In the continuous casting of steels, clogging of the submerged entry nozzle has long been a persistent and costly issue. Previous modelling attempts have assumed that inclusions of different types exhibit the same degree of adhesion when colliding with the nozzle wall - an assumption not borne out by evidence in the literature. In this thesis, a dynamic clogging model is proposed which accounts for the effects of different degrees of inclusion-wall and inclusion-clog adhesion on clog formation and growth. The overall clogging model consists of several sub-models in order to account for the different physics. The melt flow and inclusion motion are modelled using an Eulerian-Lagrangian approach. The inclusion adhesion behavior is determined by the use of a stochastic model activated when an inclusion collides with a surface. A user defined sticking probability is used to determine if an inclusion sticks to a surface (Swall for wall collision or Sclog for clog collision) or instead bounces off. A macroscopic model is used to determine clog growth, where the volume of clog in a cell is tracked and used to determine when the clog grows into adjacent cells. Finally, a modified Kozeny-Carmen equation is used as a porosity model so that the presence of the clog affects and diverts the melt flow. The modified melt flow then alters subsequent inclusion deposition and clog growth. The model is used to investigate the effects of different degrees of inclusion adhesion on inclusion deposition and clog growth. Three scenarios are examined - 1) Inclusion deposition in a pilot scale nozzle, 2) Inclusion deposition in an industrial scale slide-gate controlled nozzle and 3) Clog formation and growth in a pilot scale nozzle. The deposition studies indicate that in a pilot scale nozzle, only a minority of inclusions ever collide with the nozzle (≈ 10%). In contrast, in the industrial scale nozzle there are far more inclusion collisions with the nozzle wall, ranging from 80% when the slide-gate is 20% open to 30% when the slide-gate is 100% open. Despite the differences in nozzle geometry and flow conditions, a similar effect on inclusion deposition is seen when Swall is varied. The effects of Swall can be divided into two regimes. When 0 ≥ Swall < 0.05 there is a sharp increase in the deposition ratio as Swall increases. When Swall > 0.05 there is a small and linear increase in the deposition ratio as Swall increases. This pattern is also seen in the study of clog formation and growth in a pilot scale nozzle. The effects of Swall or Sclog on clog volume can be divided into two regimes. As Swall or Sclog increases, there is a large increase in clog volume, until the sticking probability increases above 1E-2, then any further increase results in only a small increase in clog volume. In comparison to literature data the model successfully simulates the location of clog formation, the initial jump in clogging factor and the clogging factor growth rate in the later stages of clogging. However, the model underestimates the overall increase in clogging factor, resulting in a clogging factor at the end of the simulation which is half of that seen in the experiment. / Thesis / Doctor of Philosophy (PhD) / One of the ongoing challenges in the continuous casting industry is the occurrence of nozzle clogging. Over time, a buildup of material occurs within the submerged entry nozzle, called a clog. The clog leads to the partial or complete blockage of the nozzle, resulting in increased production costs. Since studying this phenomena experimentally is difficult due to the high temperature and opacity of the molten steel, modelling provides a useful alternative approach. However, previous modelling efforts regarding nozzle clogging have treated all inclusions as exhibiting the same adhesion behavior. This thesis aims to address this issue by presenting a dynamic nozzle clogging model which accounts for the effects of different degrees of inclusion adhesion. The model is used to study both inclusion deposition and clog formation. Results indicate that even a small amount of sticking probability results in a significant degree of inclusion deposition and clogging. The effect of sticking probability on clogging can be divided into two regimes, one where the clogging is very sensitive to the sticking probability and one where it is insensitive. Finally, the model was shown to run adequately even on coarser meshes (meshes with a smaller number of larger cells), indicating its utility in industrial applications, where it can be used to predict the location of clog formation and the clog growth rate.

Cold spray is an additive manufacturing method in which powder particles are accelerated through a supersonic nozzle and impinged upon a nearby substrate, provided they reach their so-called critical velocity. True to its name, the cold spray process employs lower particle temperatures than other thermal spray processes while the particle velocities are comparably high. Because bonding occurs mostly in the solid state and at high speeds, cold spray deposits are distinguished for having low porosity and low residual stresses which nearly match those of the bulk material. One complication with the cold spray process is the tendency for nozzles to clog when spraying (in general) low-melting-point or dense metal powders. Clogging occurs when particles collide with the inner nozzle wall and bond to it rather than bouncing off and continuing downstream towards the substrate. The particles accumulate and eventually plug the nozzle passage. Clogging is inconvenient because it interrupts the spraying process, making it impossible to complete a task. Furthermore, when particle buildup occurs inside the nozzle, the working cross-sectional area decreases, which decreases the flow velocity and therefore the particle velocity, ultimately jeopardizing the particles’ ability to reach critical velocity at the substrate. In this work, computational fluid dynamics (CFD) is used to study various aspects of nozzle clogging. Nozzle cooling with supercritical CO2 as the refrigerant is investigated as a means to prevent clogging. The effects of nozzle cooling on both the driving gas and the particles are addressed. Simplified pressure oscillations at the nozzle inlet are imposed to determine whether such oscillations, if present, can cause clogging. Subsequently, more realistic and complicated flow oscillations are introduced to isolate a potential root cause of clogging. Finally, several novel nozzle internal geometries are evaluated for their effectiveness at preventing clogging. A recommendation is provided for a nozzle to be tested experimentally because it might completely prevent clogging.

The interest of gaining on-line information related to non-metallic inclusions during the steelmaking process has recently increased due to the development as well as the promising results of the Pulse Distribution Analysis with Optical Emission Spectroscopy method (PDA/OES). Even though, the time from sampling to presented results on inclusions is only about 5-10 minutes, the method has also shown limitations with respect to the determination of some inclusion characteristics. Therefore, a first step was to perform a study on other methods such as the cross-section method (CS) on a polished sample surface, the cross-section after etching method (CSE), the bromine-methanol extraction method (BME), and the electrolytic extraction method (EE). This study focused on the evaluation of these methods with respect to the time consumption for preparation and analysis of a sample, the analyzed volume and the determination of inclusion and cluster characteristics such as size, number, particle size distribution (PSD) and composition. The CS and CSE methods were found to be suitable in the determination of the largest cluster in a sample which can be recommended in order to select proper extraction parameters for further studies. The BME method was considered to be fast with the possibility of analyzing a large volume. However, the used solution is chemically stronger compared to electrolytic extraction solutions, which can affect the results. In most aspects, the EE method was found to be the most stable, reliable and accurate method with some limitations regarding the time aspect. Based on this conclusion, the EE method was selected for a comparative study with the PDA/OES method. Reliably detected size ranges by using the PDA/OES method were defined for two low-alloyed steel grades. These are 2.0-5.7 μm and 1.4-5.7 μm for steel samples taken before and after a Ca-addition during the secondary steelmaking, respectively. Moreover, agreements between the EE and PDA/OES methods were observed in the average size and number of detected inclusions when only inclusions with the size &gt; 2 μm were considered. Also, a theoretical minimum size and a maximum number ofinclusions present in the steel sample, which can be detected by using the PDA/OES method, were estimated. The work continued by successfully applying the EE method to study correlations between inclusions observed in the liquid steel samples and in a clogged nozzle (clogging material). It was found that the average sizes of spherical and non-spherical inclusions observed in the steel corresponded well with those observed in the clogging material. However, there were some differences in the frequencies of these inclusions. This was explained by a possible transformation of the present inclusions due to a reoxidation and a reaction with the nozzle refractory of the steel melt. The results of this study may contribute in the selection of proper process parameters or inclusion characteristics for future studies on the improvement and application of on-line methods. Finally, suggestions on how to present and interpret data obtained by the PDA/OES method during production of stainless steels were given in the present thesis. More specifically, the possibilities of defining operating windows with respect to inclusion composition and the use of a B-factor for Al (the total content of Al in inclusions detected by using the PDA/OES method) during the secondary steelmaking were discussed. In addition, a correlation study between B-factors for Al and numbers of inclusions (dV &gt; 4 μm) obtained by using the PDA/OES method on process samples, and corresponding slivers indices from plate products was performed. The results showed a moderate correlation between these parameters as well as an increase of the slivers index with increased values of the chosen PDA/OES data. This indicates that it could be possible to predict when there is an increased risk of having slivers on the final rolled product at an early stage of the steelmaking process. / <p>QC 20150525</p>

Non-metallic inclusions in molten steel have received worldwide attention due to their serious influence on both the steel product quality and the steel production process. These inclusions may come from the de-oxidation process, the re-oxidation by air and/or slag due to an entrainment during steel transfer, and so on. The presence of some inclusion types can cause a termination of a casting process by clogging a nozzle. Thus, a good knowledge of the inclusion behavior and deposition rate in steel flows is really important to understand phenomena such as nozzle clogging. In this thesis, inclusion behaviors and deposition rates in steel flows were investigated by using mathematical simulations and validation by experiments. A ladle teeming process was simulated and Ce2O3 inclusion behavior during a teeming stage was studied. A Lagrangian method was used to track the inclusions in a steel flow and to compare the behaviors of inclusions of different sizes. In addition, a statistical analysis was conducted by the use of a stochastic turbulence model to investigate the behaviors of different-sized inclusions in different nozzle regions. The results show that inclusions with a diameter smaller than 20 μm were found to have similar trajectories and velocity distributions in the nozzle. The inertia force and buoyancy force were found to play an important role for the behavior of large-size inclusions or clusters. The statistical analysis results indicate that the region close to the connection region of the straight pipe and the expanding part of the nozzle seems to be very sensitive for an inclusion deposition. In order to know the deposition rate of non-metallic inclusions, an improved Eulerian particle deposition model was developed and subsequently used to predict the deposition rate of inclusions. It accounts for the differences in properties between air and liquid metals and considers Brownian and turbulent diffusion, turbophoresis and thermophoresis as transport mechanisms. A CFD model was firstly built up to obtain the friction velocity caused by a fluid flow. Then, the friction velocity was put into the deposition model to calculate the deposition rate. For  the  case  of  inclusion/particle  deposition  in  vertical  steel  flows,  effects  on  the deposition rate of parameters such as steel flow rate, particle diameter, particle density, wall roughness and temperature gradient near a wall were investigated. The results show that the steel flow rate/friction velocity has a very important influence on the rate of the deposition of large particles, for which turbophoresis is the main deposition mechanism. For small particles, both the wall roughness and thermophoresis have a significant influence on the particle deposition rate. The extended Eulerian model was thereafter used to predict the inclusion deposition rate in a submerged entry nozzle (SEN). Deposition rates of different-size inclusions in the SEN were obtained. The result shows that the steel flow is non-uniform in the SEN of the tundish. This leads to an uneven distribution of the inclusion deposition rates at different locations of the inner wall of the SEN. A large deposition rate was found to occur at the regions near the SEN inlet, the SEN bottom and the upper region of two SEN ports. For the case of an inclusion/particle deposition in horizontal straight channel flows, the deposition rates of particles at different locations of a horizontal straight pipe cross- section were found to be different due to the influence of gravity and buoyancy. For small particles with a small particle relaxation time, the gravity separation is important for their deposition  behaviors  at  high  and  low  parts  of  the  horizontal  pipe  compared  to  the turbophoresis. For large particles with a large particle relaxation time, turbophoresis is the dominating deposition mechanism. / <p>QC 20150326</p>

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In this work, nozzle clogging in the submerged entry nozzle in continuous casting of Al killed steels has been studied. The study has been based on low silicon Al killed SAE 1006 (1.2006) and SAE 1008 (1.2008) grades. In this study, castabilities of 75 heats for 1.2006 steel grades and 75 heats for 1.2008 steel grades have been investigated. Castabilities of the experimental heats have been found to be affected by Al content in oxide form (Aloxy) and Ca content of the liquid steel. Castabilities have been found to decrease with increase in Aloxy and to increase with increase in Ca content and Ca/Aloxy ratio. Reoxidation has been found not to affect the castability appreciably.