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Abstract
The thermal feasibility of a newly proposed thin strip continuous casting process was investigated by using an extended finite-element model. The investigation is presented as a case study of how such a process can be modeled. Details of the thermal model are given, including the boundary-layer phase change technique developed for modeling the solidification process. Bonding of solidified melt to clad was investigated on a near-microscopic scale, using microsecond time steps to track the thermal shock of initial molten metal/clad contact. This casting process would provide a product with two quality surfaces at substantial energy savings over conventional full-thickness cast/rolled sheet production by using thin cold-rolled feedstock as a cladding. The candidate material used for study was ANSI-1020 carbon steel. Modeling parameter variations identified the melt-to-solid(clad) ratio of the product as the most important modeling and process parameter, with thermal feasibility demonstrated for values of this ratio ≤ 3.4.