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<p>The conventional manufacturing routes for silicon steel—marked by lengthy processing cycles, high energy consumption, and considerable carbon emissions—can no longer meet the increasingly stringent requirements for high magnetic induction and low core loss. In this context, planar flow casting (PFC), characterized by a short-process chain, high efficiency, and low energy demand, has emerged as a promising breakthrough technology for producing ultra-thin non-oriented silicon steel ribbons. This paper presents a comprehensive review of recent progress in the application of PFC technology to the fabrication of non-oriented silicon steel. The discussion focuses on key scientific and technical issues, including melt puddle behavior, microstructural evolution, and texture control. Drawing on numerical simulation studies from both domestic and international research, this review summarizes advances in multiphysics-coupled simulations of fluid flow, heat transfer, and solidification, with particular emphasis on melt puddle stability prediction, surface-defect evaluation, and microstructure control. The characteristics and developmental trends of mainstream simulation approaches—such as the phase-field method, the cellular automaton (CA) method, and CA-finite element coupled models—are also critically assessed. In addition, the mechanisms governing the columnar-to-equiaxed transition, the formation pathways of the {100} texture, and the effects of these structural features on magnetic performance are discussed. Despite notable progress, several challenges remain, including disturbances caused by the air boundary layer, the narrow operational process window, the thickness non-uniformity of cast ribbons, and insufficient stability of the solidified microstructure. Future research should prioritize the control of airflow behavior, the establishment of a closed and robust process window, and the identification of key factors influencing ribbon surface quality to develop a comprehensive technological framework capable of supporting industrial-scale production.</p>

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Numerical Simulation Research Progress in the Planar Flow Casting Process of Silicon Steel Ribbons

  • 期刊论文

  • 发表日期：

    2026年2月13日

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  • Jiaqi Chang,
  • Siqian Bao,
  • Qingming Chang,
  • Shouhu Zu,
  • Yuanyao Cheng,
  • Ruijun Sun,
  • Yin Zhao,
  • Yuxin Liu

摘要

The conventional manufacturing routes for silicon steel—marked by lengthy processing cycles, high energy consumption, and considerable carbon emissions—can no longer meet the increasingly stringent requirements for high magnetic induction and low core loss. In this context, planar flow casting (PFC), characterized by a short-process chain, high efficiency, and low energy demand, has emerged as a promising breakthrough technology for producing ultra-thin non-oriented silicon steel ribbons. This paper presents a comprehensive review of recent progress in the application of PFC technology to the fabrication of non-oriented silicon steel. The discussion focuses on key scientific and technical issues, including melt puddle behavior, microstructural evolution, and texture control. Drawing on numerical simulation studies from both domestic and international research, this review summarizes advances in multiphysics-coupled simulations of fluid flow, heat transfer, and solidification, with particular emphasis on melt puddle stability prediction, surface-defect evaluation, and microstructure control. The characteristics and developmental trends of mainstream simulation approaches—such as the phase-field method, the cellular automaton (CA) method, and CA-finite element coupled models—are also critically assessed. In addition, the mechanisms governing the columnar-to-equiaxed transition, the formation pathways of the {100} texture, and the effects of these structural features on magnetic performance are discussed. Despite notable progress, several challenges remain, including disturbances caused by the air boundary layer, the narrow operational process window, the thickness non-uniformity of cast ribbons, and insufficient stability of the solidified microstructure. Future research should prioritize the control of airflow behavior, the establishment of a closed and robust process window, and the identification of key factors influencing ribbon surface quality to develop a comprehensive technological framework capable of supporting industrial-scale production.