小方坯齿轮钢连铸过程中的宏观偏析模拟

基于国内某厂齿轮钢小方坯连铸生产过程，利用ProCAST软件建立移动切片模型，能够高效模拟连铸过程中的宏观偏析，模型分别模拟研究了不同过热度、二冷水量和拉坯速度等对宏观偏析的影响。模拟结果与碳偏析检测结果吻合良好，验证了移动切片模型模拟连铸坯宏观偏析的准确性。由于溶质浮力的影响，内弧侧的宏观偏析强于外弧侧。随着过热度的增加，铸坯中心碳偏析度从1.06增加至1.15。过热度控制在25 ℃范围内，可以保证铸坯的宏观碳偏析度控制在1.10范围内。随着连铸二冷水量的增加，铸坯中心偏析改善程度较小，铸坯中心碳偏析度从1.16降低至1.13。随着拉坯速度的增加，铸坯中心偏析呈现加重的趋势，铸坯中心碳偏析度由1.14增加至1.21，拉坯速度控制在1.4 m·min–1范围内，可保证铸坯中心碳偏析度低于1.15。 

Simulation of the macrosegregation in the gear steel billet continuous casting process

Macrosegregation forms due to relative motion between liquid and solid phases on the macro scale during solidification. As macrosegregation is formed during a solidification process, it is difficult to remove it in the subsequent rolling and heat treatment processes, thereby deteriorating the mechanical properties and stability of products. Studies of macrosegregation of billets for industrial trials have become a challenge due to the high temperature of the casting process. To improve macrosegregation of billet, a moving slice model was developed using the ProCAST software based on a continuous casting process of gear steel billet in a domestic steel mill. During the continuous casting process, macrosegregation can be calculated using the above model. The effects of superheat, secondary cooling water flows, and casting speed on macrosegregation were simulated. These results were consistent with the measured outcomes of carbon macrosegregation, validating the moving slice model to calculate the macrosegregation of billet. The solute concentration on the loose side is higher than that on the fixed side due to solute buoyancy. The degree of carbon segregation in the billet center increases from 1.06 to 1.15, with an increase in superheat, which should be controlled below 25 ℃ to ensure the degree of carbon segregation within 1.10. However, the degree of carbon segregation in the billet center decreases from 1.16 to 1.13, with an increase of secondary cooling water flow and a little improvement in central segregation. With an increase in casting speed, the central segregation becomes serious, and the degree of carbon segregation in the billet center increases from 1.14 to 1.21. However, when the casting speed is lower than 1.4 m·min?1, the degree of carbon segregation in the billet center comes lower than 1.15.