Experimental study and numerical simulation of solidification in large steel ingot

Large steel ingots weighing more than 100-ton are of great importance in the heavy machinery manufacturing. A three-dimensional solidification mathematical model has been developed to optimize the mold and riser design of large steel ingots. In the model, the heat transfer coefficients at the interfaces of different casting materials, including the ingot,the mold and the refractory,were determined by the temperature measurements during the solidification process in an experimental 53-ton steel ingot system. The predicted temperatures at different characteristic locations in the ingot and mold were consistent with measurements,and the simulated primary shrinkage cavity was in good agreement with the sump on the top surface of the experimental ingot. The application of the numerical simulation program indicated that the calibrated heat transfer coefficients at different interfaces are reliable for the development of several hundred tons steel ingots.