Introduction

About the Consortium

The Continuous Casting Consortium (CCC) is a cooperative research program between the University of Illinois at Urbana-Champaign (UIUC), the steel industry, and the National Science Foundation (NSF). Founded in 1991 and directed by Professor Brian G. Thomas, CCC develops comprehensive mathematical models of the continuous casting of steel and related processes.

The goal of CCC research is to enhance fundamental understanding of the continuous casting process, optimize operations, prevent defects, and solve real-world manufacturing challenges facing the steel industry.

The Continuous Casting Process

Continuous casting is the dominant method for producing steel semi-finished products such as slabs, blooms, and billets. In this process, liquid steel is poured from a ladle through a tundish into a water-cooled copper mold where it begins to solidify. The partially solidified strand is then withdrawn downward through a series of water-spray cooling zones and support rolls before being cut to length.

The process involves complex multi-physics phenomena including:

• Turbulent fluid flow in the mold and tundish
• Heat transfer and solidification of the steel shell
• Thermal and mechanical stresses in the solidifying shell
• Electromagnetic effects from flow control devices
• Inclusion and bubble transport and entrapment
• Mold flux behavior and lubrication

Research Approach

CCC researchers develop and validate mathematical models using a combination of:

• Computational fluid dynamics (CFD) simulations
• Finite element analysis (FEA) for stress and deformation
• Physical water models for flow visualization
• Plant measurements and industrial trials
• Metallurgical characterization of cast products

This integrated approach ensures that models are grounded in physical reality and provide actionable insights for industrial partners.

Industry Collaboration

CCC operates as a consortium, with member companies from the steel industry providing financial support and access to plant data, operational expertise, and real-world problems. In return, member companies receive access to research results, computational tools, and the opportunity to collaborate directly with UIUC researchers.

This model has proven highly effective, generating over three decades of impactful research with direct benefits to industrial practice. See the Membership page for information on joining the consortium.

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