CD Laboratory for Advances Process Simulation of Solidification and Melting

Solidification and remelting processes in the production of industrial metals are described and analysed using numerical methods. The results are then tested for their practical suitability in established production processes.

Almost every metallic material is melted at least once during its production and then solidified. The resulting cast structure then gives the material certain characteristic features. These include, for example, the grain size of crystals, the material texture or casting defects. These characteristics are of fundamental importance for the functional properties of the metals.

The investigation of solidification and remelting processes carried out here using numerical methods will serve as the basis for models that allow better control of production processes. Models that have already been validated or experimentally tested will be optimised and further developed until they are suitable for practical application.

In particular, the hydrodynamics of casting thin slabs (ingots) from so-called peritectic steels are being analysed. In this area, the further development of a model for special solidification processes is of particular interest. A numerical flow model (Computational Fluid Dynamics, CFD) is also being installed, adapted and used to analyse the interaction between melt and slag flows. In addition, the design of special systems (dip tube mould) for the continuous casting of steel is being optimised.

A second area is concerned with the numerical description of electroslag remelting (ESR) processes. In this area, a simulation model is validated, physical phenomena are analysed and innovative processes are developed. These include ESR processes for extremely large or hollow blocks or electroslag rapid remelting and the current conductive mould process.