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<p>Achieving optimal flow patterns and meniscus stability is crucial for producing defect-free slabs in high-speed continuous casting of square billets. This research employed a coupled multiphase numerical model incorporating molten steel, mold flux, and air to analyze the internal flow dynamics and surface behavior within the mold at casting velocities between 3.0 and 6.5&#xa0;m/min. The simulation outcomes were verified through water modeling tests and existing published data. The investigation reveals that when operating at 6.5&#xa0;m/min, the peak surface oscillation amplitude increases by about 136 pct relative to the standard 3.0&#xa0;m/min casting rate, representing a substantial enhancement. Furthermore, the depth of the mold powder layer plays a critical role in surface stability; expanding the powder layer from 30 to 50&#xa0;mm results in a 72.26 pct decrease in maximum surface disturbance. Additionally, the viscosity of the flux also plays a significant role. To maintain liquid level stability and avoid slag entrapment under high casting speeds, high-viscosity mold flux is recommended, provided that the lubrication and flux thickness are appropriate. This study provides insights into molten steel flow characteristics in ultra-high-speed square billet continuous casting molds and offers guidance for controlling flow behavior, distinguishing it from conventional high-efficiency casting methods.</p>

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Multiphase Flow Simulation of Ultra-High Casting Speed and Flux Effects on Meniscus Stability in Billet Continuous Casting

  • 期刊论文

  • 发表日期：

    2026年3月4日

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  • Hao Hu,
  • Pei Xu,
  • Mujun Long,
  • Huamei Duan,
  • Dengfu Chen

摘要

Achieving optimal flow patterns and meniscus stability is crucial for producing defect-free slabs in high-speed continuous casting of square billets. This research employed a coupled multiphase numerical model incorporating molten steel, mold flux, and air to analyze the internal flow dynamics and surface behavior within the mold at casting velocities between 3.0 and 6.5 m/min. The simulation outcomes were verified through water modeling tests and existing published data. The investigation reveals that when operating at 6.5 m/min, the peak surface oscillation amplitude increases by about 136 pct relative to the standard 3.0 m/min casting rate, representing a substantial enhancement. Furthermore, the depth of the mold powder layer plays a critical role in surface stability; expanding the powder layer from 30 to 50 mm results in a 72.26 pct decrease in maximum surface disturbance. Additionally, the viscosity of the flux also plays a significant role. To maintain liquid level stability and avoid slag entrapment under high casting speeds, high-viscosity mold flux is recommended, provided that the lubrication and flux thickness are appropriate. This study provides insights into molten steel flow characteristics in ultra-high-speed square billet continuous casting molds and offers guidance for controlling flow behavior, distinguishing it from conventional high-efficiency casting methods.