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Processes
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Numerical Simulation and Heat Transfer in Material Processing and Casting...
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Numerical Simulation and Heat Transfer in Material Processing and Casting Engineering

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Process Control and Monitoring".

Deadline for manuscript submissions: 20 April 2026 | Viewed by 4339

Special Issue Editors

Dr. Constantin Alberto Hernández Bocanegra

E-Mail Website
Guest Editor
Graduate Program in Metallurgy, Morelia Institute of Technology, Morelia 58120, México
Interests: numerical simulation; fluidinamics; steelmaking; heatr transfer
Dr. José Ángel Ramos-Banderas

E-Mail Website
Guest Editor
Graduate Program in Metallurgy, Morelia Institute of Technology, Morelia 58120, México
Interests: heat transfer; fluidinamics; continuos casting
Prof. Dr. Gildardo Solorio Diaz

E-Mail Website
Guest Editor
Mechanical Engineering Program, Universidad Michoacana de San Nicolas de Hidalgo, Morelia 58030, México
Interests: heat transfer; fluidinamics; continuos casting

Special Issue Information

Dear Colleagues,

In light of the development of new processors and increasingly advanced computing capacity, numerical simulation tools have provided increased support for various areas of engineering. However, they are now a necessary tool for improving and optimizing processes. For this reason, Processes launched this Special Issue, Numerical Simulation and Heat Transfer in Material Processing and Casting Engineering, to showcase to the scientific community advances in manufacturing processes involving different heat transfer mechanisms.

This Special Issue will focus on heat transfer processes in furnaces and reactors, steel manufacturing processes, ladle metallurgy, continuous casting, pyrometallurgy, continuous casting, reheating furnaces, heat treatment, boiling curves, etc.

Dr. Constantin Alberto Hernández Bocanegra
Dr. José Ángel Ramos-Banderas
Prof. Dr. Gildardo Solorio Diaz
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Processes is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • numerical simulation
  • heat transfer
  • continuous casting
  • steelmaking
  • furnaces
  • CFD

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Published Papers (4 papers)

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Research

21 pages, 9357 KB  
Article
Genesis of Meniscus Dynamic Distortions (MDDs) in a Medium Slab Mold Driven by Unstable Upward Flows
by Eriwiht Dominic Tello-Cabrera, Saúl García-Hernández, Enif Gutierrez, Rodolfo Morales Dávila, Jose de Jesus Barreto and Rumualdo Servín-Castañeda
Processes 2025, 13(11), 3425; https://doi.org/10.3390/pr13113425 - 25 Oct 2025
Viewed by 245
Abstract
To better understand the relationship between meniscus instabilities and the high levels of turbulence in the fluid dynamics of a continuous medium slab mold, this study investigates the magnitudes of meniscus dynamics distortions and their fluid dynamic origin using a full-scale water modeling [...] Read more.
To better understand the relationship between meniscus instabilities and the high levels of turbulence in the fluid dynamics of a continuous medium slab mold, this study investigates the magnitudes of meniscus dynamics distortions and their fluid dynamic origin using a full-scale water modeling experiment and mathematical simulations. The three-dimensional mathematical model is composed of the continuity and momentum equations, together with the standard k-ε turbulence model and the volume of fluid model, to track the dynamics of the steel interface. The results show that the medium slab mold shares flow patterns common to both conventional slab molds and funnel thin slab molds, making its fluid dynamics more complex. Despite this, the fluid dynamics within the mold do not develop a dynamic distortion phenomenon but induce upward stream flows with instability and high velocities, which generate an unstable meniscus behavior characterized by significant surface oscillations, variations in velocity, and high deformations. These latter flow characteristics are the origin of meniscus dynamic distortion (MDD), which shows a constant frequency with non-constant periodicity and different median lifecycle ranges. Full article
(This article belongs to the Special Issue Numerical Simulation and Heat Transfer in Material Processing and Casting Engineering)
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20 pages, 4748 KB  
Article
PLIF and PIV as Tools to Analyze and Validate Mathematical Models on Mixing and Fluid Flow of Physical Models of Two-Strand Tundishes
by Alberto Velázquez-Sánchez, Luis E. Jardón-Pérez, Carlos González-Rivera, Adrián M. Amaro-Villeda and Marco A. Ramírez-Argáez
Processes 2025, 13(10), 3341; https://doi.org/10.3390/pr13103341 - 18 Oct 2025
Viewed by 207
Abstract
This article demonstrates how the non-intrusive techniques PLIF (Planar Laser-Induced Fluorescence) and PIV (Particle Image Velocimetry) are used to study fluid flow and mixing in a water model of a continuous casting tundish. These techniques validate CFD models by providing hydrodynamic data and [...] Read more.
This article demonstrates how the non-intrusive techniques PLIF (Planar Laser-Induced Fluorescence) and PIV (Particle Image Velocimetry) are used to study fluid flow and mixing in a water model of a continuous casting tundish. These techniques validate CFD models by providing hydrodynamic data and by testing the models’ ability to predict mixing through simulated concentration field evolution under defined process conditions. Using PIV and PLIF yields more accurate information on turbulent mixing and impurity transport than traditional methods. Access to flow and concentration field evolution enables more precise mathematical model refinement and clarifies the impact of tundish design or operational changes on hydrodynamics and mixing. Relative errors in chemical evolution are approximately 20%, whereas velocity errors vary depending on the measurement plane, being lower for longitudinal planes and higher for transversal planes. This suggests that the turbulence model does not fully capture all low- and high-velocity zones. This approach supports reliable flow and mixing predictions in metallurgy and related fields. Full article
(This article belongs to the Special Issue Numerical Simulation and Heat Transfer in Material Processing and Casting Engineering)
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26 pages, 5050 KB  
Article
Production of Chromium–Manganese Ligature from Low-Grade Chromium and Iron–Manganese Ores Using Silicon–Aluminum Alloys as Reductants
by Yerbolat Makhambetov, Saule Abdulina, Sultan Kabylkanov, Azamat Burumbayev, Armat Zhakan, Zhadiger Sadyk and Amankeldy Akhmetov
Processes 2025, 13(10), 3158; https://doi.org/10.3390/pr13103158 - 3 Oct 2025
Viewed by 436
Abstract
This study investigates the production of chromium–manganese ligature by a metallothermic process using complex silicon–aluminum reducing agents. Low-grade chromium and iron–manganese ores from the Kempirsai and Kerege-Tas deposits in Kazakhstan were used as raw materials, while the reducing agents included alumosilicomanganese alloy (AlSiMn) [...] Read more.
This study investigates the production of chromium–manganese ligature by a metallothermic process using complex silicon–aluminum reducing agents. Low-grade chromium and iron–manganese ores from the Kempirsai and Kerege-Tas deposits in Kazakhstan were used as raw materials, while the reducing agents included alumosilicomanganese alloy (AlSiMn) and ferrosilicoaluminum (FeSiAl). Thermodynamic calculations were performed with HSC Chemistry 10 at 1400–1800 °C and reducing agent dosages of 10–100 kg per 100 kg of ore charge. Crucible smelting experiments were then carried out in a Tamman furnace, followed by large-scale laboratory trials in a 100 kVA refining electric furnace to verify reproducibility, with a total of 14 runs. The chemical composition of the ligatures varied depending on the reductant: with AlSiMn the alloy contained Fe—23.14%, Cr—53.74%, Mn—20.03%, and Si—3.06%; with FeSiAl, it contained Fe—42.01%, Cr—25.74%, Mn—27.15%, and Si—5.05%; and with FeSiCr dust, it contained Fe—34.45%, Cr—21.45%, Mn—39.82%, and Si—4.24%. X-ray diffraction (XRD) and scanning electron microscopy (SEM) analyses confirmed the presence of α-(Fe,Cr,Mn), FeSi, and Cr5Si3 phases. The results demonstrate the efficiency of complex silicon–aluminum reducing agents and the ability to regulate the composition of chromium–manganese ligatures by the selected reductant. Full article
(This article belongs to the Special Issue Numerical Simulation and Heat Transfer in Material Processing and Casting Engineering)
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15 pages, 7178 KB  
Article
Octagonal Starfish-Inspired Roller Imprinting Control for Multi-Space and Multi-Axial Microstructure Replication
by Yung-Jin Weng, Yi-Xuan Zhong, Jin-Chen Guo and Zi-Jia Wang
Processes 2025, 13(7), 1966; https://doi.org/10.3390/pr13071966 - 21 Jun 2025
Viewed by 2989
Abstract
This study proposes a novel octagonal starfish-inspired roller imprinting control for multi-space and multi-axial microstructure replication, featuring a roller printing system with a controllable mold structure for multi-space and multi-axis applications. First, a microstructure was made and a micro mold was replicated to [...] Read more.
This study proposes a novel octagonal starfish-inspired roller imprinting control for multi-space and multi-axial microstructure replication, featuring a roller printing system with a controllable mold structure for multi-space and multi-axis applications. First, a microstructure was made and a micro mold was replicated to develop and simulate a negative Poisson ratio structure as a special structure to control the polymer microstructure mold. Meanwhile, a spatial axial roller imprinting system was designed as a roller imprinting replication system for the replication and roller imprinting of microstructures to research and conduct a roller imprinting testing experiment. The experiment results showed that the multi-space and multi-axial roll imprinting processing system with a controllable mold in this research had high replication formability. The results proved that the high replication formability of the microstructure obtained through white light scanning after subsequent roller imprinting was up to 98.75%. The diameter of the microstructure reached 99.025%, and the development of this innovative system and method of new technology could obtain the expected replication formability of the microstructure. Meanwhile, good achievements were obtained through optical preliminary validation. The results of this research could provide a reference about continuous microstructure component roll forming processing for academic and technological development. Full article
(This article belongs to the Special Issue Numerical Simulation and Heat Transfer in Material Processing and Casting Engineering)
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