Mitigation of Black Streak Defects in AISI 304 Stainless Steel via Numerical Simulation and Reverse Optimization Algorithm

The formation mechanism of black streak defects in hot-rolled steel sheets was investigated to address the influence of the process parameters on the surface quality during the production of 304 stainless steels. Macro-/microstructural characterization revealed that the defect regions contained necessary mold slag components (Ca, Si, Al, Mg, Na, K) which originated from the initial stage of solidification in the mold region of the continuous casting process, indicating obvious slag entrapment during continuous casting. On this basis, a three-dimensional coupled finite-element model for the molten steel flow-thermal characteristics was established to evaluate the effects of typical casting parameters using the determination of the critical slag entrapment velocity as the criterion. Numerical simulations demonstrated that the maximum surface velocity improved from 0.29 m/s to 0.37 m/s with a casting speed increasing from 1.0 m/min to 1.2 m/min, which intensified the meniscus turbulence. However, the increase in the port angle and the depth of the submerged entry nozzle (SEN) effectively reduced the maximum surface velocity to 0.238 m/s and 0.243 m/s, respectively, with a simultaneous improvement in the slag-steel interface temperature. Through MATLAB (version 2023b)-based reverse optimization combined with critical velocity analysis, the optimal mold slag properties were determined to be 2800 kg/m³ for the density, 4.756 × 10^-6 m²/s for the kinematic viscosity, and 0.01 N/m for the interfacial tension. This systematic approach provides theoretical guidance for process optimization and slag design enhancement in industrial production.