Characteristics of medium carbon steel solidification and mold flux crystallization using the multi-mold simulator

An oscillating multi-mold simulator with embedded thermocouples was used to study the initial solidification of medium carbon steels and crystallization characteristics of the mold flux. Casting speed variations in the simulator from 0.7 m/min to 1.4 m/min at fixed oscillation frequency and stroke resulted in higher copper mold temperatures. Frequency modifications from 2.5 Hz to 5.0 Hz and stroke changes from 8.1 mm to 5.4 mm at fixed casting speeds also resulted in higher copper mold temperatures. Surface profile analysis of as-cast steel strips showed characteristic oscillation marks comparable to the narrow faces of the industrial cast slabs. The apparent effect of casting variables on the temperature and surface profiles during the solidification of the medium carbon steels could be correlated to the variations in the negative strip time and subsequent changes in the extent of mold flux infiltration. Back scattered scanning electron microscope analysis of the full length of the retrieved flux film after casting showed cuspidine crystallization ratio that increased from the upper to lower portion of the flux film. This dynamic crystallization and growth of the cuspidine phase increases as the flux is sustained at high temperatures for longer periods. Additional experiments with industrial fluxes designed for soft cooling of medium carbon steel grades showed comparable infiltration thickness of the flux, but the crystallization characteristics were significantly different, which could have a significant impact on the heat transfer rate and mechanism through the flux film.