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1
Chernyshov, E. A., I. V. Baev, and A. D. Romanov. "Mechanical properties and structure of castings at different ladle processing of liquid and crystalizing steel." Izvestiya. Ferrous Metallurgy 63, no. 8 (October 8, 2020): 644–50. http://dx.doi.org/10.17073/0368-0797-2020-8-644-650.
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The paper presents studies on the effect of external influences when pouring-in high-strength alloyed steel into thin-walled metalshell molds with external cooling and into the same molds with suspension pouring-in (complex effect on hardened casting). Prerequisites for the selection of these technologies are considered. As control metal, we have investigated the casting received in volume liquid glass form. Macrostructure, cross-sectional view and mechanical properties of the metal at normal (+20 °C) and raised (+350 °C) temperatures were studied. The most dense and uniform structure and cross-sectional view were received in casting at complex influence. It was established that the main advantage of the offered technologies is increase in uniformity of mechanical properties on the section and height of castings, especially of plastic properties and impact strength. The anisotropy of properties on the section and height of pilot castings is much less, than in control casting. As a result of the studies, it was found that the external and complex effect on the forming casting allows one to affect the macrostructure and to improve the mechanical properties of castings at various test temperatures of the samples. In castings obtained in a metal-shell form with forced cooling, there is no noticeable difference in the mechanical properties both in height and in cross section of the casting. Moreover, the strength properties are by an average 100 MPa higher than that of the control casting, while maintaining high values of ductility and toughness.
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Xiao, Xiao Feng, Qiong Xue, Ke Feng Xiao, and Xiao Lan Hu. "LFC Mold Development of Complex Parts with Free-Form Surface." Advanced Materials Research 228-229 (April 2011): 532–36. http://dx.doi.org/10.4028/www.scientific.net/amr.228-229.532.
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This paper has analyzed key techniques in foam mold development for Lost Foam Casting for different types of casting, which are complex box, pipe faucet junction ,wear-resisting and refractory alloy steel casting, Focused on complex castings with free-form surface, key points during whole technical route, which includes three-dimensional modeling, foamed pattern design, mold design and CNC program, have been discussed by utilizing modeling & manufacturing module on Unigraphics. Because of its perfect free-form surface functions and plentiful toolpath operations in CNC programming, Foam mold of complex casting with free-form surface has been designed, manufactured and assembled successfully for LFC, Qualified foamed pattern of vortical shell has been produced successfully. Several effective methods and experiences have been achieved by utilizing CAD/CAM technology.
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Yang, Da Chun. "Influence of Casting Process for Technological Yield of Thin Wall Steel Castings by Last Solidifying Feeding Mechanism." Advanced Materials Research 538-541 (June 2012): 1134–37. http://dx.doi.org/10.4028/www.scientific.net/amr.538-541.1134.
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For the steel castings which is thin wall, uniform thickness, complex structure, and no special mechanical properties, it is feasible that the foundry technology was designed according to the last solidifying feeding mechanism. Adopting this process for the thin wall steel castings, the pouring temperature must be controlled and the gating system be designed rationally. Using self-feeding shrinkage in solidification, and the casting was poured and congealing at the same time. The shrinkage of finally congealing part was fed by small riser or gating system (no riser). Using this foundry technology, the casting process yield and surface quality of casting may be improved, the production cost is reduced, and the requirements of mechanical properties can be met.
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Chen, Xiang-Ru, Qi-Jie Zhai, Han Dong, Bao-Hua Dai, and Hardy Mohrbacher. "Molybdenum alloying in cast iron and steel." Advances in Manufacturing 8, no. 1 (December 10, 2019): 3–14. http://dx.doi.org/10.1007/s40436-019-00282-1.
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AbstractMetal casting is an important manufacturing technology for efficiently producing massive components with complex shape. A large share of industrial castings is made from iron and steel alloys, combining attractive properties and low production cost. Upgrading of properties in cast iron and steel is mainly achieved by alloying and in fewer cases by heat treatment. Molybdenum is an important alloying element in that respect, increasing strength, hardness and toughness. It also facilitates particular heat treatments such as austempering. The paper describes the metallurgical functionality of molybdenum alloying in iron-based castings and demonstrates its effectiveness for applications in the automotive and mining industry.
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Saveliev, М. V., А. V. Chiglintsev, D. V. Sushnikov, P. V. Ekkert, and V. Yu Elin. "Development of steel continuous casting at the Nizhny Tagil steel-works." Ferrous Metallurgy. Bulletin of Scientific , Technical and Economic Information 76, no. 6 (July 21, 2020): 550–55. http://dx.doi.org/10.32339/0135-5910-2020-6-550-555.
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Steel continuous casting is one of fundamentals of modern steel industry. Specialists of Nizhny Tagil steel-works (NTMK) made an important contribution to the process perfection. The one-strand slab CCM of curvilinear type with radial mold and slab straightening by multipoint curve, designed and manufactured at Uralmashzavod, became a prototype for many machines, which were later manufactured at domestic and foreign steel-works in the end of 60th of the previous century. In the process of mastering of CCMs, which were put into operation within the programs of the plant modernization and transferring to BOF production with steel continuous casting, the CCMs were significantly modernized and technology of casting was perfected. To bring down the impact on the solidifying billet peel and decrease a billet swell, the scheme of the supporting rollers location was changed, which enabled to increase the length of the supported zone. A principally new scheme of billets cooling was implemented, which ensured a softer and uniform secondary cooling due to water-air “fog”. To create optimal conditions of axis zone forming during production of round billets of 430 mm diameter, a technology of protective heat screens application was used. The protective screens were installed in the end of ingot solidification zone. A large work was done on determination of optimal technological casting parameters – temperature and speed modes, types of slag forming mixtures, types of heat-insulating mixtures, methods of metal protection in the process of casting. As a result of the work done, at EVRAZ NTMK a complex of steel continuous casting was created, which enables to be flexible depending on the varying situation at the market and to produce continuously casted billets of various dimensions and wide range of steel grades.
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Küthe, Fabian, C. Afrath, and Andreas Bührig-Polaczek. "Steels with Different Carbon Content for High Pressure Die Casting in Semisolid State." Solid State Phenomena 116-117 (October 2006): 708–11. http://dx.doi.org/10.4028/www.scientific.net/ssp.116-117.708.
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Some excellent projects have been finished successfully since the last conference on the pre-industrial stage showing the great potential of thixoforming technology for steels [1][2]. Experiments presented in this paper on induction heating, process window and mould filling of three widely-used steel alloys offer an even greater field of application for industrial companies. In the past thin walled cutting tools and complex impellers made of cold working steel X210CrW12 were produced at the Foundry Institute [3][4]. Constitutive on this knowledge the field of applications is enlarged by research on two further steel alloys. Processing of 100Cr6 (roller bearing steel) and 42Cr4 (annealing steel) is challenging due to a decreasing window at a higher temperature level with decreasing carbon content. An exact procedure has been worked out to create new control programs for the induction heating unit. It is based on thermo-chemical calculations and delivers billets with feasible temperature distribution and well defined content of liquid phase. Material characterization is performed in a step-die (seven steps between 25 and 0.5mm), especially developed for demands of semi-solid casting. Mould filling capacity, micro structural evolution and mechanical properties are determined on each of the seven steps. For any reproducible process the knowledge of suitable system parameters is essential. To find the limits of the process window sensitive experimental parameters were changed systematically for each of the three steel alloys. In addition to tool temperature the process windows consist principally of content of liquid phase fs, piston velocity vP and pressure during freezing pfr. Characteristic differences appeared between the different steel grades. The thermal simulation was used to find functional dimensions for the gating system and to shorten process times. Simulation of tools system was used to estimate the additional thermal load induced by higher working temperatures. The abrasive wear at the offsets to the next steps was in the same order of magnitude for all examined steels. These results provide the opportunity for commercial steel grades to cast complex steel parts in high pressure die casting.
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Wang, Shuo Ming, Cheng Liang Du, and Ju Gao. "Study of Micro-Inclusion of 20g Steel." Advanced Materials Research 634-638 (January 2013): 1864–68. http://dx.doi.org/10.4028/www.scientific.net/amr.634-638.1864.
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According to the production process of 20g steel(120t BOF→ LF→ CC), some system analysis are introduced to research on the content of T[O] and [N] and the type, source, composition and quantity of micro inclusions in refining process, pouring process and casting billet. The results of the study show: the content of T[O] is 93.2ppm in the normal billet which is 37.8ppm more than that at steady state in the export of tundish. The content of T[O] is 140.5ppm in the compound casting billet which is 70.133ppm more than that at non-steady state in the export of tundish. The secondary oxidation of mould is serious at casting progress. In billet, the quality of CaS-SiO2-Al2O3 complex inclusion is the most, the quality of MnS inclusion is the second, and the quality of Al2O3 inclusion is the least. The sulphur content in micro-inclusion of billet is higher. The sulphur content in CaS-SiO2-Al2O3 complex inclusion is 3~15%, the sulphur content in MnS inclusion is 25%. The particle size of less than 10μm in micro-inclusions is the largest. The particle size of 0~5μm is about 60%, the particle size of 5~10μm is about 35%, the particle size of 10~15μm is about 5%. The average total volume rate of micro-inclusion is 0.149% in normal billet. The average total volume rate of micro-inclusion is 0.184% in compound casting billet which is 1.23 times than normal billet. The number of micro-inclusion is 36.5/ mm2 in normal billet. The number of micro-inclusion is 58.5/ mm2 in compound casting billet which is 60.27% higher than normal billet. The non-steady state casting has serious influence on billet cleanliness.
8
Han, Zhan Guang, and Jia Quan Zhang. "An Advanced Dynamic Secondary Cooling Control Model for Bloom Castings." Advanced Materials Research 154-155 (October 2010): 171–78. http://dx.doi.org/10.4028/www.scientific.net/amr.154-155.171.
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For bloom casting, typical quality defects such as midway crack usually occur upon improper cooling control during non-steady casting conditions specially for the production specialty steels,. A key measure to eliminate the defects formation has been presented by the adoption of more sophisticated secondary cooling strategies to balance the surface reheating due to casting speed fluctuation. With the consideration of the complex casting conditions and the characteristics of bloom casters, a dynamic control model for the secondary cooling has been developed in the paper to obtain a reasonable temperature profile and solidification progress for the bloom casting process, which is based on a slice residence time method combined with a multi-level control strategy. The feedback system, based on the difference between the calculated surface temperatures and the predetermined or measured surface temperatures, has been integrated into two-dimensional thermal model. The interlocking protection system between level-1 and level-2 is included in the model together with the data diagnosis and processing. Furthermore, the control model also offers technological interface for the introduction of new steel grades in production and the related modification to the secondary cooling parameters. It is shown from online application that the dynamic control system of secondary cooling for bloom casting is robust during operation and adaptable to any change of real casting conditions. Sound quality bloom castings according to acid etched tests have been obtained from the caster accordingly.
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Khan, Muhammad Azhar Ali. "Simulation Based Mold Design Optimization of a Spring Flap Casting." Solid State Phenomena 305 (June 2020): 178–84. http://dx.doi.org/10.4028/www.scientific.net/ssp.305.178.
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The complex nature of metal casting process brings about a need to simulate it before undertaken in a foundry. Casting simulations provide insights on flow of molten metal within the mold, solidification sequence, nature and location of defects etc. Moreover, mold design can be optimized to minimize defects without undergoing physical trials-and-errors as previously practiced in traditional metal casting. This study is based on casting an ASTM A216 WCB steel spring flap for automotive suspension system using a simulation based optimized mold design. The initial and optimized mold designs are simulated in MAGMASoft for mold filling, solidification, stress distribution and defects prediction. The results of simulations and actual castings are found to be in good agreement. It is concluded that simulations are accurate in modeling casting process and in predicting defects followed by their minimization through mold design optimization. The use of auxiliary components in a carefully designed mold can lead to a nearly defect-free and high quality cast product.
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Szajnara, J., A. Studnicki, M. Kondracki, and J. Głownia. "Technological Aspects of Low-Alloyed Cast Steel Massive Casting Manufacturing." Archives of Foundry Engineering 13, no. 4 (December 1, 2013): 97–102. http://dx.doi.org/10.2478/afe-2013-0090.
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Abstract In the paper authors have undertaken the attempt of explaining the causes of cracks net occurrence on a massive 3-ton cast steel casting with complex geometry. Material used for casting manufacturing was the low-alloyed cast steel with increased wear resistance modified with vanadium and titanium. The studies included the primary and secondary crystallization analysis with use of TDA and the qualitative and quantitative analysis of non-metallic inclusions.
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An, Hanghang, Yan Ping Bao, Min Wang, Quan Yang, Xiang Hong Wang, and Yan Yin Dang. "High-efficiency continuous casting of GCr15 bearing steel bloom based on cooperative control technique of complex electromagnetic stirring and soft reduction." Metallurgical Research & Technology 116, no. 6 (2019): 621. http://dx.doi.org/10.1051/metal/2019051.
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GCr15 bearing steel exhibits comparatively serious center macro-segregation in the continuous casting of bloom with the increase of casting speed. In the present work, the influence of complex electromagnetic stirring (M + F-EMS) and mechanical soft reduction (MSR) on the center macro-segregation in the continuous casting of 220 × 260 mm blooms of GCr15 bearing steel have been comparatively investigated to increase casting speed in order to ensure a good internal quality. Based on numerical simulation and experiments, M + F-EMS and MSR have been comprehensively evaluated and compared by combination of industrial trials. The results show that center carbon segregation first decreases and then increases with the increase of casting speed in both processes without optimization. For M + F-EMS process, when casting speed increases from 0.75 to 0.85 m · min−1, the average degree of center carbon segregation decreases from 1.2 ∼ 1.26 to 1.18 ∼ 1.25 by asymmetrical optimization; with regard to combination of M + F-EMS and MSR process, when casting speed increases from 0.75 to 0.9 m · min−1, the average degree of center carbon segregation decreases from 1.2 ∼ 1.26 to 1.08 ∼ 1.1 and the solute element distribution becomes homogeneous by optimization. In comparison, significant reduction of the center macro-segregation with the increase of casting speed can be achieved for combination of M + F-EMS and MSR process, however, it is infeasible for M + F-EMS process in the present technology situation.
12
Gao, Ju, and Cheng Liang Du. "Study of Large Inclusions in Casting Slab of 45# Steel." Advanced Materials Research 634-638 (January 2013): 1859–63. http://dx.doi.org/10.4028/www.scientific.net/amr.634-638.1859.
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According to the production process of 45#steel(120t BOF→ slag refining →CC), some system analysis are introduced to research on the type, composition and quantity of large inclusions in casting slab under slag washing process, the effect of slag washing production process on the cleanliness of casting slab is evaluated. The results of the study show that: Under slag washing process, many of large inclusions are spherical inclusions，the main type of large inclusions is CaO-SiO2-Al2O3-MnO complex inclusion andSiO2-Al2O3 inclusion; the content of large inclusions in normal slab is 5.17mg/10kg, it is lower than that under un-slag washing process; the content of large inclusions in head slab is 108.82mg/10kg, it’s 21.05 times higher than that in normal slab; the content of large inclusions in compound casting slab is 15.94mg/10kg, it’s 3.08 times higher than that in normal slab; the content of large inclusions in casting slab is slightly higher under the condition of unsteady casting; the main inclusions with a size of between 140μm and 300μm in head slab, take up 70.13%, the inclusions with a size of more than 300μm is second, take up 29.24%, and the least is inclusions with a size of between 80μm and 140μm, only take up 0.63%. The level of the molten steel fluctuated remarkably, slag entrapment and secondary oxidation is serious at the casting start and compound casting, which cause the cleanliness of casting slab decreasing. Unsteady casting has great effect on the cleanliness of casting slab.
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Yang, Jie, Dengfu Chen, Mujun Long, and Huamei Duan. "An Approach for Modelling Slag Infiltration and Heat Transfer in Continuous Casting Mold for High Mn–High Al Steel." Metals 10, no. 1 (December 26, 2019): 51. http://dx.doi.org/10.3390/met10010051.
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To clarify the characteristics of slag infiltration and heat transfer behaviors in the meniscus region during the casting of high Mn–high Al steel, a mathematical model of a continuous casting mold that couples fluid flow with heat transfer, and solidification is developed. The model is based on the change in slag composition and properties caused by the steel/slag reaction. The formation and evolution of the meniscus profile and slag films for different mold fluxes during mold oscillation are described. The results show that the rapid growth of the slag rim with a high Al2O3 content approaches and deforms the meniscus so that a series of casting problems such as slag infiltration blocking, large fluctuations in heat flux, and even meniscus breaking occur in the continuous casting process. Predictions are in good agreement with plant measurements. These findings provide an improved understanding of the complex phenomena occurring in the meniscus region and give new insights into the evaluation and optimization of mold flux properties for high Mn–high Al steel casting.
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Liao, Dun Ming, Li Liang Chen, Jian Xin Zhou, and Rui Xiang Liu. "Numerical Simulation of Thermal Stress Fields of Steel Casting." Advanced Materials Research 179-180 (January 2011): 1118–23. http://dx.doi.org/10.4028/www.scientific.net/amr.179-180.1118.
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Many defects relative to stress occur during the complicate casting process, such as hot tearing, residual stress concentration and distortion. Modeling of casting thermal stress during casting solidification process is of great significance to predict and analyze casting stress defects. Involving too many complex influencing factors, the stress simulation is very difficult and retains a hot spot of macro simulation in foundry engineering. Currently most researchers adopt integrated FDM/FEM method, i.e. using finite difference method (FDM) to calculate solidification and heat transferring, while finite element method (FEM) to simulate stress. Some universal commercial FEA packages are usually adopted. This study has tried two kinds of approaches to simulate casting thermal stress. One is based on ANSYS, a well-known powerful FEA analysis software. Another is to develop an independent own copyrighted casting stress simulation system based on FDM. The routes of these two methods were given respectively. To calibrate the simulation system, a stress frame sample and a real practical casting were simulated and pouring experiment was also carried on. The results of simulation were in agreement with the experiment results and practical cases. It indicates that these two approaches can all meet demands. When adopting FDM method, thermal analysis and stress analysis can use the same FD model, which can avoid the nodes matching between different models and reduce the errors of thermal load transferring. It makes the simulation of fluid-flow field, temperature field and stress field unify into one model. This system takes full advantages of mature FDM technology and can be used to simulate the forming of residual stress and predict the occurrence of hot tearing.
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Zhu, Li Guang, Ruo Si Wang, and Cheng Liang Du. "Study on the Large Inclusions in 20g Steel." Advanced Materials Research 634-638 (January 2013): 1874–78. http://dx.doi.org/10.4028/www.scientific.net/amr.634-638.1874.
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According to the production process of 20g steel(120t BOF→ LF→ CC), some system analysis are introduced to research on the content of T[O] and [N] and the type, source, composition and quantity of micro inclusions in refining process, pouring process and casting billet. The results of the study show: in billet, the main type of large inclusions is CaO-SiO2-Al2O3-MgO complex inclusion of sulfur contained. The content of large inclusions is 14.5mg/10kg in normal billet. The content of large inclusions is 33.14mg/10kg in compound casting billet which is 1.29 time than normal billet.The content of large inclusions whose particle size is more than 300μm in billet is 8.39mg/10kg, and make up 87% of the total. The content of large inclusions whose particle size is 140-300μm in billet is 2.29mg/10kg, and make up 15.79% of the total. The content of large inclusions whose particle size is 80-140μm in billet is 3.82mg/10kg, and make up 26.35% of the total. Unsteady casting plays an important role in the steel cleanliness.
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Bakin, I. V., A. N. Shapovalov, M. S. Kuznetsov, N. A. Shaburova, R. G. Usmanov, V. A. Golubtsov, I. V. Ryabchikov, V. G. Mizin, and V. N. Panov. "Industrial Tests of Microcrystalline Complex Alkaline Earth Metal Alloys when Casting Pipe Steel." Steel in Translation 50, no. 11 (November 2020): 795–800. http://dx.doi.org/10.3103/s0967091220110030.
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Vicario, I., J. K. Idoiaga, E. Arratibel, I. Erauskin, L. M. Plaza, I. Crespo, and P. Caballero. "Development of HPDC Advanced Dies by Casting with Reinforced Tool Steels." International Journal of Manufacturing Engineering 2015 (February 9, 2015): 1–10. http://dx.doi.org/10.1155/2015/287986.
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High pressure die casting (HPDC) dies are nowadays manufactured with high quality forged steels. Cavities are made by electrical discharge machining (EDM) or by high speed milling. The average life of an aluminium HPDC die is about 125.000 injections. Refrigeration circuits have simple configurations, because they are produced by drilling the die with straight holes. They are limitations in the distances and diameters of holes. Sensors are placed where the geometry of the die permits an easy machining. In order to obtain complex figures, several rapid prototyping methods have been developed. However, there is a limitation in the life of the dies produced by this technique, from several parts to thousands. A new method to obtain semifinished high pressure die casting dies in a steel of higher mechanical properties and with the refrigeration circuits and sensors embedded into it is described in this paper. The method consists in producing a molten steel alloy with micro-nano-special ceramic particles inserted in it and casting the composite material in sand moulds of the desired geometry. The resultant solidified near-net shape die with the cooling tubes and sensors embedded into it. A use-life and a productivity about 50% and 10% higher are obtained.
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Liu, Wei, Xinfu Pang, Shengping Yu, Congxin Li, and Tianyou Chai. "Steelmaking-Casting of Molten Steel by Decarburization Ladle Matching." Mathematical Problems in Engineering 2018 (2018): 1–15. http://dx.doi.org/10.1155/2018/7567591.
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Steelmaking–continuous casting is a complex process. The method of selecting a ladle, which also functions as a storage device, follows a specific process of the production plan. In ladle matching, several ladle attributes are considered. However, matching objectives are difficult to achieve simultaneously. Different molten steel properties have contributed to the complexity of matching constraints, and, thus, matching optimization is regarded a multiconflict goal problem. In the process of optimization, the first-order rule learning method is first used to extract key ladle attributes (performance indicators), including highest temperature, usage frequency, lowest-level material, and outlet. On the basis of a number of indicators, such as ladle temperature, quantity, material, and usage frequency, as well as skateboard quantity, the ladle matching model is established. Second, the rule of ladle selection is determined by the method of least-generalization rule learning. Third, a simulation experiment is carried out according to various scheduling order strategies and matching priority combinations. Finally, the heuristic ladle matching method based on the rule priority (RP) is determined for possible industrial applications. Results show that the accuracy of ladle selection can be improved. In particular, the numbers of ladles and maintenance times are reduced. Consequently, furnace production efficiency is also enhanced.
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Rywotycki, M., K. Miłkowska-Piszczek, and L. Trębacz. "Identification of the Boundary Conditions in the Continuous Casting of Steel." Archives of Metallurgy and Materials 57, no. 1 (March 1, 2012): 385–93. http://dx.doi.org/10.2478/v10172-012-0038-z.
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Identification of the Boundary Conditions in the Continuous Casting of SteelThe results of investigations relating the determination of thermal boundary conditions for continuous casting of steel were presented in the paper. The slab of dimensions 1100 mm x 220 mm was analyzed. In numerical calculations two models were compared. The first was the simple one and it used average heat transfer coefficient in both cooling zones. The second one used complex models in primary and secondary cooling zones. The presented models were verified on basing on an industrial data base. The problem was solved by the finite element method and the commercial numerical packet ProCAST.
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Miłkowska‐Piszczek, Katarzyna, and Jan Falkus. "Control and Design of the Steel Continuous Casting Process Based on Advanced Numerical Models." Metals 8, no. 8 (July 30, 2018): 591. http://dx.doi.org/10.3390/met8080591.
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The process of continuous casting of steel is a complex technological task, including issues related to heat transfer, the steel solidification process, liquid metal flow and phase transitions in the solid state. This involves considerable difficulty in creating the optimal process control system, which would include the influence of all the physico‐chemical phenomena which may occur. In parallel, there is an intensive development of new mathematical models and an increase in computer performance, therefore complex numerical simulations requiring substantial computing time can be conducted. This paper presents a review of currently applied numerical methods allowing the phenomena accompanying the process of continuous casting of steel to be accurately represented. Special attention was paid to the selection of appropriate methods to solve the technological problem selected. The possibilities of applying selected numerical models were analysed in order to modify and improve the existing process or to design a new one linked to the implementation of new steel grades in the current production. The description of the method of defining the boundary conditions, initial conditions and material parameters as vital components ensuring that numerical calculations based upon them in the finite element method, which is that most frequently applied, are correct is an important element of the paper. The possibility of reliably defining the values of boundary parameters on the basis of information on the intensity of cooling in individual zones of the continuous casting machine was analysed.
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Chang, Fon-Chieh, and John R. Hull. "Computer Modeling of Electromagnetic Fields and Fluid Flows for Edge Containment in Continuous Casting." Journal of Manufacturing Science and Engineering 127, no. 4 (December 17, 2004): 724–30. http://dx.doi.org/10.1115/1.2039101.
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A computer model was developed to predict eddy currents and fluid flows in molten steel. The model was verified by comparing predictions with experimental results of liquid-metal containment and fluid flow in electromagnetic (EM) edge dams (EMDs) designed at Inland Steel (Ispat Industries Ltd.) for twin-roll casting. This mathematical model can greatly shorten casting research on the use of EM fields for liquid metal containment and control. It can also optimize the existing casting processes and minimize expensive, time-consuming full-scale testing. The model was verified by comparing predictions with experimental results of liquid metal containment and fluid flow in EM edge dams designed at Inland Steel (Ispat Industries Ltd.) for twin-roll casting. Numerical simulation was performed by coupling a three-dimensional (3D) finite-element EM code (ELEKTRA) and a 3D finite-difference fluids code (CaPS-EM) to solve Maxwell’s equations, Ohm’s law, Navier-Stokes equations, and transport equations of turbulence flow in a casting process that uses EM fields. ELEKTRA is able to predict the eddy-current distribution and EM forces in complex geometry. CaPS-EM is capable of modeling fluid flows with free surfaces and dynamic rollers. The computed 3D magnetic fields and induced eddy currents in ELEKTRA are used as input to flow-field computations in CaPS-EM. Results of the numerical simulation compared well with measurements obtained from both static and dynamic tests.
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Klinkenberg, Christian, Akhil Varghese, Christoph Heering, Olga Lamukhina, Uwe Grafe, and Kirill Tokmakov. "3rd Generation AHSS by Thin Slab Technology." Materials Science Forum 941 (December 2018): 627–32. http://dx.doi.org/10.4028/www.scientific.net/msf.941.627.
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Modern steel making and hot rolling processes like CSP® thin slab technology require precise data on casting and rolling behavior of the produced steel grades. Up today only few data is available for the latest generations of advanced high strength steel (AHSS) grades. AHSS have developed by 3 generations [1, 2]. 1st Generation AHSS as dual phase (DP), complex phase (CP), martensitic (MS) and transformation induced plasticity (TRIP) steel grades are currently applied in automotive industry. 2nd and 3rd Generation AHSS typically have elevated Mn-content as well as Al and Si content. High Mn-content of up to 30% seriously affects casting and forming properties of 2nd Generation AHSS. In particular, the large solidification range of more than 100 K prevents commercial production of these steel grades by continuous casting [3]. 3rd Generation AHSS with reduced Mn-content up to about 12% are currently under development [1-4]. Investigations have been carried out to assess the CSP® thin slab process for the production of such grades. To this purpose solidification and hot forming properties of different alloys having Mn-content up to 10% have been examined by thermodynamic calculations and laboratory testing by hot forming dilatometry. The achieved flow curves match figures achieved on a hot rolling mill.
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Li, Zhuang, Di Wu, and Jian Xun Liu. "Analysis of Cracking Phenomenon Occurring during Cold Forging of ML25Mn Steel." Key Engineering Materials 324-325 (November 2006): 643–46. http://dx.doi.org/10.4028/www.scientific.net/kem.324-325.643.
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Cold forging has various advantages compared to other forming processing. Cracking phenomenon was taken place during cold forging of ML25Mn steel. In this study, microstructural analyses were made on the cracked regions of the steel. The reason of cracking phenomenon occurring during cold forging for ML25Mn steel was investigated based on SEM observation in detail. The results have shown that ML25Mn steel presents lower strength and toughness. A larger amount of inclusions which are composed of MnS and complex oxides containing Mg, Al, Mn, Fe, S, Ca and O are found, and the complex inclusion might be brought during the deoxidation and the solidification in smelting and casting. Non-metallic inclusions result in significant stress concentration, which cause cracking phenomenon occurring during cold forging of ML25Mn steel.
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Chernyshov, E. A., I. M. Baev, A. D. Romanov, and E. A. Romanova. "COLD RESISTANCE AND MECHANICAL PROPERTIES OF HIGH-STRENGTH MEDIUM ALLOY STEEL DEPENDING ON THE TECHNOLOGY OF CAST BILLETS PRODUCTION." Izvestiya. Ferrous Metallurgy 62, no. 1 (February 22, 2019): 79–84. http://dx.doi.org/10.17073/0368-0797-2019-1-79-85.
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Experimental data on influence of conditions of high-strength steel crystallization on its mechanical properties are given in the work. Special attention is paid to the cold resistance as to the most important indicator of operation properties of the responsible products defining reliability and operability of a cast final product. Serial curves of impact strength, work of crack development and percent of fibration are given depending on test temperature. The possibility of increase in cold resistance of the cast alloyed steel is shown depending on casting technology: in a volume sandy form (control casting), in a thin-walled form with the ceramic layer and compulsory cooling with air-and-water mix differentiated on height (with external cooling) and in the same form with input of microrefrigerators when filling liquid steel (with complex impact). According to the research results it was established that the impact strength of the experimental metal obtained at complex impact on the hardened metal is higher in all studied temperature interval. Distinctive feature is smoother change nature of impact strength of experimental metal and lack of sharp reduction of this indicator for control samples. Change of work of crack development also depends on conditions of crystallization and cooling of casting metal. Serial curves have shown that tested metal has smaller tendency to fragile destruction (higher cold resistance). Similar dependences are received during the research of break fibration.
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Zolotukhin, V. I., A. G. Golovko, E. I. Gordeev, and D. A. Provotorov. "MODERN EQUIPMENT FOR REFINING AND CASTING OF STEEL AND ALLOYS IN FOUNDRY PRODUCTION." Litiyo i Metallurgiya (FOUNDRY PRODUCTION AND METALLURGY), no. 1 (April 6, 2018): 28–33. http://dx.doi.org/10.21122/1683-6065-2018-1-28-33.
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The article deals with the issues of complex technology and equipment for refining and casting steel and alloys in the foundry industry. Solutions are given that make it possible to guarantee a reduction in nonmetallic inclusions in the melt, as well as to solve a number of other related problems of foundry production, such as the introduction of a bottom blowing melt system with an inert gas; the introduction of protection of the metal stream from secondary oxidation; lining the arch of an electric arc furnace, etc. Various types of products and equipment produced by NPP Vulkan-TM are shown: blowing bottom plugs and assemblies, metering nozzles, gas-dynamic protection of the metal stream from secondary oxidation, two-arm wire-feeding machine mod. TAP 2–1 with unwinding device.Advantages of the equipment for steel casting and extra-furnace steel processing are described.
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Falkus, Jan, Katarzyna Miłkowska-Piszczek, Paweł Krajewski, and Tomasz Ropka. "Method of Verification of Carbon Segregation Ratio Determined with Experimental Methods." Metals 10, no. 4 (April 10, 2020): 499. http://dx.doi.org/10.3390/met10040499.
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The problem of macrosegregation of alloying elements occurring during cast strand solidification in the continuous casting process is still valid; it is the subject of numerous experiments and theoretical considerations. A large percentage of this research is dedicated to carbon segregation, which, for understandable reasons, is vital for the production of high-carbon steels. The background knowledge on the mechanism of segregation occurrence indicates that it is a very complex effect, and a broad range of factors influencing the continuous casting process need to be considered. Therefore, it is difficult to translate information (provided by complex models of metal flow through a diphase area at the solidification interface of a cast strand) into practical engineering recommendations to reduce the macrosegregation effect. The presented study shows the latest research related to the carbon macrosegregation effect for selected high-carbon steel grades cast with a continuous caster. Problems related to the recording of the effect concerned have been pointed out. The second part of the paper presents the influence of selected casting parameters on carbon macrosegregation intensity when casting 160 × 160 billets with a six-strand caster. In this case, the main subject of the research was the influence of the casting speed on macrosegregation intensity. In the following step, an attempt was made to find the relationship between the cast strand structure and the distribution of carbon content on its cross-section. The ultimate objective of the presented study was to find an answer to the question on the technological capabilities of restricting the segregation effect.
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Zhilin, S. G., O. N. Komarov, and N. A. Bogdanova. "Production of the steel casting with improved dimensional and geometrical accuracy using complex models." IOP Conference Series: Materials Science and Engineering 709 (January 3, 2020): 033104. http://dx.doi.org/10.1088/1757-899x/709/3/033104.
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Chen, X. Grant. "Feeding Blockage of Aluminium Horizontal Continuous Casting." Materials Science Forum 519-521 (July 2006): 1827–34. http://dx.doi.org/10.4028/www.scientific.net/msf.519-521.1827.
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In recent years, the horizontal continuous casting has been increasingly applied in a variety of aluminum products such as busbars, T-bars, foundry ingots, small diameter extrusion billets and forging feedstock, due to its high productivity and relatively low cost. By introducing the continuous process for long cast periods, feeding blockage as a unique process-related complex problem has emerged, which causes casting defects, a short cast duration and even an unexpected interruption of the cast. A literature review of the feeding blockage phenomena during continuous casting in the steel and aluminum industries is presented. The causes and mechanisms of feeding blockage in the aluminum horizontal continuous casting are proposed and discussed. Typical examples of feeding blockage from the industrial scale production with results of metallographic examination are illustrated.
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Dorin, T., A. Taylor, K. Wood, J. Wang, P. D. Hodgson, and N. Stanford. "Complex precipitation phenomena in strip cast steels with high sulfur and copper contents." Journal of Applied Crystallography 49, no. 5 (September 29, 2016): 1777–85. http://dx.doi.org/10.1107/s1600576716013054.
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A series of three steel alloys with increasing Cu and S concentrations has been prepared by simulated direct strip casting. It was found that the rapid solidification that occurs during direct strip casting results in the formation of a high number density of fine MnS precipitates, while Cu was retained in solid solution above equilibrium concentration. Upon ageing the MnS particles were found to coarsen and increase in volume fraction, indicating that some S was retained in solid solution in the as-cast condition. Ageing also resulted in the precipitation of Cu-rich precipitates. A new method to determine precipitate composition from small-angle neutron scattering is presented. This methodology, in conjunction with atom-probe tomography, has been used to show that the composition of the Cu-rich precipitates depends on the alloy's bulk Cu content.
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Zhao, Ding Guo, Shu Huan Wang, and Ming Jian Guo. "Analysis of Inclusion Microstructure in Material Engineering of Steel." Advanced Materials Research 568 (September 2012): 324–27. http://dx.doi.org/10.4028/www.scientific.net/amr.568.324.
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The sample of oxide inclusion was obtained in the different stage of steelmaking for the 65 steel. The microstructure was observed by using scanning electron microscopy (SEM) to analyze the composition and type of inclusions. It was shown that the microscopic inclusions in the high carbon steel were mainly massive and cluster Al2O3, spherical and slope silicate inclusion, calcium-aluminates inclusions and sulphide complex inclusions. The measures including raw material requirement, improving of the converter, LF refining and continuous casting operations were put forward to decrease inclusion.
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Botnikov, S. A., O. S. Khlybov, and A. N. Kostychev. "Development of a Steel Temperature Prediction Model in a Steel Ladle and Tundish in a Casting and Rolling Complex." Steel in Translation 49, no. 10 (October 2019): 688–94. http://dx.doi.org/10.3103/s096709121910005x.
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Bai, Ming Hua, Jing Jing Liu, Jun Li Ge, Zhi Qiang Liu, and Zhi Ming Zhang. "Research on Inner Cooling Apparatus Sets in the Mold of 700mm×700mm Bloom." Advanced Materials Research 328-330 (September 2011): 1623–26. http://dx.doi.org/10.4028/www.scientific.net/amr.328-330.1623.
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Based on the problems emerged from market, 700mm×700mm super-large billet has been advanced. This paper calculated the casting speed and the depth of liquid core according to empirical formula for 700mm×700mm super-large billet, based on calculate and feasibility analysis acquired the appropriate casting speed is 0.2 m/min. A new mold has been advance based on mold thermoanalysis that is complex mold. Theoretically analyzed the function of setting inner cooling and deflected SEN, indicate that complex mold can improve heat transfer efficiency and equiaxed crystal ratio, reducing center segregation; level rotary flow can uniform molten steel ingredient and growth of shell, reduce the impact depth, achieve the effect of E-EMS; calculation show that reduce the depth of liquid core by applying complex mold, finally, reduce infrastructure fee of caster.
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Reshetov, V. V., and A. I. Trushin. "Horizontal CCMs in small-capacity metallurgy." Ferrous Metallurgy. Bulletin of Scientific , Technical and Economic Information 77, no. 7 (August 1, 2021): 776–81. http://dx.doi.org/10.32339/0135-5910-2021-7-776-781.
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Production of light-section rolled products and wire rods of alloyed steel grades differs by small volume of yearly output and wide range of smelted grades. To organize production of light-section rolled products of alloyed steel grades in small volumes, OJSC “Spetsmash” elaborated concept of small-capacity production, which was implemented at several plants. It was shown that horizontal CCM can be effectively applied in the small-capacity production within complexes of light-section rolled stock of alloyed steels production. At the plant “Ferrotrade” (Beloretsk) when creating a complex for production wire rods of 6.5 mm diameter of austenite class steels and nickel-based alloys, a horizontal CCM was constructed. Production of 60 mm diameter billets by the machine was mastered, which enabled to apply a rolling mini-mill, characterizing by small dimensions and power. The horizontal CCM, constructed in 2016 at the steelmaking shop of CJSC “Izhevsk pilot-mechanical plant”, was equipped by electromagnetic stirrer (EMS). It was noted that EMS was applied for the first time in domestic metallurgy at the industrial CCM of horizontal type. In the process of this CCM mastering, more than 60 heats were casted into billets of 80, 200 and 120 mm diameter. EMS application resulted in improving average point on the central porosity to 1.2—1.8 depending on the stirring modes. In 2018 the OJSC “Spetsmash” for the Research Center “Thermodeform” (Magnitogorsk) constructed an experimental horizontal CCM, designed for casting of billets of 40—60 mm diameter by direct casting of melt from the crucible of 60 kg induction furnace into the metal reservoir 776 of the machine. Development of a project of horizontal CCM for PJSC “PlasmaTek” (Ukraine, Vinnitsy) finished, designed for production of billets of 50 and 60 mm diameter within a complex of equipment for manufacturing welding electrodes not only of alloyed but also of carbon steel grades. The designed productivity of the complex is 12,000 t/year. Basic technical characteristics of the CCM presented. Small-capacity production with horizontal CCMs can be organized as independent objects and within existing steel-works for expanding product range.
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VINOGRADOV, VASILIY P., and ALEXANDER L. KUZMINOV. "DEVELOPMENT AND TESTING OF A MEASURING COMPLEX FOR MONITORING THERMAL PARAMETERS OF THE CONTINUOUS CASTING MOLD." Cherepovets State University Bulletin 4, no. 97 (2020): 9–18. http://dx.doi.org/10.23859/1994-0637-2020-4-97-1.
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he authors consider the methodology for studying thermal parameters of the mold using a measuring complex of dual-zone thermocouple sensors. The article describes experimental work on establishing the relationship between the surface quality indices of slab billets and technological parameters, thermotechnical indicators of the mold and the chemical composition of cast steel.
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Suwankan, Patrpimol, Nuttaphong Sornsuwit, and Nuchthana Poolthong. "Design of Runner and Gating Systems for the Investment Casting of 431 Stainless Steel Netting Hook through Numerical Simulation." Key Engineering Materials 659 (August 2015): 647–51. http://dx.doi.org/10.4028/www.scientific.net/kem.659.647.
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In the production of netting hook, which requires wear resistance and long service life enabling the fishing net production with high efficiency, there has been some studies to achieve its forming method for high durability and designated smooth surface. The process of investment casting or known as “lost wax casting” is one of casting methods to fabricate metal part with a complex shape. Flow behavior of stainless steel grade 431 at the temperature higher than 1600°C is a critical factor in casting mold design of the lost wax process. In the study, CAST-DESINERTMsimulating software was used to analyze flow of liquid metal to clarify the solidification of SS431 which caused defects in the product. Non-preferred heat transfer phenomena and using of the unsuitable mold design normally lead to defects in casting such as misruns, cold shuts, shrinkage, pin holes and porosity. Parameters in casting such as pouring temperature, preheating temperature, preheat time, pouring rate and cooling rate were given by the current production condition. The experimental design technique for simulation analysis of casting and gating system has been designed to be consistent and appropriate to the casting part. The cross-sectional design of the runner was two types of hexagonal and circular cross-section runner. The angle of gating system was kept constant at 90 degrees to the runner. As a results of the simulations, shrinkage porosity, filling time as well as solidification time were used to evaluate the cross-sectional design of runners. It was found that a circular cross-section runner led to the shorter filling time than a hexagonal one. Furthermore, there was no remarkable difference of shrinkage porosity in all simulated conditions. However, in terms of filling time, the results depended on the combination of runner design and gating system.
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Liu, Hao, Li Liang Chen, and Jian Xin Zhou. "Numerical Simulation of Induction Heating Process of Continuous Casting Slab." Materials Science Forum 575-578 (April 2008): 37–42. http://dx.doi.org/10.4028/www.scientific.net/msf.575-578.37.
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Compared with traditional blazing furnace, the Continuous Casting-Direct Rolling is an advanced manufacturing steel technology, which can reduce energy waste, decrease pollution and enhance efficiency. The characteristics of steels during induction heating are complex, the change of material properties with temperature makes exact analysis methods very difficult to implement. Therefore, a powerful computer aided numerical tool (i.e., finite difference analysis) is selected to numerically model the induction heating process in this paper. The mathematic model coupling with electromagnetic field and thermal field was established, and it was solved by finite difference method (FDM), thus the slab temperature distribution and its variation with time were obtained, and the characteristics in whole induction heating process were studied. To validate the program feasible, the results were evaluated and compared with experiment results, which showed that the simulation results are reliable and effective. The skin effect in heating process from the two results was studied and demonstrated, the temperature change caused by different parameters such as the induced power intensity and the corner radian were also presented, which indicate that the slab temperature can be heated uniformly through adjusting these parameters, thus the continuous casting slab can meet the rolling requirement.
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Franks, George V., France Chabert, and Enric Santanach Carreras. "Development of Near Net Shape Forming Processes of Ceramic Parts by Colloidal Processing." Advances in Science and Technology 45 (October 2006): 374–81. http://dx.doi.org/10.4028/www.scientific.net/ast.45.374.
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Techniques for producing near net shape ceramic components using aqueous forming processes are reviewed. Particular focus is on three dimensional, complex shape forming by gel casting and thin film forming by tape casting. Recent progress has been made in formulations that rely on dispersion of submicron ceramic particles in aqueous solutions containing polymers such as chitosan or poly vinyl alcohol and a temperature activated crosslinking agent (DHF, 2,5-dimethoxy- 2,5-dihydrofuran). These formulations can be produced to have low viscosity so that they can either be poured or injected into complex shape molds or cast into tapes. After casting, the suspension is heated to about 70 oC to activate the crosslinking agent. During crosslinking of the polymer, the rheological and mechanical behavior of the suspension is changed from liquid-like to solid-like. This allows the complex shaped bodies to be removed from the mold, dried and sintered. The strengthening of the cast tape due to crosslinking the polymer allows it to be dried without cracking. Rheological and mechanical behaviour, green and fired densities as well as examples of formed components will be presented. The green bodies can be readily machined with common high speed tool steel tools.
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Sergeev, N. N., A. N. Sergeev, S. N. Kutepov, I. V. Tikhonova, A. E. Gvozdev, E. V. Ageev, and D. S. Klement'yev. "Influence of Charge Quality on Physical, Mechanical and Operational Properties of Low-Alloy Steel 30KHGSA." Proceedings of the Southwest State University 24, no. 2 (October 4, 2020): 17–36. http://dx.doi.org/10.21869/2223-1560-2020-24-2-17-36.
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Purpose of reseach is to study the influence of the quality of the original charge on the complex of physical, mechanical and operational properties of structural low-alloy steel 30HGSA.Methods. As an object of research, a typical representative of low-alloy structural steels has been chosen - steel 30HGSA, smelted using metallized sponge iron pellets, ordinary scrap metal and billets obtained by the method of a boiling slag layer. In accordance with the set objectives of the study, steel 30HGSA of various melts, obtained with different charge, had the same conditions for melting, evacuation, deoxidation, casting and crystallization. The casting temperature was 1600...1620 оC and the post-vacuum treatment temperature was 1530...1560 °C. Duration of evacuation - 5 minutes. Casting of melts was carried out into cast iron molds with a siphon for 4 ... 5 minutes. Deoxidation was carried out in a ladle with aluminum in the amount of 4 ... 4.5 kg / melt. After solidification, the ingots were cooled in special wells. The ingots were cut into 3 parts: head, middle and bottom (600 × 600 mm). The middle part was then hot forged and rolled to a Ø30 mm bar. The length of the rod was 2 ... 3.4 m. After hot deformation, the rods were cooled in air.Results. Mechanical tests have been carried out. Statistical processing of experimental results has been performed. Regularities of changes in the characteristics of mechanical properties have been revealed: tensile strength, creep strength, relative narrowing of the cross-sectional area of the sample, relative elongation of the initial working length, impact strength (σВ, σ0.2, ψ, δ, aН).Conclusion. It has been found that with an increase in temperature, the mechanical properties of steel 30HGSA, smelted on various charges, decrease. It has been established that the cold brittleness threshold of 30HGSA steel is lower for purer melts on spongy iron and intermediate product KShS, the value of impact toughness at low temperatures is higher than in melting on a conventional metallized charge. Noticeable softening begins at a tempering temperature of 300 °C The temperature of the maximum tempering brittleness for steel 30HGSA, melted on a conventional metallized charge, is 550 °C It is shown that steel 30HGSA smelted with a pure original charge (spongy iron) has a lower tendency to temper brittleness than steel smelted with a conventional charge. The value of the impact toughness of the steel of this melt is higher than that of the steel of conventional melting over the entire tempering temperature range.
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Safonov, V. M., V. G. Borisevich, V. V. Kislitsa, and D. V. Morov. "Physical simulation of liquid steel motion in a thin-slab continuous caster mold." Ferrous Metallurgy. Bulletin of Scientific , Technical and Economic Information 75, no. 4 (May 18, 2019): 454–59. http://dx.doi.org/10.32339/0135-5910-2019-4-454-459.
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Industrial experience of steel casting at the thin-slab continuous caster (CC) revealed processes, having negative effect on the quality of internal structure and surface of CC thin slab. The main problems are as follows: flat streams of liquid steel, flowing through submerged snorkel into restricted dead volume, form circulating flows of extremely high velocity in both liquid core and on the slab surface. This circumstance makes specific requirements to the design and parameters of the submerged snorkel to supply the metal into the thin-slab CC mold. Despite the more than 25 years’ experience of the snorkel form and geometric parameters development, there is no single opinion on its optimal design. Results of physical simulation of the liquid motion processes in a thinslab Caster mold presented (for slab maximum width 1800 mm, thickness – 90 mm) of JSC “Vyksa Steel-works” casting and rolling complex. Description of the physical model facility quoted, as well as description of the experiment methodology and its results. The speed was measured and structure of liquid steel flows revealed in depth and sub-surface layers, as well as in slag-forming mixture at the mold surface. The comparison of two principally different variants of liquid steel feeding into the mold made. The two variants were as follows: by a flat down-directed stream with a narrow central divider (direct-flow submerged snorkel) and by four streams , two of them directed down under an angle relating the vertical axe, and the other (about 20% of total liquid consumption) – directed upward to the bath mirror (the snorkel of “hammer” type). It was determined, that steel casting with technological speed through the direct-flow snorkel was most effective into the slab of 1400 mm width and less, since in this case the sub-surface flows speed did not resulted in the intensive waves formation, constant whirls formation and slag particles dragging into deep layers of the slab. For steel casting into slab of width more than 1400 mm, it is reasonable to use a snorkel of the “hammer” type, which enables to create a favorable stable structure of circulation and decrease the tendency of slag particles dragging in the deep layers of the slab.
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Sreenivas Rao, K. V., P. Usha, S. Sanman, and R. Anilchoudary. "Modeling of Interface Heat Flux and Thermal Field of Mold Materials during Gravity Die Casting." Materials Science Forum 895 (March 2017): 85–88. http://dx.doi.org/10.4028/www.scientific.net/msf.895.85.
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One of the key controllable and influential factors to obtain a casting simulation, representative of reality, is the choice of boundary condition. The thermal boundary condition to be specified at the metal-mold interface must account for complex heat transfer phenomena associated with solidifying casting. The present study aims at estimating the heat flux at the interface of the mold and the solidifying metal by Inverse Heat Conduction Problem (IHCP) approach. Solidification studies were conducted on casting of aluminum reinforced with boron carbide composite. Copper, cast iron and stainless steel were used as mold materials. The temperature data of the mold was recorded from the beginning to end of solidification using k-type thermocouples connected to temperature data logger. This time-temperature history was used as input to the IHCP algorithm to simulate the interface heat flux and thermal field of the mold. The results indicate that the interface heat flux is highly transient and varies with the variation in the thermo-physical properties of the mold materials. The study also demonstrates that heat conduction is one dimensional in copper mold and two dimensional in cast iron and stainless steel mold during phase change.
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Gerasimenko, V. G., and L. S. Molchanov. "Directions of development of production of small- size billets for long products." Fundamental and applied problems of ferrous metallurgy, no. 32 (2018): 259–74. http://dx.doi.org/10.52150/2522-9117-2018-32-259-274.
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The aim of the work is to study the technological features of the transfer of metallurgical enterprises to the production of small-size and wire metal products from continuously cast billets. The main parameters of the rolling technology are considered: the size of the billet, the choice of the location of the continuous casting machine, the transfer scheme of continuously cast billets to small- size and wire mills. It is shown that when using a continuously cast square billet with a size of 130x130 mm and 150x150 mm, direct combination of a continuous casting machine with a rolling mill is almost impossible due to the difference in the speed of continuous casting and the roughing group of the mill. The performed calculations show that the scheme of cutting the billets and combining with the intermediate furnace is technologically feasible, however, further heating of the billets leads to significant energy losses. It has been established that an effective option for combining the continuous casting machine with a rolling mill is to use a complex of equipment with a furnace-thermostat for a billets 120 m long. This flowchart reduces the energy consumption for heating the billets by at least 53%. The proposed technology of combining the continuous casting machine with a rolling mill will provide metal savings by reducing the thickness of the scale to 0.4-0.73 mm (an average of 1.1% of the mass of the billet), improve its quality by reducing the depth of the decarburized layer from 1.1 mm to 0.3 mm. The technology provides for the transportation of liquid steel in the ladle from the steel-smelting shop, casting on the continuous casting machine, identification of defects in the billets in a hot condition, supply of the billets with a temperature of 8500С to high-temperature furnaces for heating and subsequent rolling.
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Kudashov, D. V., E. S. Mursenkov, P. P. Stepanov, G. V. Semernin, V. V. Kislica, S. A. Somov, A. V. Lozovskiy, and M. R. Jarmuhametov. "Assimilation of Pipe Steel Extra-Furnace Treatment and Casting Technology with Specification for Resistance to H2S Media Under Casting and Rolling Complex Conditions." Metallurgist 61, no. 7-8 (November 2017): 656–65. http://dx.doi.org/10.1007/s11015-017-0547-0.
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Muenstermann, S., F. Kuethe, M. Buenck, R. Telle, and A. Buehrig‐Polaczek. "Near‐net shaping of geometrically complex diving knife by semisolid steel casting using ceramic mould system." International Journal of Cast Metals Research 24, no. 1 (February 2011): 6–12. http://dx.doi.org/10.1179/136404610x12816241546492.
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Guo, E. J., S. C. Zhao, L. P. Wang, T. Wu, B. P. Xin, J. J. Tan, and H. L. Jia. "Numerical simulation of casting process to assist in defects reduction in complex steel tidal power component." IOP Conference Series: Materials Science and Engineering 117 (March 2016): 012037. http://dx.doi.org/10.1088/1757-899x/117/1/012037.
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Soltani, Esmaeil. "An Investigation on Continuous Steel Slabs Casting Line and Mechanical Design of a 3R Robot for Sampling from Melting Arc Furnaces." Advanced Materials Research 83-86 (December 2009): 31–35. http://dx.doi.org/10.4028/www.scientific.net/amr.83-86.31.
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Automation of industrial activities is one of the most essential needs in recent years since the operator has smaller role in the process. Creation of the various robotic systems in the different industries causes relaxing the operators from working in hard positions, increases the accuracy, efficiency and velocity in the process and decreases the wastage and price of product. In this paper, the study on melting station and continuous casting line in Mobarakeh Steel Complex is provided. The needs for elimination of difficulties and increasing the automation level of steel slabs casting line with checking the all stations from robotic and automation point of view for stations with the capability of automation system necessitates a suitable robotic system. In this case, selected robot should be able to support the velocity, accuracy, load capacity and other characteristics. Considering the sensitive conditions around the electric arc furnace (E.A.F), a suitable sampling robot with 3-degree freedom in which all three joints moves in revolute form (RRR) has been designed.
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Lin, Tao, Yong Liang Shi, and Hui Ping Shao. "Preparation of TiC Hard Metal by Presssureless Infiltration Method." Advanced Materials Research 652-654 (January 2013): 102–5. http://dx.doi.org/10.4028/www.scientific.net/amr.652-654.102.
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The steel matrix composites pressureless infiltration technology was studied in this paper. It is necessary to develop a reasonable process, select the appropriate gel system and additives, and prepare the complex shape of the large-size steel matrix composites by using gel-casting. For reactive melt infiltration technique, the porous skeleton was prepared by gelcasting preparation of the titanium powder and ceramic particles mixed, and the C-containing liquid metal infiltration of the porous skeleton. To improve the wettability between the molten metal and the ceramic phase, it is used for the process Ti-C in situ reaction to accelerate the impregnation process. Finally, the steel matrix composites with higher density were prepared.
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Li, Zhuang, Di Wu, and Wei Lv. "Study on the Crack Forming during Cold Forging Process of ML25Mn Steel." Applied Mechanics and Materials 184-185 (June 2012): 1255–58. http://dx.doi.org/10.4028/www.scientific.net/amm.184-185.1255.
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The important factors that affect the formability of the cold forging steel are its surface quality and internal defects. The cracking phenomenon was taken place during cold forging of ML25Mn steel. In this study, microstructural analyses were made on around the cracked regions of the steel. The reason of cracking, which occurred during cold forging for ML25Mn steel, was investigated based on SEM observation in detail. The results have shown that the crack forming during cold forging process is not related to the chemical composition for ML25Mn steel. Cracking is not resulted from high hardness of the steel rods. There are some non-metallic inclusions in the matrix of ML25Mn steel, and the film-like inclusions are composed of MnS, CaS and complex oxides containing Mg, Al, Mn, Fe, S, Ca and O. The formation of non-metallic inclusions is the result of the deoxidation and the solidification during smelting and casting of steel.
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Il’yasov, A. E., S. N. Sharkaev, A. B. Akhmetov, G. D. Kusainova, and V. I. Yablonsky. "Deoxidizing and modifying properties of alkaline earth metals within ferroalumosilicocalcium and ferrosilicobarium alloys." Ferrous Metallurgy. Bulletin of Scientific , Technical and Economic Information, no. 9 (September 25, 2018): 58–64. http://dx.doi.org/10.32339/0135-5910-2018-9-58-64.
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Modification of alloys, in particular, by calcium and barium, is one of the promising directions for obtaining alloys with a fine crystalline structure. Complex ferroalloys – ferroalumosilicocalcium and ferrosilicobarium – were developed in the Chemical and Metallurgical Institute after Zh. Abishev. It was shown, that modification of steel by silicon-aluminum complex alloys containing chemically active elements – calcium and barium, should become one of the most effective methods to improve the quality of machine-building metal products.The chemical compositions of the smelted ferroaluminosiliconcalcium and ferrosilicobarium presented. The melting range of the nonmetallic compound formed during the deoxidation of steel by complex alloy containing calcium determined. Results of mechanical tests of the specimens of steel, modified by a complex alloy containing barium considered. A comparison of microstructure of the current production route steel and deoxidized with the complex alloys was carried out.In the course of metallographic studies of experimental steel specimens, a modifying influence on the morphology of nonmetallic inclusions by calcium and barium, supplied in a complex with aluminum and silicon alloys, was established.Metal processing by complex alloys such as ferrosilicoaluminum with calcium (FASC) and ferrosilicobarium (FSAB) indicates the possibility of achieving a higher degree of refining from oxide nonmetallic inclusions and a more even distribution of them in the ingot.The results of the industrial heats also indicated a possibility of improving of quality of casting through the decreasing of hot thermal cracks and gas-shrinkage defects, cleaner grain boundaries, a significant reduction in the number and size of carbide inclusions.
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Bașliu, Vasile, Maria Vlad, and Gelu Movileanu. "Obtaining Composite Materials with Technological Role by Incorporating Granular Particles in Metal Matrix." Advanced Materials Research 1143 (February 2017): 79–84. http://dx.doi.org/10.4028/www.scientific.net/amr.1143.79.
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Our paper aims to develop new materials in view of meeting the requirements of reducing pollution in steel plant production. The concept of composite with technological role based on creating new complex metal matrix with solid particles in granular form has multiple purposes, among which we mention reduction of pollution in steels department and reduction of economic losses through recovery and reusing of granular ferroalloy particles. This paper proposes a method and technology for obtaining composite materials using A6061 aluminium alloy as matrix and granular SiC disperse particles. Due to its high carbon content (30%), the composite can be used as complex deoxidiser and decarburization agent in steel elaboration. For the preparation of these composite A6061/SiC, the Stir Casting Vortex method has been considered in order to ensure a high embedding yields in granular state and it was with conducted a rigorous control of process parameters (temperature, speed of rotation, improved ways of introducing particles in granular state). The obtained composites have been characterized for morphology, chemical composition and structural analysis by scanning electron microscopy with energy-dispersive X-ray spectroscopy and X-ray diffraction methods
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Sowa, L. "Effect Of Steel Flow Control Devices On Flow And Temperature Field In The Tundish Of Continuous Casting Machine." Archives of Metallurgy and Materials 60, no. 2 (June 1, 2015): 843–47. http://dx.doi.org/10.1515/amm-2015-0216.
Full textAbstract:
AbstractThe mathematical model and numerical simulations of the liquid steel flow in a tundish are presented in this paper. The problem was treated as a complex and solved by the finite element method. One takes into consideration in the mathematical model the changes of thermophysical parameters depending on the temperature. The single-strand tundish is used to casting slabs. The internal work space of the tundish was modified by flow control devices. The first device was a pour pad situated in the pouring tundish zone. The second device was a dam. The third device was a baffle with three holes. The dam and baffle were placed in the tundish at different positions depending on the variant. The main purpose of using these was to put barriers in the steel flow path as well as give directional metal flow upwards which facilitated inclusion floatation. The interaction of flow control devices on hydrodynamic conditions was received from numerical simulations. As a result of the computations carried out, the liquid steel flow and steel temperature fields were obtained. The influences of the tundish modifications on the velocity fields in liquid phase of the steel were estimated, because these have essential an influence on high-quality of a continuous steel cast slab.