Journal of Iron and Steel Research, International, 2014, 21 (Supplement 1)

Heat Transfer and Deformation Behavior of

Shell Solidification in Wide and Thick Slab
Continuous Casting Mold
Jing-xin SONG, Zhao-zhen CAI, Feng-yun PIAO, Miao-yong ZHU
(School of Materials and Metallurgy, Northeastern University, Shenyang 110819, Liaoning, China)

Abstract: With the considerations of the behaviors of shell deformation, mold flux film and air gap dynamic distribution
in shell/mold gap, a two dimensional slice-travel transient thermo-mechanical coupled model of simulation shell
solidification in wide and thick slab continuous casting mold was developed by using the commercial program ANSYS.
The evolutions of strand-mold system thermal behaviors, including the air gap formation and the mold flux film dynamical
distribution in shell/mold gap and shell temperature field, and the evolutions of shell deformation and stress distribution of
peritectic steel solidified in a 2120 mm wide and 266 mm thick slab continuous casting mold were analyzed. The results
show that the air gap formation and the thick mold flux film distribution mainly concentrate in the regions 0–21 mm and 0–7
mm, 0–120 mm and 0–100 mm off the shell wide and narrow faces corners, and thus the hot spots are given rise to form in
the regions 15–55 mm and 15–50 mm off the shell wide and narrow face corners. The shell server deformation occurs in
the off-corners in the middle and lower parts of the mold. The stress evolution in shell surface is tensile stress, while that
in shell solidification front is compressive stress.
Key words: continuous casting mold; heat transfer; shell deformation; air gap; numerical simulation

The shell solidification in continuous casting
mold is a rather complex process that is coupled with
thermal and mechanical behaviors, which are related
to numerous of defects occurring in slabs surface
and subsurface during practical continuous casting.
Intending to increase the understanding of shell thermal
and mechanical behaviors in continuous casting molds
to improve the casting process, numerous studies[1-13]
have been conducted over the past few decades by
numerical simulation. However, among these previous
studies, most of the mathematical models neglected
the effects of mold flux film on shell heat transfer[1-6,11]
or assumed that the mold flux film distribution in
shell/mold gap was uniform or changed linearly
with the mold height[7-10,12,13]. It is obvious that the
assumptions did not conform to the actual case of
practical continuous casting that the mold flux film in
mold distributes dynamically both along mold height
and circumference with the evolutions of shell/mold
gap and shell temperature, and affects the shell thermal
and mechanical behaviors greatly.
Wide and thick slab continuous casting is an
important part of slab continuous casting process. Due
to the large section of the strand and low casting speed,
the thermal and mechanical behaviors of the shell
solidification in the mold would be more complex,
since the shell shrinks more severely and thus causes
the mold flux film distribution and air gap formation in
the shell/mold gap to vary more dynamically. In order
to describe the thermal and mechanical behaviors
of shell solidification in the mold closely to the
practical continuous casting, a two dimensional slice-
travel transient thermo-mechanical coupled model
was developed by using the commercial program
ANSYS. Based on these, the characteristics of air gap
formation, mold flux film dynamical distribution, the
shell temperature field, as well as the evolution of shell
deformation and stress of peritectic steel solidification
in the mold were analyzed.
1 Mathematical Model
1.1 Shell/mold interfacial heat transfer model
An effective model for describing the heat transfer
of strand-mold system is the basis for numerically
investigating the shell thermal and mechanical
behaviors within mold. In practical wide and thick
slab continuous casting, the shell heat transfer in the
mold is not only affected by mold cooling structure
and cooling system, but also controlled by shell/
mold gap heat transfer behavior significantly since
the formation of air gap, the distribution of mold flux
film, and mold/solid flux interfacial contact thermal

Foundation Item: Item Sponsored by National Outstanding Young Scientist Foundation of China (50925415); Fundamental
Research Funds for the Central Universities of China (N100102001); Postdoctoral Science Foundation of China (2012M510822)
Biography: Jing-xin SONG, Doctor Candidate, Senior Engineer; E-mail: caizz@smm.neu.edu.cn

1
 Heat Transfer and Deformation Behavior of Shell Solidification in Wide and Thick Slab Continuous Casting Mold
resistance distribution are non-uniform, which would
greatly reduce the uniformity of shell heat transfer.
Intending to consider the behaviors of shell/mold
gap non-uniform heat transfer, a shell/mold interface
heat transfer model, which was used to support the
heat fluxes for shell surface and mold hot face, was
developed with the consideration of air gap formation
and mold flux film dynamical distribution.
Fig. 1 schematically shows the heat transfer
process in shell/mold gap. During practical continuous
casting, the liquid flux infiltrates the shell/mold gap
from the mold top and forms a film. Because of mold
Fig. 1 Schematic diagram of heat transfer process in shell/mold gap
T h er ef o r e , a c co r d i n g t o t h e r el a ti o n s h i p
between shell surface temperature and the mold
flux solidification temperature, the heat transfer in
the gap can be divided into two modes, namely the
compositions of the heat transfer media of mode I are
liquid flux, solid flux, and mold/solid flux interfacial
contact thermal resistance, and that of mode II are air
gap, solid flux, and mold/solid flux interfacial contact
thermal resistance, respectively. The heat flux of the
shell/mold gap can be expressed as
Tshell − Tmold
q=
Rliquid flux + Rsolid flux + Rair gap + Rinterfacial contact
where, q is the heat flux of shell/mold gap, °C•W/m2,
Tshell and Tmold are the temperatures of shell surface and
mold hot face, °C. They are determined by the strand-
mold system heat transfer model mentioned in section
1.2. Rliquid flux, Rsolid flux, Rair gap and Rinterfacial contact are the
thermal resistances of the liquid flux, solid flux, air
cooling the film solidifies and shrinkage quickly
occurs, and a contact thermal resistance generates
between mold and solid flux layer. At the upper part
of the mold because the shell surface temperature is
high enough to melt the flux, the mold flux film at the
side of solidifying shell is liquid, and therefore, the
mold flux film in the shell/mold gap at this height is
in solid-liquid coexistence status. However, the shell
surface temperature decreases below the mold flux
solidification temperature and the mold flux film in the
gap solidifies completely. The air gap forms at the side
near the solidifying shell once it continuously contracts.
gap, and mold/solid flux interface, respectively, m2•W-1.
The expressions of them were shown in our previous
publication[14].
1.2 Themo-mechanical finite element model
Based on the heat fluxes for shell surface and
mold hot face supported by the shell/mold interfacial
heat transfer model, a two dimensional slice-travel
transient thermo-mechanical coupled finite element
model of a quarter of strand-mold system was
developed by commercial program ANSYS, as shown
in Fig. 2.
(1) In the model, the heat transfer and stress analysis
were carried out by using the sequential coupling
method. The heat transfers of the strand and mold were
governed by the transient conduction equations, which
were shown as follows
∂H (T ) ∂ ∂T ∂ ∂T
= (λ ( T ) ) + (λ ( T ) ) (2)
∂t ∂x s ∂x ∂y s ∂y
2
 Heat Transfer and Deformation Behavior of Shell Solidification in Wide and Thick Slab Continuous Casting Mold

(a) Calculation domain; (b) Transverse section of slice.

Fig. 2 Schematic of shell thermal-mechanical simulation model in slab mold

where εie is effective inelastic deformation rate, 1/s,

∂T ∂  ∂T  ∂  ∂T 
ρc
=  λm  +  λm  (3) A is pre-exponential factor, 1/s, Q A is the ratio of
∂t ∂x  ∂x  ∂y  ∂y 
activation energy and gas constant, K, ξ is multiplier
where, H(T) and λ s(T) are the enthalpy, J/kg, and of the stress, σ is effective Cauchy stress, MPa,
heat conductivity, W/(m•°C), of the steel. In order to s is deformation resistance, MPa, m is the strain
account the convection effect of molten steel flow on rate sensitivity of stress, s is the time derivative
shell solidification, the effective heat conductivity of deformation resistance, MPa, h 0 is hardening/
of the molten steel was applied by magnifying the softening constant, MPa, s is the coefficient for
conductivity 6.0 times suggested by Han et al[10]. and deformation resistance saturation value, MPa, n is
Li et al[12]. The values of them were shown in previous the strain rate sensitivity of saturation value, α is
work[14]. ρ, c and λm are the density, kg/m3, specific the strain rate sensitivity of hardening or softening.
heat, J/(kg•°C), and heat conductivity, W/(m•°C), of The corresponding values of the parameters used
mold copper plate. in the model were shown in the work by Koric and
The stress evolution of the solidifying shell Thomas[17].
was predicted by the Anand constitutive model[15, 16] The boundary conditions of strand-mold system
to consider the creep phenomenon of shell at high heat transfer were set as: (1) the heat fluxes of the
temperature in mold, which were shown as Eq. (4). symmetrical plane of slab and mold and the cold face
1
(4) of steel backup were 0; (2) the heat fluxes of shell
εie = A exp(−QA /(T + 273))[sinh(ξ ⋅ σ / s )] m
surface and mold hot face around the circumferences
The evolution equation for s is
were determined dynamically by the shell/mold interfacial
heat flux model mentioned in section 1.1; (3) the
heat transfer between mold and cooling water was
considered as convection heat transfer that the transfer
coefficient, hw, were shown as follows[18]
hw d w ρw uw d w 0.8 cw uw 0.4
= 0.023( ) ( ) (6)
α εie λw µw λw
 
  where λw is the heat conductivity coefficient of water,
s  s  W/(m•°C); dw is the hydraulic diameter of the water
= n sign 1 − n  (5) slots, m; ρ w, u w, μ w and c w are the density, kg/m 3,
QA   s  εie exp  QA   
        velocity, m/s, viscosity, Pa•s, and specific heat of
T + 273)    A  (T + 273)     cooling water, J/(kg•°C), respectively.

3
 Heat Transfer and Deformation Behavior of Shell Solidification in Wide and Thick Slab Continuous Casting Mold

The boundary conditions for stress model were
given as: (1) the contact behavior between shell
surface and mold hot face was rigid-to-flexible; (2)
the effect of mold narrow face taper was treated as
displacement increment as a function of height from
meniscus to mold exit; (3) the ferro-static pressure was
loaded on solidification front at solid phase fs=0.884
with an algorithm that reject the “liquid element”
dynamically as solidification proceeded[14]. The value
of the pressure was determined as
P = ρmolten gvct
(7)
where, ρmolten is density of molten steel, kg/m3; vc is
casting speed, m/s; t is time, s.
2 Model Validation
In practical wide and thick slab continuous
casting, the shell solidification process in the mold
cannot be observed or detected directly. Nevertheless,
the temperature profiles of the mold copper plates
and the shell growth in the mold can clearly reflect
the strand-mold system heat transfer conditions.
Therefore, in the present study, the results of the mold
copper plate temperatures and the shell growth in the
mold calculated by the model and the measured values
gathered from the practical continuous casting were
compared to validate the validity of the model for shell
thermo-mechanical behaviors simulation in wide and
thick slab continuous casting mold.
Fig. 3 shows the comparisons of the predicted
temperatures of the mold wide and narrow face copper
plates at the thermocouple positions under the casting
conditions of producing peritectic steel wide and
thick slabs in a plant and the corresponding measured
temperatures gathered by the thermocouples buried
in the mold walls under a steady casting state. The
main compositions of the peritectic steel are C 0.15
wt%, Si 0.25 wt%, Mn 1.50 wt%, P 0.015 wt%, S
0.008 wt%, and the balance Fe. The corresponding
material properties of the steel were shown in our
previous work[14] that were calculated from a solute
microsegregation model[19]. The operating conditions
were shown in Table 1. As evident in the figures, all
the available temperatures measured by the upper
and lower rows of thermocouples at the mold wide
and narrow faces fluctuate between 118 and 106 °C
and between 116 and 103 °C, respectively. The
temperatures of both the wide and narrow faces are

120 TC1 TC2 TC3 TC4 TC5 TC6 TC7

TC8 TC9 TC10 TC11 TC12 TC13 TC14

100
Temperature,℃

Measured by:
Thermocouple TC1 Thermocouple TC8
80 Calculated at mold upper row Thermocouple TC2 Thermocouple TC9
thermocouples positions Thermocouple TC3 Thermocouple TC10
Calculated at mold down row Thermocouple TC4 Thermocouple TC11
60 thermocouples positions Thermocouple TC5 Thermocouple TC12
Thermocouple TC6 Thermocouple TC13
Thermocouple TC7 Thermocouple TC14
40
0.0 0.2 0.4 0.6 0.8 1.0 18:17:53 18:18:33 18:19:13 18:19:53 18:20:33 18:21:13
Distance from mold wide face centerline, m Time

120 TC15

TC16
Temperature, ℃

100

80 Measured by:
Calculated at mold upper row
thermocouples positions Thermocouple TC15
Calculated at mold down row Thermocouple TC16
60 thermocouples positions

40
0.00 0.02 0.04 0.06 0.08 0.10 0.12 18:17:53 18:18:33 18:19:13 18:19:53 18:20:33 18:21:13
Distance from mold narrow face centerline, m Time

Fig. 3 Comparison of the predicted temperatures of mold copper plates at the positions of
thermocouples installation and the corresponding measured temperatures of the wide face (a)
and the narrow face (b) of the mold

4
 Heat Transfer and Deformation Behavior of Shell Solidification in Wide and Thick Slab Continuous Casting Mold
Table 1 Mold operating conditions of the peritectic steel continuous casting
Operation condition
Slab width/mm 2120
Slab thickness/mm 266
Mold height/mm 900
Meniscus level(from top)/mm 100
Flux consumption per ton steel/kg 0.5
Pour temperature/oC 1539
Taper/% 1.0
predicted by the model at the positions where the
thermocouples are installed in the range of measured
values.
Fig. 4 shows comparison between the simulated
and measured shell growths of wide and narrow faces.
The measured data were obtained from the slab shell
in a mold break-out accident during casting of the
peritectic steel under the same casting conditions
shown in Table 1. It can be seen from the figure
that the predicted shell thicknesses are less than the
measured thicknesses in the range of 0–350 mm below
the meniscus. The reason for this discrepancy is that
the molten steel from Submerged Entry Nozzle (SEN)
ports flows upwards, and a great proportion of steel
superheat near the mold wall is removed during this
process because of convective heat transfer with the
solidifying shell during practical casting[20]. However,
in the present model, the initial calculation condition
for the strand was set as the pouring temperature.
Therefore, the shell solidified more slowly at the
upper part of the mold compared with the actual case.
Nevertheless, the values were in good agreement with
results of Hanao’s equation[21]. Moreover, the shell
growth in lower portion of the mold is coincident
with the practice well because most of the molten
steel superheat was removed. Hence, the model is
competent for the present studies.
3 Results and Discussion
3.1 Air gap formation
Fig. 5 shows the air gap formation around the
corners of the shell wide and narrow faces. Under
the casting conditions, the air gap first forms in the
shell corner at 140 mm below meniscus in the mold,
and presents different formation characteristics from
the wide face and narrow face, as shown in Fig. 5(a).
On the wide face, because of a lack of compensation
5
Operation condition
Casting speed/(m•s-1) 0.014
Water temperature/ C
o
Input 33
Output 40
Water flow/(L•s-1)
Wide face 83.50
Narrow face 9.75
Fig. 4 Comparison of the predicted and the measured
shell thickness profiles
by the mold wide face taper, the air gap in the corner
grows continuously along the casting direction, and
the maximum thickness appears at mold exit. The
thickness is 0.93 mm. Compared to the wide face, the
formation of the air gap in shell narrow face corner
is quite different. It increases quickly in the upper
portion of the mold, and then starts to decrease sharply
from the position of 600 mm below meniscus to mold
exit, because the shell shrinkage slows and the mold
taper compensates. The maximum thickness of the air
gap appears at 600 mm below meniscus, of which the
value is 0.95 mm.
Figs. 5(b) and 5(c) show the air gap formation
along the direction of shell circumference at 300, 500
mm, and mold exit around the shell corners of wide
and narrow faces. The air gap reduces rapidly along
the direction from the shell corners to the midst of the
wide and narrow faces with the shell moving down.
The reason for appearance of the phenomenon is
that the mold flux films around the corners increase
rapidly along the direction from the corner to the midst
with the shell moving down, as shown in Fig. 6. The
formation of the air gaps away from the corners is
 Heat Transfer and Deformation Behavior of Shell Solidification in Wide and Thick Slab Continuous Casting Mold

1.0 1.0
1.0 Wide face corner
Narrow face corner 0.8 0.8
0.8
300 mm bellow meniscus

Air gap thickness, mm

Air gap thickness, mm

300 mm bellow meniscus
Air gap thickness, mm

0.6 500 mm bellow meniscus 0.6 500 mm bellow meniscus

0.6 800 mm bellow meniscus 800 mm bellow meniscus

0.4 0.4
0.4

0.2 0.2
0.2

0.0 0.0
0.0
0 100 200 300 400 500 600 700 800 60 50 40 30 20 10 0 35 30 25 20 15 10 5 0
Distance from steel bath level, mm Distance from slab wide face corner, mm Distance from slab narrow face corner, mm

Fig. 5 Air gap formation at shell corner along mold height (a) and around the circumferences of
shell wide face (b) and narrow face (c)

impeded by the thicker mold flux film. Thus, the air distribution along the direction of shell circumference
gaps mainly concentrate in the regions of 0–21 mm at 100, 300, 500 mm, and mold exit around the shell
and 0–7 mm from the corners of shell wide and narrow corners of wide and narrow faces. In the upper part of
faces, respectively. mold, the mold flux films around both the wide and
3.2 Mold flux film distribution narrow faces of the shell decrease gradually from the
Fig. 6 shows the mold flux film dynamical corners to the midst. Nevertheless, the distribution
distribution behaviors around shell corner along the is relatively uniform. The differences between the
direction of mold height and shell circumference. thicknesses of the corners and the midst are just 0.18
The thickness of mold flux film changes gently at the mm and 0.09 mm for the wide and narrow faces,
height of 0–50 mm below meniscus due to the shell respectively, when the shell moves to 100 mm below
gentle shrinkage for its high temperature. As the shell the meniscus.
moving down, since the shell shrinkage increases with However, with the shell continuously moving
its temperature decreases, more liquid flux flows into down, because the mold flux films completely solidify
the shell/mold gap. Because the liquid flux solidifies gradually from the corners to the midst of the wide
completely first appearing at shell corner at 140 mm and narrow faces and because the shell/mold gap size
below meniscus, the mold flux films at shell corners broadens continuously, the mold flux films around
of the wide and narrow faces become constant from the corners of the wide and narrow faces of the shell
the position to mold exit. However, since the surfaces increase rapidly from the corners to the midst and then
of the shell off-corners of wide and narrow faces are decrease again due to the reduction of the shell/mold
high enough for mold flux melting, the liquid fluxes gap size around the off-corners. Thus, the distribution
always exist in the regions from meniscus to the mold of the mold flux films in the gap tends to first increase
exit. Thus, the thicknesses of the mold flux films vary and then decrease in the regions 0–120 mm and 0–100
dynamically with the shell/mold gap size accordingly. mm from the corners of the shell wide and narrow
Figs. 6(b) and 6(c) shows the mold flux film faces to the midst in the middle and lower parts of

0.30 1.8 1.8

2.5 Total thickness Liquid flux thickness
Narrow face corner
Narrow face off corner 0.25 1.6 1.6
100 mm bellow meniscus 100 mm bellow meniscus
Mold flux total thickness, mm

Wide face corner

Mold flux total thickness, mm

2.0
Mold flux total thickness, mm

Wide face off corner 300 mm bellow meniscus 300 mm bellow meniscus
Liquid flux thickness, mm

1.4 1.4
0.20 500 mm bellow meniscus 500 mm bellow meniscus
800 mm bellow meniscus 800 mm bellow meniscus
1.5 1.2 1.2
0.15
1.0 1.0
1.0
0.10
0.8 0.8
0.5 0.05
0.6 0.6

0.00 0.4
0.0 0.4
0 100 200 300 400 500 600 700 800 120 100 80 60 40 20 0 0 20 40 60 80 100 120
Distance from meniscus, mm Distance from slab wide face corner, mm Distance from slab narrow face corner, mm

Fig. 6 Mold flux distribution at shell corner along mold height (a) and around the circumferences of
shell wide face (b) and narrow face (c)

6
 Heat Transfer and Deformation Behavior of Shell Solidification in Wide and Thick Slab Continuous Casting Mold

the mold. The maximum difference in the thicknesses 3.4 Shell deformation and stress distribution
between the regions and the corresponding midst Fig. 8 shows the shell deformation and maximum
reaches 0.84 mm at the mold exit and 0.93 mm at 300 principal stress distribution at the distances 100, 300,
mm below the meniscus, respectively. and 500 mm below the meniscus and at the mold
3.3 Strand-mold temperature distribution exit. The deformed shell geometries were magnified
Fig. 7 shows the temperature field of the strand- fivefold in the figures.
mold system transverse section at distances 100, 300, At the initial solidification stage, because the shell
and 500 mm below the meniscus and at the mold at this stage is thin and hot, the shell shrinkages along
exit under the heat transfer conditions of the shell/ the directions from the corner to the wide and narrow
mold gap. The temperature of the strand at the initial faces midst are small. The shell deformation mainly
solidification stage is quite uniform, except for the concentrates on shell corner, as shown in Fig. 8(a).
corner, where the temperature decreases rapidly due However, as the shell moves down, it shrinks severely.
to the two dimensional heat transfers, as shown in Because the insufficient mold narrow face taper and
Fig. 7(a). However, with the shell moving down, the the lack of wide face taper are unable to support the
heat transfers around both the shell corner and the weak shell, the serious deformations occur in the shell
off-corners gradually slow because the thick mold off-corners in the middle and lower parts of the mold.
flux film and air gap fill in the gaps of these regions, Under such deformation characteristics of
as shown in Figs. 5 and 6. When the shell moves shell, the stress in shell surface layer shows tensile
downward to 300 mm below the meniscus, hot spots stress, while the solidification front is compressive
begin to form in the regions 15–55 mm and 15~50 mm stress. With the shell solidification proceeding, the
from the corners of the shell wide and narrow faces shell stress increases continuously. Moreover, the
until mold exit. shell severe deformation breaks the continuity of
50
Distance from slab narrow face center, m
Distance from slab narrow face center, m

80 50
0.16 0.16 50
80
140 11 0
140 1 10
170 1 40
0.14 200 0.14
13 1 70
0 230 1 15
1480 1456 00 13 0
00
14 0

1480 1456
110

80

0.12
170

0.12 80
1514

140
200

15 14

0.10
110

0.10
230

80
170

0.08 0.08
1.00 1.02 1.04 1.06 1.08 1.10 1.00 1.02 1.04 1.06 1.08 1.10
Distance from slab wide face center, m Distance from slab wide face center, m
200
230

50
Distance from slab narrow face center, m

50
50

Distance from slab narrow face center, m

0.16 50
0.16
50 50
80
110 80
0.14 140 0.14 11
170 0
1150 1150
13
11

00 1300 130
80

50

0.12 1480 1456 0

0.12 50
80

50 1480 1480 14
4 56
11 0
1 51 4

0.10 0.10
15

110
14

50
140

0.08 0.08
1.00 1.02 1.04 1.06 1.08 1.10 1.00 1.02 1.04 1.06 1.08 1.10
Distance from slab wide face center, m Distance from slab wide face center, m
1300

Fig. 7 Temperature fields of strand-mold system at distances 100 mm (a), 300 mm (b), and 500
0

mm (c) below the meniscus and at the mold exit (d)

7
 Heat Transfer and Deformation Behavior of Shell Solidification in Wide and Thick Slab Continuous Casting Mold

Fig. 8 Deformation and maximum principal stress of shell at distances 100 mm (a), 300 mm (b), and 500 mm (c)
below the meniscus and at the mold exit (d)

shell stress distribution around the narrow face off-
corners, as shown in Fig. 8(b) and (c). It is not good
for continuous casting that the off-corner cracks may
occur during the continuous casting.
4 Conclusions
Based on the analysis of the characteristics of
air gap formation and mold flux film distribution
in shell/mold gap, strand-mold system temperature
field, and shell deformation and the stress
evolutions in 2120 mm×266 mm wide and thick
slab continuous casting mold during the peritectic
steel solidification, the following conclusions were
obtained:
(1) The air gap grows continuously in shell
wide face corner along casting direction, while in the
narrow face, it increases quickly in mold upper part
and then turns to decrease sharply in the lower part. It
reduces rapidly along the direction from shell corners
to the midst of the wide and narrow faces that mainly
concentrates in the regions 0–21 mm and 0–7 mm
from the wide and narrow faces corners.
(2) Mold flux firstly solidifies at shell corner and
distributes from corner to the midst of wide face and
narrow faces first increase and then decrease. It mainly
concentrates in the regions 0–120 mm and 0–100 mm
from shell wide and narrow faces corners.
(3) The temperature of the strand is quite uniform
at the initial solidification stage, but forms the hot
spots in the regions 15–55 mm and 15–50 mm from
the corners of the shell wide and narrow faces when
the shell moves downward to 300 mm below the
meniscus.
(4) Shell deformation at shell initial solidification
stage is quite small, but it becomes severe at the middle
and lower portions of the mold. The stress in shell
surface layer is tensile stress, while it is compressive
stress in the solidification front. It generally increases
with the shell solidification proceeding.
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