Modeling of the continuous casting of steel—past,present, and future

This lecture honoring Keith Brimacombe looks over the history, current abilities, and future potential of mathematical models to improve understanding and to help solve practical problems in the continuous casting of steel. Early finite-difference models of solidification, which were pioneered by Keith Brimacombe and his students, form the basis for the online dynamic models used to control spray water flow in a modern slab caster. Computational thermal-stress models, also pioneered by Brimacombe, have led to improved understanding of mold distortion, crack formation, and other phenomena. This has enabled process improvements, such as optimized mold geometry and spray-cooling design. Today, sophisticated models such as transient and multiphase fluid-flow simulations rival water modeling in providing insights into flow-related defects. Heat-flow and stress models have also advanced to yield new insights. As computer power increases and improvements via empirical plant trials become more costly, models will likely play an increasing role in future developments of complex mature processes, such as continuous casting. The Brimacombe Memorial Lectureship was established in 1999 by the Process Technology Division of the Iron & Steel Society to honor Dr. J. Keith Brimacombe’s outstanding accomplishments in the area of process metallurgy, his dedication to the steel industry, and his profound effect on people in the industry; and also to acquaint members, students, and engineers with the many exciting opportunities that exist in the area of process metallurgy and to inspire them to pursue careers in this field. Brian G. Thomas is a professor of mechanical engineering at the University of Illinois and director of the Continuous Casting Consortium. He received his Bachelors of metallurgical engineering from McGill University in 1979 and Ph.D. in metallurgical engineering in 1985 from the University of British Columbia. In between, he worked in the Materials Research Department of Algoma Steel (Sault Ste. Marie, ON). His recent research efforts focus on the development and application of mathematical models of all aspects of the continuous casting of steel and related processes. Dr. Thomas has authored with co-workers over 150 technical publications on his research, which has been recognized with a Presidential Young Investigator Award from NSF, Outstanding Young Manufacturing Engineer Award from SME, Xerox Award for UIUC Faculty research, and more than ten best paper awards from AFS, AIME, ISS, TMS, CIM, and ASM International. He has participated in several short courses to transfer technology to industry, including the annual Brimacombe Continuous Casting Course.