Micro continuous casting, which includes, for example, single-roll casting, twin-roll casting, and EFG, is a comprehensive casting method concept for high-performance material produced with rapid solidification. When a new material functionalized through micro continuous casting is industrially developed, the caster type generally differs between design (experimental) phases because of the discrepancy of the purpose in each design phase. In the present design method, experimental data is arranged as ‘solidification structure map’ with local field properties, solidification rates, and temperature gradients, as the dominant general parameters is assisted with the casting simulation of temperature and flow field without microstructure prediction. The present method could reduce the design steps necessary for conventional design, in which the fully empirical method has been adopted, because no solidification microstructure model can determine the structure for industrial accuracy for untested material composition or casting conditions.
The present design method requires high accuracy for solidification models because the shape of the ‘solidification structure map’ changes significantly by the model accuracy in a casting simulation.