Gas bubbles are of major importance in most metallurgical processes. They promote chemical reactions, homogenize the melt, or float inclusions. Thus, their dynamics are of crucial interest for the optimization of metallurgical processes. In this work, the state of knowledge of bubble dynamics at the bubble scale in liquid metals is reviewed. Measurement methods, with emphasis on liquid metals, are presented, and difficulties and shortcomings are analyzed. The bubble formation mechanism at nozzles and purging plugs is discussed. The uncertainty regarding the prediction of the bubble size distribution in real processes is demonstrated using the example of the steel casting ladle. Finally, the state of knowledge on bubble deformation and interfacial forces is summarized and the scalability of existing correlations to liquid metals is critically discussed. It is shown that the dynamics of bubbles, especially in liquid metals, are far from understood. While the drag force can be predicted reasonably well, there are large uncertainties regarding the bubble size distribution, deformation, and lift force. In particular, the influence of contaminants, which cannot yet be quantified in real processes, complicates the discussion and the comparability of experimental measurements. Further open questions are discussed and possible solutions are proposed.

To account for increasing economic and ecological pressure, the steel industry is obligated to continuously optimize all processes. An important optimization approach is numerical modeling although its potential is limited by the accuracy of the mathematical models. In a previous work, a validation database was created and a validation score was derived from this data which allows a comprehensive qualitative accuracy assessment for those models. Here, this system is employed for a systematic optimization of the isothermal flow in the casting ladle. For that, different submodels, namely the turbulence models, subgrid turbulence models, bubble-induced turbulence and interfacial closure models as well as influencing factors, such as the grid resolution or the initial bubble size, are analyzed. It is shown that the large eddy turbulence model is more accurate than the Reynolds-average approach because it is able to reproduce the anisotropy of turbulence in the bubble region. In accordance with the literature, a grid dependency of the lift force is found which can be reduced using an averaged shear field as an additional variable. For the interfacial closure models, the combination of the Tomiyama drag model for fully contaminated systems and the Tomiyama lift correlation showed the best agreement with the experimental data. The results of the survey are summarized to a best-practice guideline with which the validation score can be increased from 38.7 with the Reynolds-average approach to 85.1 on a coarse grid respectively, and 87.8 on a fine grid. However, some upscaling problems of the numerical system from the water model to the real ladle are revealed. There is a need to find accurate yet efficient grid resolutions which make the large eddy turbulence model affordable with the current computational resources. Furthermore, alloying elements or non-metallic inclusions might alter the interfacial forces considerably. However, no studies on their effect have been published yet.

As-quenched low-carbon martensitic steels (<0.2 wt.% C) contain auto-tempered carbides. Auto-tempering improves the work hardening and upper-shelf impact energy; however, an efficient characterization method to determine the degree of auto-tempering has not been available. This paper demonstrates an efficient image processing tool that calculates the relative auto-tempered carbide fraction by analyzing scanning electron microscope micrographs. By the process of image segmentation, the qualitative volume fraction of auto-tempered carbides can be determined, and an associated color map produced, which distinguished the levels of auto-tempering. This image processing tool could become useful for the optimization of new low-carbon steel’s mechanical properties.

In numerical computation of ladle metallurgy, multiphase models are essential. Still, these models are afflicted with great uncertainty, making a validation with experimental data mandatory. Validation experiments fundamentally differ from physical modeling experiments because emphasis is on a complete documentation of all boundary conditions and a detailed uncertainty assessment. For this work, the experimental design for a comprehensive accuracy assessment of numerical models and reported quantities were jointly determined with international numerical experts. The framework comprises a plume analysis and flow measurements in the single- and multiphase regions of a water model with defined conditions. All influencing factors are documented extensively and their contribution to the overall data uncertainty is quantified. Detailed data are made publicly available within a validation benchmark database for isothermal multiphase flow in metallurgical ladles. A first draft of a standardized validation procedure, including a single number validation score, is proposed. Using the available data, the accuracy of numerical models can be quantified more accurately and comparably, which helps in advancing the model’s further development. It also lays the foundation for a standardization of the validation process, which can lead to greater acceptance of the numerical results.