We at Transvalor are proud to announce our active role in the SHELL-CRACK project, where we contribute as subcontractors to SWERIM, the project coordinator. This groundbreaking initiative, funded by the Research Fund for Coal and Steel (RFCS) under project No. 101156718, is poised to revolutionize the prediction, detection, and mitigation of hot cracks and surface defects in continuous casting through an integrated approach combining pilot-scale thermo-mechanical experiments and advanced numerical simulations.
The SHELL-CRACK Project: A Scientific Leap in Continuous Casting
SHELL-CRACK introduces an innovative methodology that integrates both material properties and process-specific parameters to establish novel and extended cracking criteria applicable across the entire continuous casting process—from microstructural evolution to large-scale caster operations. This project will refine existing knowledge by leveraging high-fidelity plant trials, where cutting-edge sensors will monitor critical variables such as mold temperature, surface integrity, and microstructural transformations. The correlation of these parameters will provide invaluable insights into defect formation mechanisms, enabling proactive intervention strategies.
Coordinated by Swerim AB, the SHELL-CRACK consortium unites leading industrial and academic stakeholders, including ArcelorMittal, SSAB, Tata Steel Nederland, Acciaierie di Verona - Gruppo Pittini, SMS group, RINA, Universitat Politècnica de Catalunya, Luleå University of Technology, and Sapotech. Their combined expertise ensures a multidisciplinary approach to tackling the challenges of defect formation in steel casting.
As Europe transitions towards sustainable metallurgy, SHELL-CRACK equips the steel industry with advanced tools to overcome the challenges associated with lower-quality scrap utilization and fossil-free Direct Reduced Iron (DRI) and Hot Briquetted Iron (HBI). The project thus aligns with the European Green Deal, supporting both enhanced production quality and the preparation of European casters for future sustainable steelmaking.
Transvalor’s Role in SHELL-CRACK
Transvalor will play a pivotal role in the project, working in close collaboration with SWERIM’s team to simulate the continuous casting process using THERCAST®. Our primary focus is to model the mechanical behavior of steel during solidification, leveraging THERCAST®' advanced material mechanical models to incorporate new cracking criteria. These criteria will be based on material properties and local process conditions, including temperature distributions, stress evolution, and strain localization effects. Our experts will actively contribute to both the conceptualization and implementation of these new criteria within THERCAST®.
Development of the Cracking Criteria: A Rigorous Scientific Framework
- Theoretical Formulation of Cracking Susceptibility
At an initial stage, cracking susceptibility criteria will be formulated based on experimental data generated in laboratory-scale thermo-mechanical testing. These criteria will integrate constitutive equations derived from three key methodologies found in scientific literature:
- Reduction of Area (RA)
- True Total Energy Approach
- True Fracture Strength-Ductility Method
The combination of these approaches will enhance our theoretical understanding of crack initiation and propagation at elevated temperatures. The developed constitutive equations will establish a comprehensive stress-strain-temperature relationship, forming the basis for an initial Theoretical Cracking Index.
THERCAST® simulations will provide all relevant physical parameters required for the calculation of this index. These simulations will allow for efficient post-processing, enabling automated evaluation via Python scripting. To validate the model, lab-scale experimental setups will be replicated numerically, ensuring that all material properties embedded in the extended constitutive equations are accurately represented.
- Incorporation of Microstructural Variables
The initial theoretical index will be expanded to incorporate critical microstructural variables that influence crack susceptibility. These include:
- Ferrite Potential (FP)
- Extent of the mushy zone
- Microstructure morphology (grain size, primary/secondary dendrite arm spacing - PDAS/SDAS)
- Microsegregation and precipitate formation
- Phase transformations (characterized via SEM, EBSD, XRD, etc.)
THERCAST® will be instrumental in this development, as it possesses the capability to compute key microstructural characteristics such as dendrite arm spacing, solidification grain structures, and segregation patterns based on local temperature fields and alloy compositions. Additionally, Cellular Automata Finite Element (CAFE) simulations will be conducted to derive accurate solidification structures.
- Validation and Integration with Advanced Modelling Tools
Transvalor will collaborate closely with SWERIM to refine the material parameters necessary for these advanced simulations. Experimental data generated in SHELL-CRACK will be complemented by thermodynamic, kinetic, and phase-field modeling using Micress and THERCAST®, enhancing our understanding of microstructure evolution and crack sensitivity. If project findings indicate that micro- and macrosegregation significantly influence crack formation in specific steel grades or product geometries.
Dissemination of SHELL-CRACK’s Breakthroughs to the Steel Community
The SHELL-CRACK consortium, including Transvalor as a subcontractor, is committed to making its findings publicly available to advance knowledge across the European steel industry. By the project’s completion in 2027, the newly developed cracking criteria will be shared openly with the scientific and industrial communities. This aligns with the European Commission’s emphasis on research dissemination and knowledge transfer.
To achieve this, SHELL-CRACK partners will organize dedicated dissemination events, publish findings in international conferences and peer-reviewed journals, and share insights via LinkedIn posts and openly available technical reports.
Stay tuned for updates from SHELL-CRACK and Transvalor as we push the boundaries of steel casting technology!
Disclaimer
"Funded by the European Union. Views and opinions expressed are however those of the author(s) only and do not
necessarily reflect those of the European Union or Research Fund for Coal and Steel. Neither the European Union nor the
granting authority can be held responsible for them."
