Prediction of Longitudinal Cracks Based on a Full-Scale Finite-Element Model Coupled Inverse Algorithm for a Continuously Cast Slab

A full-scale finite-element model of a slab and its mold is developed to predict the appearance of longitudinal cracks during continuous casting, in which the measured data are combined with the model through an inverse algorithm. The simulation results show that the stress distributions in the slab are not symmetrical, reflecting the non-uniformity of the thermo-mechanical behavior. The longitudinal crack sensitivity index is highest at 60–100 mm below the meniscus, and the position of an actual longitudinal crack agrees well with the calculated result. This illustrates the validity of the proposed method for predicting longitudinal cracks, and hence demonstrates the necessity of building the full-scale model integrated with measured data.