A twin roll casting system includes a pair of counter-rotating casting rolls having an adjustable nip therebetween, a casting roll controller configured to adjust the nip between the casting rolls in response to control signals; a cast strip sensor measuring a parameter of the cast strip and generating strip measurement signals; and an iterative learning control (ILC) controller receiving the strip measurement signals and providing control signals to the casting roll controller. The ILC controller includes a fault detection algorithm receiving the control signals and the strip measurement signals and generating a fault detection signal indicating when a fault condition is detected and an iterative learning control algorithm to generate the control signals. The fault detection algorithm indicates a fault condition when it detects the control signal exceeding an upper control saturation threshold or the ILC controller operating a state that is not guaranteed as stable.

An in-mold solidified shell thickness estimation apparatus includes: an input device; a model database configured to store a model formula and a parameter related to a solidification reaction of a molten steel inside a mold of a continuous casting facility; and a heat transfer model calculator configured to estimate an in-mold solidified shell thickness by calculating temperature distributions of the mold and of the molten steel inside the mold by solving a three-dimensional unsteady heat transfer equation. The heat transfer model calculator is configured to correct errors in a temperature of a mold copper plate and in an amount of heat removed from the mold, by correcting an overall heat transfer coefficient between the mold copper plate and the solidified shell.

A computer determines a thickness and/or a temperature of a metal strip. The computer determines the temperatures occurring along a respective rotation part of the respective surface elements of the rotary elements and a rotary element shape which forms in the region of a draw-off point on the respective surface element, by a respective rotary element model and using an exchanged enthalpy quantity, the respective contact time with a metal and a respective cycle time exchanged per time unit of a respective rotary element of a casting device with the environment thereof. The temperature of the metal situated in the die region, and the heat flow from the metal to the respective surface element, are determined by a respective metallurgical solidification model and using a metal temperature, the temperatures of the surface elements, the rotary element shape and characteristic metal values.

A device includes: an input device configured to receive an input of measurement results of a temperature and components of molten steel in a tundish of continuous casting facilities, measurement results of a width, a thickness, and a casting speed of a cast slab casted in the continuous casting facilities, and molten steel flow rate distribution in a mold; a model database configured to store a model expression and a parameter related to solidification reaction of molten steel in the mold; a convertor configured to convert a molten steel flow rate in the mold into a heat conductivity parameter; and a calculator configured to estimate a solidified shell thickness in the mold based on temperature distribution of the mold and steel in the mold calculated by solving a three-dimensional transient heat conduction equation using the measurement results.

A device includes: an input device configured to receive an input of measurement results of a temperature and components of molten steel in a tundish of continuous casting facilities, measurement results of a width, a thickness, and a casting speed of a cast slab casted in the continuous casting facilities, and molten steel flow rate distribution in a mold; a model database configured to store a model expression and a parameter related to solidification reaction of molten steel in the mold; a convertor configured to convert a molten steel flow rate in the mold into a heat conductivity parameter; and a calculator configured to estimate a solidified shell thickness in the mold based on temperature distribution of the mold and steel in the mold calculated by solving a three-dimensional transient heat conduction equation using the measurement results.

Systems and apparatus for continuously casting thin strip where one or more expansion rings are positioned within at least one of a pair of casting rolls, and automatically measuring a thickness of the cast strip close to the first side edge of the strip using at least one sensor. If the thickness measured is too thin, automatically decreasing the radial dimension of the expansion ring arranged in close proximity to the first side edge to cause the cylindrical tube to contract and increase the thickness of the cast strip during casting. If the thickness measured indicates that the thickness of the cast strip is too thick, automatically increasing the radial dimension of the expansion ring arranged in close proximity to the first side edge to cause the cylindrical tube to expand and reduce the thickness of the cast strip during casting.

A crack-free continuous casting mold configured so that occurrence of cracks at a casting billet can be reduced even in a case where a casting speed exceeds 500 mm/min. The continuous casting mold continuously casts a casting billet while cooling molten metal by a cooling device provided at a cooling casting mold. The cooling device includes multiple cooling nozzles configured to release coolant water to the casting billet pulled out of the cooling casting mold to cool the casting billet. Multiple ejection ports of the multiple cooling nozzles are arranged along an outer circumferential direction of a surface of the casting billet. Each ejection port has a short side and a long side, and is configured such that the long side is arranged along an axial direction of the casting billet.

This disclosure concerns methods and apparatus for continuously casting thin strip where one or more expansion rings are positioned within at least one of a pair of casting rolls, and automatically measuring a thickness of the cast strip close to the first side edge of the strip using at least one sensor, and if the thickness measured is too thin, automatically decreasing the radial dimension of the expansion ring arranged in close proximity to the first side edge to cause the cylindrical tube to contract and increase the thickness of the cast strip during casting, and if the thickness measured indicates that the thickness of the cast strip is too thick, automatically increasing the radial dimension of the expansion ring arranged in close proximity to the first side edge to cause the cylindrical tube to expand and reduce the thickness of the cast strip during casting.

A crack-free continuous casting mold configured so that occurrence of cracks at a casting billet can be reduced even in a case where a casting speed exceeds 500 mm/min. The continuous casting mold continuously casts a casting billet while cooling molten metal by a cooling device provided at a cooling casting mold. The cooling device includes multiple cooling nozzles configured to release coolant water to the casting billet pulled out of the cooling casting mold to cool the casting billet. Multiple ejection ports of the multiple cooling nozzles are arranged along an outer circumferential direction of a surface of the casting billet. Each ejection port has a short side and a long side, and is configured such that the long side is arranged along an axial direction of the casting billet.

Methods and apparatus for continuously casting thin strip where one or more expansion rings are positioned within at least one of a pair of casting rolls, and automatically measuring a thickness of the cast strip close to the first side edge of the strip using at least one sensor, and if the thickness measured is too thin, automatically decreasing the radial dimension of the expansion ring arranged in close proximity to the first side edge to cause the cylindrical tube to contract and increase the thickness of the cast strip during casting, and if the thickness measured indicates that the thickness of the cast strip is too thick, automatically increasing the radial dimension of the expansion ring arranged in close proximity to the first side edge to cause the cylindrical tube to expand and reduce the thickness of the cast strip during casting.