Structure of turbulent flow in a slab mold

The structure of the turbulent flow in a slab mold is studied using a water model, various experimental techniques, and mathematical simulations. The meniscus stability depends on the turbulence structure of the flow in the mold; mathematical simulations using the k-ε model and the Reynolds-stress model (RSM) indicate that the latter is better at predicting the meniscus profile for a given casting speed. Reynolds stresses and flow vorticity measured through the particle-image velocimetry (PIV) technique are very close to those predicted by the RSM model, and maximum and minimum values across the jet diameter are reported. The backflow in the upper side of the submerged entry nozzle (SEN) port (for a fixed SEN design) depends on the casting speed and disappears, increasing this process parameter. At low casting speeds, the jet does not report enough dissipation of energy, so the upper flow roll is able to reach the SEN port. At high casting speeds, the jet energy is strongly dissipated inside the SEN port, the narrow wall, and in the mold corner, weakening the momentum transfer of the upper flow roll, which is unable to reach the SEN port. At low casting speeds, meniscus instability is observed very close to the SEN, while at high casting speeds, this instability is observed in the mold corner. An optimum casting speed is reported where complete meniscus stability was observed. The flow structure at the free surface indicates a composite structure of islands with large gradients of velocity at high casting speeds. These velocity gradients are responsible for the meniscus instability.