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计算流体力学方法在连铸结晶器中的应用进展

Progress in application of computational fluid dynamics in continuous casting mold

  • 摘要: 连铸结晶器内的高温熔体多相流直接决定了铸坯的洁净度、均匀度与精细度, 是影响铸坯最终质量的核心因素之一。该体系以高度非稳态的湍流为主导, 钢液、气泡、熔渣及夹杂物等多相介质在结晶器内共存并相互作用, 同时耦合传热、传质、相变、电磁场等复杂物理化学过程, 形成典型的非线性非平衡态多物理场耦合系统, 呈现出高度的复杂性和显著的不确定性。受限于结晶器内高温熔体物性变化大、本构关系复杂、相界面影响因素多及边界物理量梯度大等特征, 高温熔体多相流动结构、凝固行为中的关键参数难以实现实时、精确监测, 导致传统的试验研究在机理解析深度和参数获取完整性方面存在明显局限。在此背景下, 计算流体力学方法凭借其在揭示复杂流动机制及内部演化机理方面的显著优势, 逐渐成为研究连铸结晶器内高温熔体多相流的关键技术手段。本文从多相流模型、湍流模型、群体平衡模型、多相体积平均凝固模型及电磁外场调控模型等角度出发, 系统回顾了计算流体力学方法在连铸结晶器中的应用进展与研究现状, 重点分析了不同模型在描述复杂多相流动及凝固过程等方面的优势与局限性, 最后结合高质化连铸坯制备的发展趋势, 展望了精细化建模、多尺度耦合及工程适用性等的未来发展方向。

     

    Abstract: The high-temperature molten metal multiphase flow in a continuous casting mold directly governs the cleanliness, homogeneity, and refinement of the strand, and is therefore one of the core factors determining the final quality of the strand. This system is dominated by highly unsteady turbulence, in which multiple phases including molten steel, gas bubbles, slag, and non-metallic inclusions coexist and interact with each other. It is simultaneously coupled with complex physicochemical processes such as heat transfer, mass transfer, phase transformation, and the electromagnetic fields, forming a typical nonlinear and non-equilibrium multiphysics coupling system that exhibits high complexity and significant uncertainty. Owing to the characteristics inside the mold such as large variations in thermophysical properties of the high-temperature molten metal, complex constitutive relationships, numerous factors affecting the phase interface, and steep gradients of boundary physical quantities, real-time and accurate monitoring of key parameters related to the multiphase flow structures and solidification behavior of the high-temperature molten metal remains extremely challenging. Thus, traditional experimental studies have obvious limitations in the depth of mechanistic analysis and the completeness of parameter acquisition. In this context, computational fluid dynamics (CFD) with its significant advantages in revealing complex flow mechanisms and internal evolution processes has gradually become a key technical method for studying high-temperature molten metal multiphase flow in continuous casting mold. This paper systematically reviews the application progress and research status of CFD in continuous casting mold from the perspectives of multiphase flow models, turbulence models, population balance models, multiphase volume-averaged solidification models, and electromagnetic external field regulation models. It focuses on analyzing the advantages and limitations of different models in describing complex multiphase flow and solidification processes. Finally, combined with the development trend of high-quality continuous casting strand production, the future development directions in terms of refined modeling, multiscale coupling and engineering applicability are prospected.

     

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