| Abstract Scope |
In continuous casting, understanding shell growth during early solidification is essential for improving strand surface quality and casting efficiency. Conventional thermocouple-based simulators are limited by low spatial resolution, slow response, and point-specific measurements, restricting their ability to capture complex mold–steel interfacial phenomena. This work introduces a fiber optic-enhanced mold simulator that employs silica fiber sensors to achieve real-time, distributed thermal mapping with sub-millimeter precision. A water-cooled copper mold was instrumented with high-NA silica fibers and tested with peritectic advanced high-strength steel and commercial mold fluxes under thick-slab casting conditions. The Rayleigh-based distributed sensing system detailed monitoring of temperature gradients, heat flux near the meniscus, and shell growth dynamics under mold oscillation. Results revealed strong correlations between mold thermal profile and shell surface morphology, providing insights into defect formation mechanisms. This platform offers a robust tool for evaluating steel grades, mold fluxes, studying transient solidification, and advancing casting control strategies for improved safety, quality, and efficiency. |