Continuous casting represents 96% of all steel products made worldwide. To cast new alloys, optimal process parameters must be determined that reduce quality issues. Traditionally, this is a time-consuming and expensive process due to the need to run multiple casting trials. Alternatively, numerical models can be used to help guide development of optimal process parameters. In this thesis, a 3D thermal-solute-mechanical finite element model has been created using the THERCAST software to simulate the casting process of a new advanced high strength steel grade at Stelco’s Lake Erie Works facility. The model represents the caster from mould to exit, and takes into account heat transfer from the mould, sprays, rolls, and ambient air. The model has been extensively validated using plant measurements from steel shim trials and pyrometer data. The model is used to investigate the evolution of temperature and shell thickness along the cast length, and the effect of spray cooling and casting speed on the surface temperature at unbending to predict transverse cracking during secondary cooling. It was found that the susceptibility to cracking increased with lower casting speed and increased water spray cooling. Increasing the casting speed had a negligible effect, and it was found to decrease with decreasing water spray cooling. This decreased water spray cooling is also accompanied by an increase in metallurgical length, so further work is required to determine appropriate safety factors to ensure the steel is completely solidified. However, preliminary results of solute and mechanical models are also presented. Further work is required to improve the predictions made by these simulations. / Thesis / Master of Applied Science (MASc)