Research Progress on the Formation Mechanism and Control of Solute Segregation During Continuous Casting Solidification

doi:10.11900/0412.1961.2025.00305

Acta Metall Sin

2026, Vol. 62

Issue (5): 855-874 DOI: 10.11900/0412.1961.2025.00305

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Research Progress on the Formation Mechanism and Control of Solute Segregation During Continuous Casting Solidification

ZHU Miaoyong¹^,²(

), WANG Weiling¹^,²(

)

1 School of Metallurgy, Northeastern University, Shenyang 110819, China
2 Institute of Steel Sustainable Technology, Liaoning Academy of Materials, Shenyang 110167, China

Cite this article:

ZHU Miaoyong, WANG Weiling. Research Progress on the Formation Mechanism and Control of Solute Segregation During Continuous Casting Solidification. Acta Metall Sin, 2026, 62(5): 855-874.

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Abstract

Continuous casting is a critical process in the modern iron and steel manufacturing industry. The solidification segregation of continuously cast strands largely affects the yield rate, performance, and service life of steel products. National strategic drives have imposed increasingly stringent demands on the requirements for iron and steel materials. So, macro- and meso-scopic segregation in the solidification of continuously cast strands has become increasingly prominent as the types of alloying elements increase and strand sections continue to be enlarged. This paper elaborates the segregation distribution characteristics in the transverse and longitudinal sections of continuously cast strands and clarifies the formation mechanisms of subsurface segregation, white banding, segregation in the columnar-to-equiaxed transition region, V-shaped segregation, and central/centerline segregation. It also analyzes the generation modes of melt flow and the mechanism of solute segregation cooperatively induced by the melt flow and solidification structure. The paper further identifies the main factors influencing different types of solute segregation and introduces the technical principles and development status of electromagnetic stirring and mechanical reduction. The importance of refining the solidification microstructure for homogenization control is emphasized. Finally, the paper outlines key research directions for high-homogenization control theories and technologies for ultralarge-section continuously cast strands of high-alloy steels, providing a reference for high-quality continuous casting production of base metals for large structural components.

Key words: continuous casting solidification macro- and meso-scopic segregation formation mechanism of segregation homogenization control control with external field

Received: 30 September 2025

ZTFLH:

TF777

Fund: National Natural Science Foundation of China(U24A20100);National Natural Science Foundation of China(52174306)

Corresponding Authors: ZHU Miaoyong, professor, Tel: (024)83686995, E-mail: myzhu@mail.neu.edu.cn; WANG Weiling, associate professor, Tel: (024)83671706, E-mail: wangwl@smm.neu.edu.cn

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https://www.ams.org.cn/EN/10.11900/0412.1961.2025.00305 OR https://www.ams.org.cn/EN/Y2026/V62/I5/855

Fig.1 Typical segregation structures of continuously cast slab in transverse section (a) and longitudinal section (b)

Fig.2 Typical segregation structures (a1, b1) and carbon segregation ratios (a2^[25], b2) of continuously cast billet in transverse section (a1, a2^[25]) and longitudinal section (b1, b2) (CET—columnar-to-equiaxed transition, V line—vertical centerline from inner arc side to outer arc side, SD line—diagonal from top-left corner to bottom-right corner)

Fig.3 Schematics of formation mechanism of negative segregation beneath surface of continuously cast strand (M-EMS—mold electromagnetic stirring, SEN—submerged entry nozzle)

Fig.4 Schematics of formation mechanism of white band in continuously cast strand (S-EMS—strand electromagnetic stirring. Stage I—stirring starting, Stage II—during stirring, Stage III—stirring stopping. $C s 1$ —solute concertation in state I just after stirring starting, $C s 2$ —solute concertation in state II during stirring, $C s 3$ —solute concertation in state III after stirring stopping)

Fig.5 Schematics of formation mechanism of positive segregation in CET zone in continuously cast strand

Fig.6 Schematics of formation mechanism of V-shaped segregation in continuously cast strand

Fig.7 Schematic of formation mechanism of centerline segregation induced by bulging of solidified shell

Fig.8 Schematic of formation mechanism of centerline segregation induced by dendrite bridging and solidification shrinkage

Fig.9 Schematic of formation mechanism of centerline segregation induced by thermal shrinkage

Fig.10 Schematics of electromagnetic stirring devices and principles (F-EMS—final electromagnetic stirring. iu and iv are u and v phases of current I)

Fig.11 Schematics of reduction technologies at solidification end
(a) roller reduction (b) thermal reduction (c) forging

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