Formation of macrosegregation of 5 t steel ingots cast in sand molds with and without water-cooled copper tube is simulated by solving macroscopic mass, momentum, species and energy conservation equations with the consideration of shrinkage formation. Predicted macrosegregation pattern of the ingots shows a fair agreement with the experimental data. Both calculations and experiments reveal that some positive segregation patches are formed at the bottom of ingot. With the water-cooled copper tube inserted in the sand mold, the ingot cast has a less intensive macrosegregation. Mechanisms of macrosegregation formation are numerically analyzed. Explanations regarding the influences of fluid flow and temperature change upon the segregation formation are provided.
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