Structural optimization and heat-fluid-solid simulation of a graded corundum-calcium hexaluminate purging plug by a multi-objective genetic algorithm approach

The purging plug is essential for enhancing production efficiency in molten steel refining, yet it faces challenges related to structural integrity due to its lifespan often not aligning with the ladle's repair cycle. This study introduces a novel corundum-calcium hexaluminate purging plug with gradual holes designed to alleviate internal stress concentration. Utilizing a multi-objective optimization model and fluid-solid coupling heat transfer method, the impact of structural parameters on thermal and mechanical properties was systematically investigated. The numerical simulation results indicate that increasing the number of gradient layers positively impacts temperature distribution. Notably, the D-210 (1.0 mm diameter) aperture reduces the stress gradient Δ σ max by 648.06 MPa compared to D-212 (1.2 mm diameter) at the Y = 0.313 m section. Additionally, variation in inclination angle impacts tensile stress σ t and shear stress τ , an inclination angle of 6° (α6) reduces maximum tensile stress by 211.41 MPa compared to an angle of 0° (α0).