT ( Zero Ductility Temperature) because of temperature fluctuation in initial solidification area, and lead to the formation of "melt-overflow" type oscillation marks. And in this situation, any force exert on the shell might brake the dendrite, then the new type oscillation marks formed.
Based on the analysis of calculation and experiment results, the formation mechanism of all kinds of oscillation marks could be explained, and the temperature fluctuation was considered to be a key factor to the formation of oscillation marks. The ITF( Index of Temperature Fluctuation) was proposed to evaluate the effect of temperature fluctuation on billet surface defects, the variation of ITF lead to the non-uniform shell thickness, and then the billet mechanical properties was heterogeneous, furthermore lead to the formation of surface defects. So, it was useful to improve the billet quality by depressing the ITF as low as possible.
In the fourth part of this paper, the impact of argon blowing on the slab quality was studied in experiment and numerical simulation respectively, the deformation of bubbles during floating and its influence on the velocity field in the area of steel-slag interface were calculated, and the mechanism of bubble entrapment in the solidification front was proposed.
The experiment device of argon blowing was designed, mercy was used in the experiment, and a resistance probe was developed to measure the quantity of bubbles. The results showed that most of bubbles were escaped form liquid surface, some of the bubbles which moved to the solid-liquid interface were captured and then entrapped by the solidified shell. The level set method was used to simulate the three phase flow, and the shape deformation of bubbles with different diameter was calculated, vertical velocity in the steel-slag interface was analyzed, also the possible influence on slag entrapment was discussed. The dip test was carried to observe bubble behavior in front of solid-liquid interface, it was found that some bubbles were captured, while other bubbles could escape form the interface. Observation on the slab specimens, it was found that bubbles were existed at the bottom of oscillation marks, and the bubble was surrounded by dendrites, maybe the floating bubbles were blocked by the dendrites in the meniscus ,it might to be an important reason why bubbles were entrapped in the solidified shell.
Based on the investigation of above key dynamic issues, the temperature distribution and variation in initial solidification area under mold oscillation was revealed, and then the formation mechanism of oscillation marks was proposed. Also, the dynamic behavior of gas bubble in the liquid metal and in solidification front was described comprehensively, and it would be used to determine the reasonable argon blowing parameters.
引文
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