Abstract 

In this study, a heat transfer model that takes under consideration the micro-segregation phenomena has been extensively deployed for solidification studies concerning the plant casters is also applied to show the casting speed and superheat effects upon internal soundness. Τhe solidification path of C45R, 42CrMo4, S355 grades was simulated using Thermocalc® and DICTRA software in order to examine the phases formed in crucial process temperature windows for the casting. Coupled Heat Transfer/Simple Micro-Segregation Model software has been deployed to simulate the effect of cooling rate on solidus temperature, and solid fraction during solidification. The solidus temperature results computed by the HT/SM and DICTRA were found to be in good agreement. However, the differences in the predicted solidification fractions may derive from the fact that DICTRA uses an average cooling rate whereas the heat transfer SM model takes into account also the local cooling rates in the solidification progress.