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<p>Thermo-mechanical failures of mold copper plates during high-speed continuous casting present a critical challenge to production efficiency and slab quality. This study integrates industrial failure analysis with a fully coupled 3D thermo-mechanical model incorporating dynamic slag film and air gap distributions, strand shrinkage, and fluid–structure interaction to investigate crack initiation and wear mechanisms. Validated against plant measurements, the model exhibits temperature deviations within 2 °C. Results show that the narrow face copper plate in Mold I endures considerably higher thermo-mechanical loads than the wide face, with peak temperatures reaching 371.7 °C and 322.0 °C, von Mises stresses of 382.4 and 355.7 MPa, and total deformations of 0.38 and 0.27 mm, respectively—all occurring 20 mm below the meniscus (located approximately 100 mm below the mold top). Analysis indicates that cracks within the region 100 to 140 mm below the mold top on the narrow face are caused by thermal stresses exceeding the material yield limit, while abrasive wear along the vertical edges corresponds to peak friction stresses reaching 22.11 kPa. A comparison of three narrow face copper plates coating layer structures (Molds I–III) reveals that the functionally graded coating design (Mold III) demonstrates optimal performance. It reduces the peak temperature by 47.2 °C (to 324.5 °C), decreases the von Mises stress by 38.2 MPa (to 344.2 MPa), and diminishes the total deformation by 0.05 mm (to 0.33 mm), while substantially enhancing wear resistance in critical regions. This work provides both a validated modeling framework and an effective coating optimization strategy for extending mold service life under high-speed casting conditions.</p>

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Thermo-mechanical Behavior of Slab Mold Copper Plates During High-Speed Continuous Casting and Its Coating Layer Structure Optimization

  • 期刊论文

  • 发表日期：

    2025年11月4日

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  • Jiyin Jiang,
  • Zhaozhen Cai,
  • Miaoyong Zhu,
  • Zhenyu Niu

摘要

Thermo-mechanical failures of mold copper plates during high-speed continuous casting present a critical challenge to production efficiency and slab quality. This study integrates industrial failure analysis with a fully coupled 3D thermo-mechanical model incorporating dynamic slag film and air gap distributions, strand shrinkage, and fluid–structure interaction to investigate crack initiation and wear mechanisms. Validated against plant measurements, the model exhibits temperature deviations within 2 °C. Results show that the narrow face copper plate in Mold I endures considerably higher thermo-mechanical loads than the wide face, with peak temperatures reaching 371.7 °C and 322.0 °C, von Mises stresses of 382.4 and 355.7 MPa, and total deformations of 0.38 and 0.27 mm, respectively—all occurring 20 mm below the meniscus (located approximately 100 mm below the mold top). Analysis indicates that cracks within the region 100 to 140 mm below the mold top on the narrow face are caused by thermal stresses exceeding the material yield limit, while abrasive wear along the vertical edges corresponds to peak friction stresses reaching 22.11 kPa. A comparison of three narrow face copper plates coating layer structures (Molds I–III) reveals that the functionally graded coating design (Mold III) demonstrates optimal performance. It reduces the peak temperature by 47.2 °C (to 324.5 °C), decreases the von Mises stress by 38.2 MPa (to 344.2 MPa), and diminishes the total deformation by 0.05 mm (to 0.33 mm), while substantially enhancing wear resistance in critical regions. This work provides both a validated modeling framework and an effective coating optimization strategy for extending mold service life under high-speed casting conditions.