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  • 1.
    Saleem, Saud
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Casting of Metals.
    On the surface quality of continuously cast steels and phosphor bronzes2016Doctoral thesis, comprehensive summary (Other academic)
    Abstract [en]

    This thesis work concerns about the importance of the cast surfaces, surface phenomenon such as the formation of the oscillation marks and exudation and related defects including cracks and segregation that happened during the continuous casting. All of the investigated materials were collected during the plant trials while an in-depth analysis on these materials was performed at the laboratory scale with certain explanations supported by the schematic and theoretical models. The work consists on different material classes such as steels and phosphor bronzes with a focus on the surface defects and their improvements. In order to facilitate the theoretical analysis which could be capable of explaining the suggested phenomenon in the thesis, a reduced model is developed which required lesser computational resources with lesser convergence problems.

  • 2.
    Saleem, Saud
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Casting of Metals.
    Fredriksson, Hasse (Contributor)
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Casting of Metals.
    The influence of peritectic reaction/transformation on crack susceptibility in the continuous casting of steelsIn: Metallurgical and Materials Transactions B, ISSN 1073-5615Article in journal (Other academic)
  • 3.
    Saleem, Saud
    et al.
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Casting of Metals.
    Vynnycky, Michael
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Casting of Metals.
    Fredriksson, Hasse
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Casting of Metals.
    A Study of the Oscillation Marks’ Characteristics of Continuously Cast Incoloy Alloy 825 Blooms2016In: Metallurgical and Materials Transactions. A, ISSN 1073-5623, E-ISSN 1543-1940, Vol. 47, no 8, p. 4068-4079Article in journal (Refereed)
    Abstract [en]

    A comprehensive experimental study of oscillation mark (OM) formation and its characteristics during the solidification of Incoloy alloy 825 in the continuous casting of blooms is investigated by plant trials and metallographic study. The experiments involved two heats with the same casting and mold conditions and sampling at different locations across the strand. The metallographic study combined macro/micro-examinations of OMs and segregation analysis of Cr, Mn, Mo, Ni, and Si by microprobe analysis. The results show that OMs have widely different characteristics, such as mark type, depth, segregation, and accompanying microstructure. Furthermore, the mark pitch can vary considerably even for the similar casting conditions, leading to different conditions for the marks’ formation in relation to the mold’s cyclic movement. Finally, a mechanism for the OM formation is discussed and proposed. Possible solutions for minimizing the observed defects by optimizing the mold conditions are suggested.

  • 4.
    Saleem, Saud
    et al.
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Casting of Metals.
    Vynnycky, Michael
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Casting of Metals.
    Fredriksson, Hasse
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Casting of Metals.
    Effect of casting parameters on the formation of oscillation marks during continuous castingManuscript (preprint) (Other academic)
    Abstract [en]

    In the present investigation, oscillations marks formed at the surfaces of two different steel grades are studied; this includes metallographic investigation. The characteristics of the marks are examined rigorously, and the analysis is performed serially. The statistical data is compared withanalytical relations and possible reasons for the deviations from the average values are discussed.From the ongoing analysis, it can be seen that the formation of the primary shell is an important parameter which can affect the depth of the depression. Moreover, the results show that theformation of the oscillation marks is a complex phenomenon and that there could be more than one explanation for their formation.

  • 5.
    Saleem, Saud
    et al.
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Casting of Metals.
    Vynnycky, Michael
    KTH, School of Engineering Sciences (SCI), Centres, Faxén Laboratory. KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Casting of Metals.
    Fredriksson, Hasse
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Casting of Metals.
    The Influence of Peritectic Reaction/Transformation on Crack Susceptibility in the Continuous Casting of Steels2017In: Metallurgical and materials transactions. B, process metallurgy and materials processing science, ISSN 1073-5615, E-ISSN 1543-1916, Vol. 48, no 3, p. 1625-1635Article in journal (Refereed)
    Abstract [en]

    The work presented here examines the surface cracks that can form during the continuous casting of near peritectic steels due to the volume changes during the peritectic reaction/transformation. The investigated samples were collected during plant trials from two different steel grades. The role and mode of the peritectic reaction/transformation are found to depend on the composition of the alloy, resulting in different types of surface cracks. The effect of the local variation in the cooling rate on the formation of the different types of cracks present in each steel grade, which can be due, for example, to the formation of oscillation marks, is demonstrated. The enhanced severity of the surface and internal oxidation, both of which depend on the alloy composition and consequent peritectic reaction, is highlighted. Experimental and theoretical studies show that different types of surface cracks can occur in peritectic steels depending upon the alloy composition and cooling rate, both of which define the fraction of the remaining liquid upon completion of the peritectic reaction/transformation.

  • 6.
    Vynnycky, Michael
    et al.
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering. Univ Sao Paulo Sao Carlos, Dept Appl Math & Stat, Inst Math & Comp Sci, POB 668, BR-13560970 Sao Carlos, SP, Brazil.
    Saleem, Saud
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering. Kanthal, Sandvik Heating Technol, Sorkvarnsvagen 3, S-73427 Hallstahammar, Sweden.
    On the explicit resolution of the mushy zone in the modelling of the continuous casting of alloys2017In: Applied Mathematical Modelling, ISSN 0307-904X, E-ISSN 1872-8480, Vol. 50, p. 544-568Article in journal (Refereed)
    Abstract [en]

    In the continuous casting of alloys, it is well-known that the mushy zone is decisive for the final properties of the casting. Most numerical models' for the process use enthalpy based methods on fixed grids which determine the extent the mushy zone implicitly. Here, on the other hand, we develop a methodology for explicitly resolving the geometrical extent of the mushy zone; this involves a sharp-interface formulation to solve a dual moving boundary problem to locate the solidus and liquidus isotherms. The results compare favourably with those from enthalpy-based methods, and the advantages of our approach with respect to future multiphysics calculations are discussed. 

  • 7.
    Vynnycky, Michael
    et al.
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Casting of Metals.
    Saleem, Saud
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Casting of Metals.
    On the resolution of thermal gradients in a model for the continuous casting of binary alloysIn: Applied Mathematics and Computation, ISSN 0096-3003Article in journal (Other academic)
  • 8.
    Vynnycky, Michael
    et al.
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering. University of São Paulo, Brasilia.
    Saleem, Saud
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering. Sandvik Heating Technology, Sweden.
    Devine, K. M.
    Florio, B. J.
    Mitchell, S. L.
    O’Brien, S. B. G.
    On the formation of fold-type oscillation marks in the continuous casting of steel2017In: Royal Society Open Science, E-ISSN 2054-5703, Vol. 4, no 6, article id 170062Article in journal (Refereed)
    Abstract [en]

    Asymptotic methods are employed to revisit an earlier model for oscillation-mark formation in the continuous casting of steel. A systematic non-dimensionalization of the governing equations, which was not carried out previously, leads to a model with 12 dimensionless parameters. Analysis is provided in the same parameter regime as for the earlier model, and surprisingly simple analytical solutions are found for the oscillation-mark profiles; these are found to agree reasonably well with the numerical solution in the earlier model and very well with fold-type oscillation marks that have been obtained in more recent experimental work. The benefits of this approach, when compared with time-consuming numerical simulations, are discussed in the context of auxiliary models for macrosegregation and thermomechanical stresses and strains.

  • 9.
    Vynnycky, Michael
    et al.
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering.
    Saleem, Saud
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Casting of Metals.
    Fredriksson, Hasse
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Casting of Metals.
    An asymptotic approach to solidification shrinkage-induced macrosegregation in the continuous casting of binary alloys2018In: Applied Mathematical Modelling, ISSN 0307-904X, E-ISSN 1872-8480, Vol. 54, p. 605-626Article in journal (Refereed)
    Abstract [en]

    The modelling of macrosegregation in the continuous casting of alloys normally requires resource-intensive computational fluid dynamics (CFD). By contrast, here we develop an asymptotic framework for the case when macrosegregation is driven by solidification shrinkage; as a first step, a binary alloy is considered. Systematic asymptotic analysis of the steady-state two-dimensional mass, momentum, heat and solute conservation equations in terms of the shrinkage parameter indicates that the overall problem can be reduced to a hierarchy of decoupled problems: a leading-order problem that is non-linear, and a sequence of linear problems, with the actual macrosegregation of the solute then being determined by means of one-dimensional quadrature. A numerical method that solves this sequence is then developed and implemented, and yields realistic macrosegregation profiles at low computational cost.

  • 10.
    Vynnycky, Michael
    et al.
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Casting of Metals.
    Saleem, Saud
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Casting of Metals.
    Fredriksson, Hasse
    KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Casting of Metals.
    Towards an asymptotic framework for solidification shrinkage-induced macrosegregation in the continuous casting of binary alloysManuscript (preprint) (Other academic)
    Abstract [en]

    The modelling of macrosegregation in the continuous casting of alloysnormally requires resource-intensive computational fluid dynamics(CFD). By contrast, here we develop an asymptotic framework for thecase when macrosegregation is driven by solidification shrinkage; as a firststep, a binary alloy is considered. Systematic asymptotic analysis of thesteady-state two-dimensional mass, momentum, heat and solute conservationequations in terms of the shrinkage parameter indicates that theoverall problem can be reduced to a hierarchy of decoupled problems: aleading-order problem that is non-linear, and a sequence of linear problems,with the actual macrosegregation of the solute then being determinedby means of one-dimensional quadrature.

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