Originalarbeit 507 BHM, 160. Jg. (2015), Heft 10–11 © Springer-Verlag Wien Ludwig et al. BHM (2015) Vol. 160 (10–11): 507–512 DOI 10.1007/s00501-015-0416-8 © Springer-Verlag Wien 2015 Recent Developments and Future Perspectives in Simulation of Metallurgical Processes Andreas Ludwig 1 , Menghuai Wu 1,2 and Abdellah Kharicha 1 1 Department of Metallurgy, Montanuniversitaet Leoben, Leoben, Austria 2 Christian-Doppler Laboratory for Advanced Process Simulation of Solidifcation and Melting, Department Metallurgy, Montanuniversitaet Leoben, Leoben, Austria Schlüsselwörter: Prozesssimulation, Makroseigerungen, Elektromagnetisches Rühren, Elektroschlacke Umschmel- zen, Kupfer-Raffnationselektrolyse, Fluid-Struktur-Inter- aktion, Deformationen im Zweiphasengebiet fest/füssig, Graphikkarten, Prozesskettensimulationen, automatische Optimierung Introduction Numerical process simulations are nowadays standard for designing and optimization of metallurgical processes [1]. Furnace construction, tundish planning, or design- ing of continuous casting machines are assisted by the beforehand use of simulation tools. On the other hand, many metallurgical processes need multiphase and/or multiphysics descriptions to account for essential process details, yet often these descriptions are missing or only roughly available. In the present report, which is based on two former review reports by the same authors [2, 3], we give a short overview on present developments and future directions in the feld. 1. Multiphase Simulation 1.1 Particle and Bubble Motion During the continuous-casting process, argon gas is injected into the submerged entry nozzle (SEN) to prevent attachment of nonmetallic inclusions to the inner wall of the SEN, to prevent air from entering the SEN, to promote desired fow patterns, and to promote the fotation of non- metallic inclusion. The most common way of modeling particle and bubble motion is the so-called disperse phase method (DPM), where the trajectory of particles/bubbles (or packets of particles/bubbles) are estimated by solving Newton’s law of motion. This can be done with or without Abstract: The present report addresses briefy the most important issues for simulation of metallurgical process- es, namely multiphase issues (particle and bubble mo- tion; crystal motion during solidifcation), multiphysics is- sues (electromagnetic stirring; electro-slag remelting; Cu- electro-refning; fuid-structure interaction; mushy zone deformation), process simulations on GPUs, though-pro- cess modelling, and automatic optimization via simula- tion. The present state-of-the art as well as requirements for future developments are presented and discussed. Keywords: Process simulation, Electromagnetic stirring, Electro-slag remelting, Cu-electro-refning, Fluid-structure interaction, Mushy zone deformation, GPU, Though-pro- cess modelling, Automatic optimization Aktuelle Forschung und zukünftige Entwicklung im Bereich Simulation metallurgischer Prozesse Zusammenfassung: Die vorliegende Arbeit beschreibt in Kürze die wichtigsten Gesichtspunkte bezüglich Simu- lationen metallurgischer Prozesse. Dies sind Mehrpha- senaspekte (Partikel- und Gasblasenbewegung; Kristall- bewegung während der Erstarrung), multiphysikalische Ansätze (Elektromagnetisches Rühren; Elektroschlacke- Umschmelzen; Kupfer-Raffnationselektrolyse; Fluid- Struktur-Interaktion; Deformationen im Zweiphasengebiet fest/füssig); Prozesssimulation auf Graphikkarten, durch- gängige Prozesskettensimulationen und automatische Optimierung mittels Simulation. Der aktuelle Stand der Forschung sowie Notwendigkeiten für zukünftige Entwick- lungen werden präsentiert und diskutiert. A. Ludwig () Department of Metallurgy, Montanuniversitaet Leoben, Franz-Josef-Strasse 18, 8700 Leoben, Austria e-mail: smmp@unileoben.ac.at Received August 20, 2015; accepted August 25, 2015; published online October 1, 2015