Novel model for calculating the interface heat flux between roller and molten steel/solidified shell during twin-roll strip casting
During the twin-roll strip casting (TRSC) process, molten steel rapidly cools on the copper roller surface, forming a sub-rapid solidified shell. The distribution of thermal resistance at the roller/steel interface is a critical factor influencing casting efficiency and product quality. To address t...
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| Language: | English |
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Elsevier
2025-09-01
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| Series: | Case Studies in Thermal Engineering |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2214157X25008974 |
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| author | Jingzhou Lu Wanlin Wang Peisheng Lyu Aihua Chen Hualong Li |
| author_facet | Jingzhou Lu Wanlin Wang Peisheng Lyu Aihua Chen Hualong Li |
| author_sort | Jingzhou Lu |
| collection | DOAJ |
| description | During the twin-roll strip casting (TRSC) process, molten steel rapidly cools on the copper roller surface, forming a sub-rapid solidified shell. The distribution of thermal resistance at the roller/steel interface is a critical factor influencing casting efficiency and product quality. To address this, a novel “process parameters - heat flux” (PPHF) model is proposed, which integrates roller/steel temperatures, deposited film, and air gap effects to predict spatial heat flux distribution under varying process conditions. Unlike traditional methods requiring in-situ temperature measurements, this model can directly calculate the heat flux along the roller arc. Validation via Q235 steel experiments on a TRSC test line confirmed an accuracy within 5 % error. Key findings demonstrate that the interface heat flux increases with the increasing casting speed and superheat. When the casting speed increases from 55 m/min to 65 m/min, the corresponding heat flux rises from 12.48 MW/m2 to 13.27 MW/m2. When the superheat increases from 30 °C to 90 °C, the corresponding heat flux rises from 12.12 MW/m2 to 13.83 MW/m2. The PPHF model can provide real-time heat flux prediction to support dynamic process control in industrial TRSC, bridging the gap between simulation and production optimization. |
| format | Article |
| id | doaj-art-b5ef22778aab4639bf3d32d26a6e9d77 |
| institution | Kabale University |
| issn | 2214-157X |
| language | English |
| publishDate | 2025-09-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Case Studies in Thermal Engineering |
| spelling | doaj-art-b5ef22778aab4639bf3d32d26a6e9d772025-08-20T03:49:55ZengElsevierCase Studies in Thermal Engineering2214-157X2025-09-017310663710.1016/j.csite.2025.106637Novel model for calculating the interface heat flux between roller and molten steel/solidified shell during twin-roll strip castingJingzhou Lu0Wanlin Wang1Peisheng Lyu2Aihua Chen3Hualong Li4School of Metallurgy and Environment, Central South University, Changsha, 410083, Hunan, China; International Union Research Center for Clean Metallurgy, Central South University, Changsha, 410083, Hunan, ChinaSchool of Metallurgy and Environment, Central South University, Changsha, 410083, Hunan, China; International Union Research Center for Clean Metallurgy, Central South University, Changsha, 410083, Hunan, ChinaSchool of Metallurgy and Environment, Central South University, Changsha, 410083, Hunan, China; International Union Research Center for Clean Metallurgy, Central South University, Changsha, 410083, Hunan, China; Corresponding author. School of Metallurgy and Environment, Central South University, Changsha, 410083, Hunan, China.Institute of Research of Iron and Steel, Shasteel, Zhangjiagang, 215625, Jiangsu, ChinaInstitute of Research of Iron and Steel, Shasteel, Zhangjiagang, 215625, Jiangsu, ChinaDuring the twin-roll strip casting (TRSC) process, molten steel rapidly cools on the copper roller surface, forming a sub-rapid solidified shell. The distribution of thermal resistance at the roller/steel interface is a critical factor influencing casting efficiency and product quality. To address this, a novel “process parameters - heat flux” (PPHF) model is proposed, which integrates roller/steel temperatures, deposited film, and air gap effects to predict spatial heat flux distribution under varying process conditions. Unlike traditional methods requiring in-situ temperature measurements, this model can directly calculate the heat flux along the roller arc. Validation via Q235 steel experiments on a TRSC test line confirmed an accuracy within 5 % error. Key findings demonstrate that the interface heat flux increases with the increasing casting speed and superheat. When the casting speed increases from 55 m/min to 65 m/min, the corresponding heat flux rises from 12.48 MW/m2 to 13.27 MW/m2. When the superheat increases from 30 °C to 90 °C, the corresponding heat flux rises from 12.12 MW/m2 to 13.83 MW/m2. The PPHF model can provide real-time heat flux prediction to support dynamic process control in industrial TRSC, bridging the gap between simulation and production optimization.http://www.sciencedirect.com/science/article/pii/S2214157X25008974ModelSub-rapid solidificationTwin-roll strip castingThermal resistanceHeat transfer |
| spellingShingle | Jingzhou Lu Wanlin Wang Peisheng Lyu Aihua Chen Hualong Li Novel model for calculating the interface heat flux between roller and molten steel/solidified shell during twin-roll strip casting Case Studies in Thermal Engineering Model Sub-rapid solidification Twin-roll strip casting Thermal resistance Heat transfer |
| title | Novel model for calculating the interface heat flux between roller and molten steel/solidified shell during twin-roll strip casting |
| title_full | Novel model for calculating the interface heat flux between roller and molten steel/solidified shell during twin-roll strip casting |
| title_fullStr | Novel model for calculating the interface heat flux between roller and molten steel/solidified shell during twin-roll strip casting |
| title_full_unstemmed | Novel model for calculating the interface heat flux between roller and molten steel/solidified shell during twin-roll strip casting |
| title_short | Novel model for calculating the interface heat flux between roller and molten steel/solidified shell during twin-roll strip casting |
| title_sort | novel model for calculating the interface heat flux between roller and molten steel solidified shell during twin roll strip casting |
| topic | Model Sub-rapid solidification Twin-roll strip casting Thermal resistance Heat transfer |
| url | http://www.sciencedirect.com/science/article/pii/S2214157X25008974 |
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