Numerical Simulation on the Fluid Flow, Air Entrainment, Heat Transfer, and Solidification during Top Pouring and Cooling of a 303 Ton Heavy Ingot

Abstract

Herein, a mathematical model combined with the k–ε turbulence model, volume of fluid multiphase model, and heat transfer and solidification model is established to investigate the steel–air two‐phase flow and solidification during the filling process of a 303 ton heavy steel ingot. The measured temperatures at different times are employed to validate the current mathematical model. The results show that the predicted results are in good agreement with the measured results. At the initial stage of the filling process, a double‐roll flow pattern is formed near the junction between the liquid surfaces due to the high speed of the jet flow. The maximum impinging depth of the jet flow is 1.8 m and the maximum splash height of the molten steel is 0.3 m. An empirical formula for the variation of the entrained air volume with time is proposed. The maximum growth rate in the horizontal direction is 0.08 mm s−1. In the vertical direction, the maximum growth rate of the solidified shell on the central axis is 0.12 mm s−1. The distribution of primary dendrite arm spacing and secondary dendrite arm spacing is obtained by combining the predicted cooling rate.