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Process metallurgy

Dedicated to Professor Dr.-Ing. Klaus Wiinnenberg on the occasion of his 651h birthday

Heat Flux Density and Heat Transfer Coefficient between Steel Melt and Metallic
Substrates
Michael Thiemann and Achim R. Buchner

Max-Planck-lnstitut fur Eisenforschung, DOsseldorf/ Germany

The solidification of low carbon (LC) steels on metallic substrates was investigated with a twin roll caster and a model mould. The substrate
materials were steel, Ni, and two copper alloys, which are typical for the industrial construction of moulds. Heat flux density, heat transfer
coefficient, growth rate, and cooling rate were evaluated.

Keywords: solidification of steel, thin strip casting, heat flux density, heat transfer coefficient.

Introduction Twin roll experiments


The strip casting experiments were executed with a twin
Thin strip casting of steel with the twin roll method has
roll caster in laboratory scale, figure 1. In a typical casting
been investigated intensively since about 20 years [1-3].
experiment an amount of 10 kg induction molten steel is
Large savings of energy and equipment are expected from
poured into a tundish; there the super heating is about
this technique, which is now on the border of industrial ap-
70 °C; the melt flows through a ceramic filter into a sub-
plication [4-7]. Nevertheless the twin roll casting process
merged entry nozzle with two lateral outlets, and it is filled
still includes a large number of partial problems, which
into the gap between the rolls.
have to be understood and eliminated.
The rolls are made of steel (1.2344), copper alloy covered
The process of strip formation depends on the heat trans-
with 0.1 cm Ni, CuNi3Si, or CuNiBe. In the contact time
fer between material and rolls in the range of the pool. The
shell growth takes place on both rotating roll surfaces. The
amount of heat flux as well as its homogeneity over the pool
spring loaded separating force of the rolls was about 5 kN,
dimensions is of importance. From the heat flux the param-
the casting speed close to 15 m/min, and the casting rate
eters relevant for the microstructure [8], namely solidifica-
about 15 kg/min.
tion front velocity and cooling rate, can be calculated [3].
Productivity, surface quality and strip defects depend on
these aspects.
In this paper investigations on heat contact between melt
and substrates (rolls or walls) and its homogeneity are re-
ported. Heat flux and heat transfer coefficient are studied in
dependence on substrate material and alloy composition.
Experiments with a laboratory twin roll caster and with a
model mould are carried out.

Experiments

The twin roll cast experiment was studied here, because it


is close to the real demands, and the inhomogeneous heat
transfer is visible at the strip. The model mould experi-
ments, on the other hand, give a more quantitative informa-
tion on solidification, as several thermocouples are applied
in each wall; thus the local heat contact variation can be bet-
ter evaluated. Furthermore, these experiments take place in
a closed vessel, and so casts under He instead of air are pos-
sible.
The chemical composition of the low carbon steels used Figure 1. Principal construction of the twin roll caster; 1 : induction
in all experiments was: 0.08% C, 0.4% Mn, 0.05% Al, furnace, 2: tundish, 3: nozzle, 4: liquid steel, 5: solidified shells,
0.01 % S, 0.01 % P; 0% or 0.07% Ti. 6: rolls, 7: strip, 8: pyrometer.

732 steel research 74 (2003) No. 11 /12


Process metallurgy

Below the roll nip a compact strip left the caster with a 1.5 cm thickness. At the positions of the thermocouples
typical thickness of about 0.2 cm and 6.5 cm of width. The windows of 1.5 cm width were installed. (In the twin roll
strip surface temperature was continuously measured by a case this effect is not critical as the relative substrate-melt
pyrometer 13 cm below the roll nip. More details are given velocity there is about 5 times larger.)
in [l]. The temperatures in the walls were measured by four
In the steel- or CuNi3Si-rolls special information on heat equidistant NiCr-NiAl thermocouples in each wall covered
flux was to be obtained by a NiCr-NiAl thermocouple in with a sheathing ofNiCr16Fe. They were fixed at the meas-
one of the rolls 0.1 cm below the surface. Since the experi- urement position by a bajonet connection in combination
ments lasted less than 50 sec, the thermocouple cable could with an elastic spring, to ensure a proper contact pressure in
be coiled beside the casting roll, thus enabling a simple data spite of thermal expansion. The positions were 6 cm above
transfer to the registration device, which realises a data ac- the filter, 0.1 cm beyond the wall interface. The thermocou-
quisition rate of 500 per second. Due to the measurement ple contact devices were protected against overheating by
deficiencies discussed below, the real temperature curves four water cooled copper blocks. Figure 3 shows examples
are not obtained directly; nevertheless important informa- of measured curves. The large scatter within one wall is vis-
tion on heat transfer is estimated in an approximative way ible as well as the differences between the walls.
from the measured curves. The thermal resistance between the thermocouple tip and
the wall as well as the heat loss by the thermocouple sheath-
Model mould experiments ing and wires cause an inaccuracy in the measured temper-
ature signal. Following to [9-10] each thermocouple was
The bottom casting experiments were executed with a
calibrated, and the measured temperature signals were cor-
model mould, figure 2, in a vacuum furnace.
rected. Figure 4 exemplarily shows the measured and cor-
An induction melt of 17 kg steel was poured into a
rected temperatures in the steel wall.
tundish. The melt passed a ceramic filter and filled the
chamber (14 cm x 14 cm x 22 cm) between the walls. The
super heating was typically 100 °C, and the maximum pool 400
level was about 12 cm. The melt temperature was controlled steel
350
by two Pt-PtRh thermocouples in a position of 1 cm and 6 CuNi3Si - - - - - --
cm above the filter. The wall materials were the same as the 300
roll materials mentioned above. In contrast to the twin roll
250
experiments and in order to investigate the role of nickel
substrate over a longer time a wall made of pure nickel in- E 200
stead of copper covered with O. lcm nickel was used. The I-
150
wall thickness was 3.5 cm.
In principle the heat flux within the wall can be faster 100 ·.· ....: ...·

than the increase of the melt level, and then this problem .-- ·: ::: ..-- .,----:
.. :;::----· .: .. .-.... -~= :: ;; ::: .. :~: :. ~: ......... ::: -
..... :. ::..: ;~- ·: .
50 •.,..,,,;;::::::::::i::::;;;::::::;;;_,:·,... ,-
must be treated as a two-dimensional one; as the melt ve-
locity is only about 4 cm/sec, this effect was estimated to be 0
0.0 0.5 1.0 1.5 2.0 2.5 3.0
critical. By a simple measure the heat propagation problem
t [s)
can be reduced to one dimension. To avoid the wall internal
heat movement from the wall ranges below the thermocou- Figure 3. Temperature curves measured at four different positions
ples, the substrate walls were masked by ceramic plates of in the walls of steel and CuNi3Si; low carbon steel, air.

400
measured 0
350 corrected 0

300

250

e:200
I-
150

100

50

0.5 1.0 1.5 2.0 2.5 3.0


t [s]

Figure 2. Construction of the model mould; 1: tundish, 2: Zr02-filter, Figure 4. Example for the effect of temperature curve correction;
3: NiCr-NiAI thermocouples, 4: Pt-PtRh thermocouples, 5: cooling steel wall; low carbon steel.
copper element, 6: ceramic plate, 7: substrate wall.

steel research 74 (2003) No. 11 /12 733


Process metallurgy

From the corrected temperature signal the heating rate at 1500


the measurement position was determined; then the heat D LC steel
flux density at the wall surface was calculated by solving m LC steel + Ti
the inverse heat conduction problem, see [11]. ~ 1450
~
2
~
Results and Discussion Q)
c. 1400
E
.!!
Q)
Heat flux and strip quality 0
~
In the twin roll casting process the heat transfer often ~ 1350
c.
varies from position to position in the interface between roll
l'5
and melt. The inhomogeneous heat transfer can be demon-
1300
strated by observation of the hot strip just after leaving the Steel Ni CuNi3Si CuNiBe
rolls; the brightness variation refers to the temperature scat-
ter, figure 5. The corresponding strip surfaces are also pre-
120
sented. Obviously there is a strong connection between
D LC steel
temperature distribution and surface quality. The more ho-
100 m LC steel+ Ti
mogeneous the temperature is distributed the more is the
surface free of defects. The well known positive influence E 80
of Ti-addition [12] is visible. The use of Ni covered rolls in- 6
ii
·5
stead of steel rolls increases the temperature scatter, and it Q) 60
-c,
results in more surface defects like cracks, wrinkles, and de- -c,

pressions. The observations are completed by pyrometer lii


-c, 40
c
measurements of the strip surface temperature during the <'5
casting process, figure 6. The mean strip temperature de- 20

0
Steel Ni CuNi3Si CuNiBe

LC steel LC steel LC steel+0.07 % Ti


Steel rolls Ni rolls Ni rolls Figure 6. Strip temperatures measured by a pyrometer 13 cm be-
low the roll nip; mean temperatures and standard deviations.

creases, when the roll material is changed from steel to cop-


per alloys. Ti reduces the temperature scatter, as it is indi-
cated in the calculated standard deviation.
It should be mentioned that the visual impression of spot-
tiness degree in figure 5 is found not quantitatively in the
standard deviations in figure 6, which are calculated over
the whole strip. Possibly in the calculations also electronic
scatter is included.

Hot strip just below the roll nip Thermal quantities from twin roll casting experiments
A very detailed study of heat transfer coefficients and
heat flux densities was possible by use of the thermocouple-
equipped rolls. As an example figure 7 shows a whole tem-
perature curve; eight peaks are visible corresponding to
eight passages of the thermocouple through the pool. Any
peak consists of an increase (starting with the contact to the
pool) and a decrease (during the heat removal into the roll
in the rest of roll rotation).
The development of the roH temperature is obtained from
the starting temperatures in any peak (in this case of non
water cooled rolls). The roll surface velocity was calculated
from the mean time interval between the starting points of
the peaks (to be used in the calculation of pool contact
Strip after cooling times).
Figure 8 shows details of a peak in magnification. From
Figure 5. Strip temperature distributions and strip surfaces under
various conditions; strip width 6.5 cm. a visually estimated starting time to the temperature in-

734 steel research 7 4 (2003) No. 11 /12


Process metallurgy

soo-,-~~~~~~~~~~---,-~~ --.----.----.---,--.--,
550
T,
500
450
400 h,
350
~300 F
t- 250

200
150 R.
100
50

~ ~ ~ ~ % w ~ ~ ~ ro
I [s]

Figure 7. Measured temperature curve during the casting experi- Figure 9. Sketch of the pool [3]; F = roll force, d = strip thickness,
ment; low carbon steel, steel rolls. hp = pool height, hip = liquid pool height, hrp = rigid pool height,
T, = starting roll temperature, R = roll radius.

280

260 .I, ._
------------
solid pool
contribution
variation of heat contact in the pool. The roll surface area
with the thermocouple below (area of about 1 mm2) meets
by chance areas with better or worse heat contact in a sta-
240 tistic manner. As the peak height follows from the heat
flown into the roll, it images the variable heat transfer coef-
~ 220 ficients between material and roll.
i=' liquid pool Now heat transfer coefficients in the small area of obser-
200 <S- contribution
vation are estimated, which refer to the liquid pool. For any
180 peakj a local value aj is estimated as follows:
The total heat qJ°1°1 flown over the total pool time shall
160
ti be proportional to the total peak height LlTJ°tal, figure 7;
the heat flown during the time t1 of the liquid pool shall be
M2 M4 M6 MB ~o ~2 ~4 ~6 ~8 ~o ~2
t[s]
a portion of this, which is characterized by the ratio "% liq-
uid pool" as to be deduced from figure 8; it is
Figure 8. Magnification of the third peak from figure 7; to: begin of t:...T/P = t:...Tr01 • (% liquid pool).
pool contact; t1: end of liquid pool = begin of rigid pool. It is assumed in the liquid pool of peak j:

creases due to heat gain from the pool. An important detail (1)
can be discussed at point t1, where the temperature curve
shows a break. As outlined in [3], the pool consists of two µ = unknown factor; t:,,TjP from figures 7 and 8.
main ranges, figure 9. The mean heat flux density is obtained after dividing by
In the upper part (over the height h1p) of the pool there is the liquid pool time t1 (from figure 8):
liquid melt between the growing half shells; in this part the
rolling force F cannot be submitted; thus the heat contact
between half shells and rolls is bad; from estimations in [3]
(2)
this part of the pool is nearly the whole pool, in real cases
e.g. 12 cm long. When solid bridges from the two half shells
begin to meet, the roll force F can be submitted, and the
pressure between material and rolls is growing thus strong- The local heat transfer coefficient is estimated from the
ly increasing the heat transfer. As estimated in [3], this heat flux density as usual by
range of length hrp is less than about 3 mm, i.e. only a very
small portion of the whole pool. It is concluded that t1 in
figure 8 marks a sudden heat transfer increase, i.e. the (3)
change from liquid to solid pool. This could be also con-
firmed by calculating pool-times after [3] and comparing
them with t1 from figure 8. Tuq (LC steel) ... 1530 °C; T,j = roll temperature before
In figure 7 it is visible that the height of the peak is vary- pool contact, see figure 7.
ing strongly. This can be understood by help of figure 5. {Jj and the denominator are assumed to be constant over
The temperature distribution in the strip corresponds to the short times as they are given in a twin roll pool.

steel research 74 (2003) No. 11/12


735
Process metallurgy

The assembly of peaks can be understood as number of Table 2. Calculation of individual heat transfer coefficients ai and
arbitrary local measurements, and the mean value of all lo- heat flux densities for a cast of low carbon steel in CuNi3Si rolls.
cal aj shall be close to a mean a, measured over the whole
a; qj
pool area of about 160 cm 2 (in these experiments). a can Peakj
[W/cm2 K] [W/cm2]
be estimated from the strip thickness, some physical con- I 0.22 326
stants and the pool contact length, to be measured from the
2 0.20 299
coloured shape at the side dams after the experiment (de-
tails see [3]). It is 3 0.16 222

4 0.17 238

(4) 5 0.15 207

6 0.18 236

n = number of evaluated peaks


From equations (2) to (4) one can eliminate the unknown
factorµ and obtains the individual heat transfer coefficients
Results from model mould experiments
as
Figure 10 gives the evaluation of q(t) from measured
temperature curves for two examples. The curves start with
(5) a maximum value, and they decrease due to a growing so-
lidified shell; this increases the total heat resistance between
solidification front(= heat source) and interface.
In the following investigations mean values of four ther-
mocouples and the maximum values of q-curves are used,
An application of this procedure is outlined in table 1 for which are valid for small times as given in a twin roll ex-
the example of figure 7 (peak 6 was not taken into account periment. The influences of alloy composition, substrate,
due to an irregular shape); a (from a strip thickness 2.6 mm and surrounding atmosphere on q are presented in figure
and a pool contact time 0.736 sec) was 0.264 W/cm 2K. 11. q is increased largely when He is used instead of air; Ti-
The C/.j and <X-j from table 1 give an impression on a the addition decreases q; the substrates have a large influence
variation of the heat flux corresponding to a strip spottiness on q; it seems that the larger the heat conductivity of the
as seen in figure 5 (left side). For comparison a similar eval- substrate is, the smaller is q.
uation was carried out with a CuNi3Si-roll, and the results Similar to equation (3) the heat transfer coefficients are
are presented in table 2; mean value a there was 0.18 calculated fromq; the wall contact temperatures were about
W/cm 2K. 60 °C. The a-values are presented in figure 12. The influ-
The mean heat flux densities calculated from tables 1 and ences are roughly the same as in figure 11.
2 are of large difference: 350 W/cm2 for steel rolls, 255 From q the structure relevant quantities Vs and Ts
(veloc-
W /cm 2 for CuNi3Si rolls. The standard deviations were ity and cooling rate at the solidification front) can be calcu-
close to 17 % in both cases. lated. From [8] (only latent heat, shell cooling neglected) it
is

Table 1. Calculation of individual heat transfer coefficients ai and


heat flux densities qi for a cast of low carbon steel in steel rolls
(peaks of figure 7); nomenclature see equations (1) - (3).
steel
CuNi3Si o

!:i.Ttotal estimated !!!.Tip a; <l;


Trj f1j
%liq.
Peakj J J 2
["CJ (s] [W/cm2 K] [W/cm ]
["CJ pool ["CJ

l 20 0.39 91.5 75 69 0.30 451

2 90 0.60 111 84 93 0.28 397

3 162 0.66 109 88 96 0.28 372

4 217 0.71 1!5 92 106 0.29 382

88 81 0.23 288 o-l-~,--~~~~~~~~~~--.-~,---,-~~--1


5 274 0.72 92
0.0 0.5 1.0 1.5 2.0 2.5 3.0
7 324 0.71 77 92 71 0.23 277 Time[s]

8 352 0.55 75 84 63 0.25 292 Figure 10. Calculated heat flux densities versus time for steel or
CuNi3Si walls; low carbon steel, air.

736 steel research 74 (2003) No. 11/12


Process metallurgy

aoo~-------------------, 800

700
LC steel, air D 700
LC steel, air D
LC steel + Ti, air ~ LC steel + Ti, air ~
f0
600 LC steel, He - ~600
Ill
LC steel, He -

i500 ~500
Q)
iljj 400 1i,
~400
"O .s
~ 300
.:::: ~ 300
m200
I
200

100 100

0 0
Steel Ni CuNi3Si Cu Ni Be Steel Ni CuNi3Si CuNiBe

Figure 11. Mean heat flux density at the melt-wall interface at the Figure 14. Mean cooling rate of the solidification front.
beginning of contact; model mould experiments, variable alloys,
substrates, and atmospheres.

a.a~-----------------~ Examples are shown in figure 13 and 14. Qualitatively


SZ'
'E 0.7 LC steel, air CJ the same dependences on the parameters are found as for
0
LC steel + Ti, air ~ the heat flux density.
i 0.6 LC steel, He -
~
-~ 0.5 Comparison between twin roll and model mould
10.4 results
-Bi 0.3
Several observation had been made which suggest that
c
£l 0.2 the heat transfer in the twin roll caster and the model mould
1i,
t 0.1 are not fully comparable. Possibly the different contact ve-
locities are a reason for that . A discrepancy is evident from
Steel Ni CuNi3Si CuNiBe the comparison of figure 6 (from twin roller) and 11 (from
model mould). The strip temperatures in figure 6 include an
Figure 12. Mean heat transfer coefficient at the melt-wall interface information on the heat loss of the material in the pool; the
at the beginning of contact; model mould experiments, variable al- lower the strip temperature is, the larger the heat transfer
loys, substrates, and atmospheres.
must be in total. As the pool contact times are not very dif-
ferent for different rolls, the heat flux density should be all
the larger too. This however is not found in the model
Vs(t) = <j(t) (6) mould experiments, see figure 11.
p·H1 Some values of figures 11 and 12 from the model mould
can be compared with corresponding values from the strip
T,(t) = <'/2(t) (7) casting experiments, see tables 1 and 2. Mean values of a
>..p·H1 and for steel substrates coincide very well; in the case of
CuNi3Si substrates the quantities from the twin roller are
p = density, }. = heat conductivity, Ht= heat of fusion about 50% larger, which is not understood up to now. Be-
sides an influence of the melt-substrate velocity the devia-
tion could also be a statistical effect, as only four single
0.8 measurements are included in the model mould values.

0.7 LC steel, air D


LC steel + Ti, air ~
0.6 LC steel, He - Acknowledgement
'iii'
~
~0.5
The financial support of the Deutsche Forschungsge-
~ 0.4
.c meinschaft is gratefully acknowledged .
~ 0.3
(A2003118; received on 11 September, 2003)
C!i 0.2

0.1 Contact: Dr. rer. nat. Achim R. Buchner


0.0 Max-Planck-Institut fur Eisenforschung GmbH
Steel Ni CuNi3Si CuNiBe
Max-Planck-Str. I
Figure 13. Mean growth rate of the solidification front. 40237 Dusseldo,f I Germany

steel research 74 (2003) No. 11/12 737


Process metallurgy

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(2002), 45.
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