Toward better control of microstructure in steel casting via robust computational tool

Purpose and goal:

The quality and properties of cast products depend on the microstructure and casting defects that are formed during production. The overall goal of this project is to develop an industry-friendly platform for process and solidification modeling of advanced steels to provide better control of both microstructure and defects. In this continuation project, MICAST is extended with new simulation functionality for the electroslag remelting (ESR) method and improves the ability to predict hot cracking of continuous casting materials.

Expected results and effects:

Hot cracking in continuous casting of steel will be predicted based on a newly developed multi-scale elastic-plastic finite element method and criteria for hot cracking. The electroslag remelting (ESR) will be simulated using OpenFOAM, which enables the use of advanced flow and solidification models together with the CALPHAD method. In addition, complete phase transformation kinetics during cooling to room temperature will be modeled by combining CALPHAD and CCT data.

Approach and implementation:

The project is divided into four work packages: 1) thermomechanical modeling in continuous casting; 2) process and solidification modeling in ingot remelt casting (ESR); 3) software development; 4) documentation and dissemination of results. The results will be verified through laboratory and operational tests. Finally, the developed MICAST software will be used by the industrial parties in process parameter studies of their processes.

The usability of the software will be improved through discussions between developers and users and at joint project meetings.