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1
Ściężor, Wojciech, Andrzej Mamala, and Paweł Kwaśniewski. "Analysis of Properties of Selected Aluminium Alloys, Obtained by Twin Roll Casting Method and Subjected to Cold Rolling Process." Key Engineering Materials 641 (April 2015): 202–9. http://dx.doi.org/10.4028/www.scientific.net/kem.641.202.
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Modern manufacturing technologies of flat cold-rolled products made of aluminium and its alloys are based on raw materials produced with the use of continuous casting technology. One of the most frequently used integrated production processes, based on continuous casting of metal, is twin roll casting method (TRC). In TRC method liquid metal flows into the area formed by two water-cooled rolls, solidifies and next is deformed (rolled) which allows to obtain strip with several millimetres thickness. Thanks to this, it is possible to eliminate hot rolling stage from the typical production technology, and directly subject obtained sheets to cold rolling process.This paper presents results of cold rolling strain dependency on the mechanical properties of tested aluminium alloys from 1XXX, 3XXX and 8XXX series, produced in the laboratory conditions with the use of TRC method. Furthermore the rolling loads and basic mechanical properties, determined in an uniaxial tensile, were examined.
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TADA, Koichi, and Atsumi OHNO. "Production of aluminum strip through continuous casting with a heated rotary mold." Journal of Japan Institute of Light Metals 41, no. 6 (1991): 406–11. http://dx.doi.org/10.2464/jilm.41.406.
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Shi, Chen, Gaofeng Fan, Xuqiang Mao, and Daheng Mao. "Effects of Ultrasonic Bending Vibration Introduced by an L-Shaped Ultrasonic Rod on the Microstructure and Properties of a 1060 Aluminum Alloy Strip Formed by Twin-Roll Casting." Materials 13, no. 9 (April 25, 2020): 2013. http://dx.doi.org/10.3390/ma13092013.
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In order to achieve the industrial application of ultrasonic energy in the continuous casting and rolling production of aluminum alloy, a new type of L-shaped ultrasonic rod was used to introduce an ultrasonic bending vibration into the aluminum melt in the launder during the horizontal twin-roll continuous casting and rolling process of a 1060 aluminum alloy. The effects of the ultrasonic bending vibration on the microstructure and properties of the 1060 aluminum alloy cast rolling strip and its subsequent cold rolling strip were studied experimentally, and the effect of the ultrasonic-assisted refining with different amounts of Al-Ti-B refiner was explored. The results show that under the same addition amount of Al-Ti-B refiner, the ultrasonic bending vibration can refine the grains of the cast rolling strip, make the distribution of precipitates more uniform, reduce the slag inclusion defects, and improve the mechanical properties to a certain extent. The microstructure and properties of the ultrasonic cast rolling strip with 0.18 wt% Al-Ti-B refiner or 0.12 wt% Al-Ti-B refiner are better than those of the conventional cast rolling strip, but the microstructure and properties of the ultrasonic cast rolling strip with 0.09 wt% Al-Ti-B refiner are slightly worse than those of the conventional cast rolling strip. Moreover, after cold rolling, the effect of the ultrasonic bending vibration on the improvement of the microstructure and properties of the aluminum alloy strip is inherited. A comprehensive analysis shows that the use of ultrasonic energy in this paper cannot completely replace the effect of the Al-Ti-B refiner, but it can reduce the addition amount of the Al-Ti-B refiner by 1/3.
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Nerl, Christoph, Martin Wimmer, Hartmut Hoffmann, Erhard Kaschnitz, Falko Langbein, and Wolfram Volk. "Development of a continuous composite casting process for the production of bilayer aluminium strips." Journal of Materials Processing Technology 214, no. 7 (July 2014): 1445–55. http://dx.doi.org/10.1016/j.jmatprotec.2014.02.018.
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Chernomas, V. V., S. N. Khimukhin, and T. S. Khimukhina. "Optimization of Technological Parameters of the Process for Obtaining a Strip by the Combined Method of Metal Casting and Deformation." Materials Science Forum 992 (May 2020): 473–79. http://dx.doi.org/10.4028/www.scientific.net/msf.992.473.
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In order to obtain high-quality metal products with the desired properties (process stability) using the combined methods of metal casting and deformation, it is necessary to take into account the specific parameters of this process and the fact that the metal in the crystallizer stays simultaneously in several physical states: liquid, liquid-solid, solid-liquid and solid. Structurally, the mold consists of four walls moving relative each other along a given sophisticated trajectory. The object of the research is the production technology from non-ferrous alloys using the combined method of continuous casting and metal pressure treatment. The thermal processes occurring in the mold of a continuous horizontal metal casting and deformation installation (CHMCDI) during the formation of metal products have been examined as a research subject. The methods of physical modeling of the thermal processes which take place in the system “crystallizing metal-tool deformation” under different conditions of the mold cooling (using closed-perforated tubes and straight-flow tubes) have been used. Subsequent data processing of the full factorial experiment using the least square method as well as solving the optimization problem by using the Pareto principle of optimality made it possible to determine the optimal parameters for the process of obtaining metal products from aluminum alloys (TV = 40 oС; рv = 0.7 kg / cm2; SR = 5.8), which have been confirmed by the results of the experimental test on obtaining the strip from technical aluminum AD0 strip with a cross section of 40–12 mm.
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von Bargen, Roland, Axel von Hehl, and Hans Werner Zoch. "Artificial Ageing Behaviour of Al-4Zr Micro Sheets." Materials Science Forum 765 (July 2013): 456–60. http://dx.doi.org/10.4028/www.scientific.net/msf.765.456.
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The continuous miniaturization of products needed e.g. in the automotive or the microelectronics sector requires process chains, which allow the manufacturing of microscopically small components in high quantities. The development of the required processes and technologies is the aim of the Collaborative Research Centre 747 “Micro Cold Forming” of the German Research Foundation. As a necessary step in the manufacturing process chain heat treatment enables the adjustment of the semi-finished micro components to cold forming. Finally, the in-service characteristics of the aluminium components have to be adjusted by precipitation hardening that increases the strength values beyond those which can be achieved by strain hardening. To provide high strength aluminium alloys with an improved thermal stability new alloy concepts and advanced production processes have been developed within the Collaborative Research Centre (CRC). Besides the scandium containing foils made of alloy Al-2Sc, foils of a novel alloy Al-4Zr with approximately 4 mass-% Zirconium has been produced by means of physical vapour deposition (PVD). In contrast to conventional strip casting techniques the PVD process operates with low temperatures, which should suppress premature precipitation during the foil production and ensure the supersaturated solid solution that is a prerequisite for precipitation hardening. Samples of this material were subsequently artificially aged and characterized by ultra micro hardness measurements (UMH), transmission electron microscopical (TEM) analysis and differential power scanning calorimetry (DPSC) to evaluate the applied aging parameters.
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Vončina, Maja, Kristijan Kresnik, Darja Volšak, and Jožef Medved. "Effects of Homogenization Conditions on the Microstructure Evolution of Aluminium Alloy EN AW 8006." Metals 10, no. 3 (March 24, 2020): 419. http://dx.doi.org/10.3390/met10030419.
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The industrial production of products, such as foil and aluminium alloy strips, begins with the production of semi-finished products in the form of slabs. These are produced by the continuous casting process, which is quick and does not allow the equilibrium conditions of solidification. Non-homogeneity—such as micro and macro segregation, non-equilibrium phases and microstructural constituents, as well as stresses arising during non-equilibrium solidification—are eliminated by means of homogenization annealing. In this way, a number of technological difficulties in the further processing of semi-finished products can be avoided. The aim of this research was the optimization of the homogenization annealing of the EN AW 8006 alloy. With the Thermo-Calc software, a thermodynamic simulation of equilibrium and non-equilibrium solidification was performed. Differential scanning calorimetry (DSC) was performed on selected samples in as-cast state and after various regimes of homogenization annealing and was used for the simulation of homogenization annealing. Using an optical microscope (OM), a scanning electron microscope (SEM) and an energy dispersion spectrometer (EDS), the microstructure of the samples was examined. Based on the results, it was concluded that homogenization annealing has already taken place after 8 h at 580 °C to the extent, that the material is then suitable for further processing.
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Pokusová, Marcela, and Marián Murgaš. "Using Electromagnetic Levitation for Continuous Casting of Thin Aluminium Alloys Strip." ISIJ International 55, no. 8 (2015): 1669–76. http://dx.doi.org/10.2355/isijinternational.isijint-2014-843.
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Tian, Peng, Yong Lin Kang, Jing Tao Zhu, Zhe Qin, Xu Tao Zheng, and Fan Wang. "Achievements of Endless Strip Production in Rizhao Steel." Materials Science Forum 944 (January 2019): 344–50. http://dx.doi.org/10.4028/www.scientific.net/msf.944.344.
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The equipment and technology characteristics of endless strip production line in Rizhao steel were analyzed and the achievements of endless strip production in Rizhao steel were illustrated with detailed productive data in 2017. The achievements of endless continuous casting process was introduced from the aspects of the mold level deviation, the casting speed and the tundish temperature. The achievements of endless continuous rolling process was described from the rolling length, the mechanical properties and the microstructure at different position along the width. The achievements of endless continuous casting and rolling process was discussed from the product qualification rate, the yield rate, the thin strip ratio, the accident rate and the energy consumption. The productive practice of endless strip production (ESP) shows that the longest number of continuous casting furnace reached to 15 heats (4500 tons), the longest rolling length in single casting period was 182 km, the qualified rate of products was up to 99.73%, the yield rate was up to 97.51% and the thin strip ratio had a maximum value of 40.57%. At the same time, its accident rate was below 2.02% and its energy consumption was less than 27.26 kgce·ton-1. These achievements indicated that the ESP line in Rizhao steel had the advantages of low cost, good performance and green manufacturing, so the endless rolling technology will be rapidly promoted and the hot rolled thin products by ESP will further expand the market.
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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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Yu, Lin Hui, Ming Gang Shen, Ji Dong Li, Yi Yong Wang, Jian Ming Su, and Chu Fei Han. "The Technology Study of Steel Belt Feeding Machine of Crystallizer of Continuous Casting." Applied Mechanics and Materials 727-728 (January 2015): 513–16. http://dx.doi.org/10.4028/www.scientific.net/amm.727-728.513.
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Crystallizer steel belt feeding technology make use of melt’s fusion decalescence, controlling the distribution of melt temperature field, restrain the columnar crystal’s growing to eliminate the composition segregation and internal loose of continuous casting. And it will improve the continuous casting’s quality. By discussing the effect of casting speed, the size of steel, casting section and other factors on the steel belt feeding speed, making comparison of different casting section get strip suitable feeding speed and range of strip size, combining with a steel for steel strip feeding test mold, its theoretical and practical production results the basic agreement
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Jiao, Guo Hua, Gang Huang, De Zhi Wen, Chun Quan Zhou, and Kai Ming Wu. "Mechanical Properties of Heat Treated 30CrMo Steel Produced by Compact Strip Production." Advanced Materials Research 97-101 (March 2010): 1065–68. http://dx.doi.org/10.4028/www.scientific.net/amr.97-101.1065.
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Mechanical properties of heat treated 30CrMo steel produced by CSP (Compact Strip Production) and conventional continuous casting process. Results showed that 30CrMo steel produced by CSP exhibits higher hardness than that produced by conventional continuous casting process. The higher hardness was attributed to fine-grained microstructures in the as-rolled CSP strips.
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Huang, Gang, Guo Hua Jiao, De Zhi Wen, Chun Quan Zhou, and Kai Ming Wu. "Mechanical Properties of Heat Treated 65Mn Steel Produced by Compact Strip Production." Advanced Materials Research 168-170 (December 2010): 832–36. http://dx.doi.org/10.4028/www.scientific.net/amr.168-170.832.
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The mechanical properties of the heat treated 65Mn steel that produced by CSP (Compact Strip Production) and conventional continuous casting process were investigated. Measured results showed that 65Mn steel produced by CSP exhibits higher hardness than that produced by conventional continuous casting process. The better mechanical property was attributed to fine-grained microstructures in the as-rolled CSP strips.
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Knych, Tadeusz, Piotr Uliasz, and Marzena Piwowarska. "The Continuous Casting Technology of the Aluminum Rod Assigned for the Wire for Electrical Purposes." Materials Science Forum 690 (June 2011): 87–90. http://dx.doi.org/10.4028/www.scientific.net/msf.690.87.
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New technologies of the production of the aluminium charge assigned for drawing, including the tests on the process of continuous casting (CC). This type of technology, which includes the casting of copper and zinc, is widely spread in the world (trademarks: Upcast, Rautomead and Vertic). Yet, there is a lack of experience in the production and reproduction of the cast wires made of aluminium and its alloys assigned for electrical purposes. That is why the authors of the work aimed at investigating the casting process of the aluminium wires obtained with the technology of continuous casting.
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Xiong, Zhiping, Andrii G. Kostryzhev, Yanjun Zhao, and Elena V. Pereloma. "Microstructure Evolution during the Production of Dual Phase and Transformation Induced Plasticity Steels Using Modified Strip Casting Simulated in The Laboratory." Metals 9, no. 4 (April 16, 2019): 449. http://dx.doi.org/10.3390/met9040449.
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Instead of conventional steel making and continuous casting followed by hot and cold rolling, strip casting technology modified with the addition of a continuous annealing stage (namely, modified strip casting) is a promising short-route for producing ferrite-martensite dual-phase (DP) and multi-phase transformation-induced plasticity (TRIP) steels. However, at present, the multi-phase steels are not manufactured by the modified strip casting, due to insufficient knowledge about phase transformations occurring during in-line heat treatment. This study analysed the phase transformations, particularly the formation of ferrite, bainite and martensite and the retention of austenite, in one 0.17C-1.52Si-1.61Mn-0.195Cr (wt. %) steel subjected to the modified strip casting simulated in the laboratory. Through the adjustment of temperature and holding time, the characteristic microstructures for DP and TRIP steels have been obtained. The DP steel showed comparable tensile properties with industrial DP 590 and the TRIP steel had a lower strength but a higher ductility than those industrially produced TRIP steels. The strength could be further enhanced by the application of deformation and/or the addition of alloying elements. This study indicates that the modified strip casting technology is a promising new route to produce steels with multi-phase microstructures in the future.
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Jang, Dong In, and Shae K. Kim. "Development of Non-SF6 Strip Casting Process for Mg Alloys." Materials Science Forum 620-622 (April 2009): 149–52. http://dx.doi.org/10.4028/www.scientific.net/msf.620-622.149.
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For non-SF6 process and melt cleanliness, CaO added AZ31 Mg alloy has been developed for strip casting. Mg alloys were usually ignited during conventional casting, the continuous casting and strip casting. Protective gases should be used in order to prevent the ignition of Mg alloys during melting and casting processes. However, protective gases have the disadvantages of global warming potential, high production cost and corrosion of steel based equipments. To solve ignition problem and overcome environmental issue, this paper discussed the effects of CaO addition and amount on strip casting process in terms of non-SF6 process and melt cleanliness.
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de Pádua Lima Filho, Antonio, and Rafael Shoiti Ikeda. "Continuous Production of Metal Matrix Composites from the Semisolid State." Solid State Phenomena 192-193 (October 2012): 83–88. http://dx.doi.org/10.4028/www.scientific.net/ssp.192-193.83.
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Continuous strip metal matrix composite (MMC) casting of 0.3 mm diameter hard-drawn stainless steel (316L) wire in a quasi-eutectic SnPb (64Sn36Pb) matrix was performed by a two-roll melt drag processing (TRMDping) method, with the wire being dragged through a semisolid puddle with a fibre contact time of approximately 0.2 s. A slag weir placed at the nozzle contained two wire guide holes: one located near the upper roll, and the other located between the rolls. A successful continuous composite strip casting with good fibre alignment was achieved by inserting and embedding the wire into the matrix using the guide hole between the rolls. Degeneration of eutectic/dendrite structures led to the formation of globular structures. The occurrence and formation mechanisms of cracks, de-lamination and voids in the matrix were discussed. TRMDping is economically viable and has significant benefits over other MMC fabrication methods.
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Ding, Pei Dao, Bin Jiang, Jian Wang, and Fu Sheng Pan. "Status and Development of Magnesium Alloy Thin Strip Casting." Materials Science Forum 546-549 (May 2007): 361–64. http://dx.doi.org/10.4028/www.scientific.net/msf.546-549.361.
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Conventional production process of magnesium alloy strips involves many steps, including multi-hot rolling and multi-heat treatment, which is time-consuming and needs high energy cost. By use of thin strip casting, magnesium alloy cast strip with a thickness of less than 8mm can be produced and then rolled to the strip of the needed thickness, which is a short, energy saving and high effective process. In this paper, development of magnesium alloy strips prepared by single and twin roll casting has been summarized. Existing problems have been discussed and its development trends pointed out. Magnesium alloy strips prepared by single roll casting are suitable for Mg-based functional materials but not for structural materials because of low quality or high cost. Horizontal twin roll casting of magnesium alloy, based on aluminium alloy thin strip casting, has been industrialized in Australia and is close to industrialization in China. Vertical twin roll casting of magnesium alloy, based on steel thin strip casting, can reach a speed of more than 30m/min and higher productivity, but the process stability is lower and its research and development is just beginning. Horizontal twin roll casting should be developed for the thicker cast strip, more than 4mm thick, while vertical twin roll casting for the thinner, less than 4mm.
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Fu, Yun Li, and Kai Ming Wu. "Microstructural Characterization of Non-Oriented Low Silicon Steel Produced by Compact Strip Production." Advanced Materials Research 168-170 (December 2010): 827–31. http://dx.doi.org/10.4028/www.scientific.net/amr.168-170.827.
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The macro structures, microstructures, textures and precipitates in non-oriented electrical steels were studied by means of optical microscopy, scanning electron microscopy (SEM), electron back scattering dispersion (EBSD) and transmission electron microscopy (TEM) in the specimens produced by conventional continuous casting process and thin slab continuous casting and direct rolling process. Results showed the macro structures in as-cast slabs and the microstructures in as-rolled strips were more fine-grained and uniform with regard to compact strip production (CSP) process, compared with that in conventional process. No obvious texture was observed in hot rolled strips produced by CSP process.
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Wang, Xiang Jie, Jiao Zhang, Yun Peng Huang, Zhi Hao Zhao, and Jian Zhong Cui. "Experimental Study on Horizontal Continuous Casting of 6061 Aluminium Alloy Bar Process." Key Engineering Materials 480-481 (June 2011): 100–103. http://dx.doi.org/10.4028/www.scientific.net/kem.480-481.100.
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The aluminium alloy bar is mainly obtained by hot extrusion in the past. In order to increase the production efficiency and reduce the cost, a new mold is designed, and horizontal continuous casting is used to produce the aluminium alloy bar in this work. The results show that aluminium alloy bar can be cast by horizontal continuous casting. The asymmetry of the sump is overcome by optimizing the design of the mold. When the temperature of the melt was 730°C, casting speed is 650 mm/min, cooling water is 15 L/min, the quality of lubricating oil is 0.5 ml/min, and the ingot with good surface quality can be cast.
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Lekhov, O. S., A. V. Mikhalev, and M. M. Shevelev. "Production of three-layer steel bimetallic strips in the unit of continuous casting and deformation. Report 1." Izvestiya. Ferrous Metallurgy 62, no. 8 (September 13, 2019): 594–99. http://dx.doi.org/10.17073/0368-0797-2019-8-594-599.
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High technical and economic efficiency of the use of bimetals in chemical, oil, transport and energy engineering and other industries is described. The urgency of creating high-performance continuous processes for the production of bimetallic strips is substantiated. The authors have established the main technological tasks for development of the processes of obtaining bimetal of wide class. The paper describes resource-saving production technology of three-layer bimetals alloyed steel – constructional steel – alloyed steel at the unit of combined process of continuous casting and deformation. Possibilities of the proposed technology are outlined from the standpoint of improving the quality of bimetallic strips. The initial data are given to determine the temperature change over time of the main steel strip as it passes through the molten metal of the alloyed steel. The equations are given for non-stationary heat conduction, initial and boundary conditions for determining the temperature fields of main strip and cladding layer when obtaining a three-layer bimetallic strip on the unit of a combined process of continuous casting and deformation. The values of density, thermal conductivity and heat capacity for steel St3 were determined in a given temperature range. A procedure is described for calculating temperatures in the ANSYS package by solving a non-stationary heat conduction problem in a flat formulation by the finite element method. The authors have described the geometric model for calculating the temperature of strip and molten metal of the cladding layer. Values of the coefficient of heat transfer between the main strip and molten metal of the cladding layers of bimetallic strip are given adopted for calculation. Characteristic points are indicated in the model for calculating the temperatures of main strip and molten metal of the cladding layer. The graphs show temporal changes in these temperatures at production of a three-layer bimetallic strip on the unit of combined process of continuous casting and deformation. Calculated data on the time variation of temperature of main strip and molten metal of the cladding layer at characteristic points are given for different values of the contact heat transfer coefficient.
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Lekhov, O. S., A. V. Mikhalev, and M. M. Shevelev. "PRODUCTION OF THREE-LAYER STEEL BIMETALLIC STRIPS IN THE UNIT OF CONTINUOUS CASTING AND DEFORMATION. REPORT 2." Izvestiya. Ferrous Metallurgy 62, no. 10 (November 3, 2019): 763–68. http://dx.doi.org/10.17073/0368-0797-2019-10-763-768.
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The paper states urgency of the problem of determining stressstrain state of metals of the cladding layer and the main strip in production of three-layer bimetal: alloyed steel-constructional steelalloyed steel. Temperature field of the main strip and cladding layer is given to calculate stress-strain state of metals of three-layer bimetallic strip. Initial data for calculating this stress-strain state are given. To assess the effect of coefficient of friction between cladding layer s and the main strip on stress-strain state of metals in deformation zone, three values of it are taken. Geometric model is described for calculating stress-strain state and metal flow in deformation center of cladding layer. Characteristic lines and points of calculation are provided. Technique for solving the problem of determining stresses and flows in deformation focus is described by finite element method using ANSYS app. Regularities of flow of cladding layer’s metal along the length of deformation center and movement of the main strip of bimetallic ingot are given. Values of mutual displacement of layers of bimetallic strip are determined as a function of deformation degree of the cladding layer. And the recommendations are given on this degree to improve quali ty of a three-layer bimetal. Regularities of distribution of axial and tangential stresses in deformation center are presented for production of steel three-layer bimetallic strips in the unit of combined continuous casting and deformation. Stress state of the cladding layer’s metal in focus of cyclic deformation was estimated from the position of improving quality of three-layer bimetallic strips produced in such unit.
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Yang, Luo Cheng, Hong Xi Zhu, Cheng Ji Deng, Wen Jie Yuan, and Jun Ding. "Effect of Water Gap in Delivery System on Twin Roll Strip Caster by Simulation." Key Engineering Materials 602-603 (March 2014): 652–55. http://dx.doi.org/10.4028/www.scientific.net/kem.602-603.652.
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In continuous casting process, the mould is the core of the continuous caster, and the vast majority of the surface defects of steel is originated in the crystallizer. Choosing a reasonable water gap in the delivery system is particularly important, especially in twin roll strip continuous casting, the flow delivery system thin belt has a close relationship with the quality of the products. Experiments to skateboard and water gap, STEEL AISI 4340 materials chosen as the simulation material at the same time, distribution water gap taking the form of a set themselves by using the finite element software COMSOL simulation calculation of different gaps opening mode of velocity field, and fluid line back to the high wall, made a comprehensive analysis in different speak way open comprehensive effect is best, the most conducive to the production of high quality material. The experiment determines the best form of water gap, improving the efficiency of the actual production. Make it to the actual production has a certain guiding significance.
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Ju, Dong Ying, Hong Yang Zhao, Xiao Dong Hu, Koichi Ohori, and Mituo Tougo. "Thermal Flow Simulation on Twin Roll Casting Process for Thin Strip Production of Magnesium Alloy." Materials Science Forum 488-489 (July 2005): 439–44. http://dx.doi.org/10.4028/www.scientific.net/msf.488-489.439.
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Strip continuous casting by twin roll method is a rapidly solidifying process, which can directly produce thin strips,reduce energy consumption and product cost of various metal materials. However, the casting of magnesium alloys with large solidifying ranges lead to some problems such as surface and internal defect, variation of solidification finish point for Mg sheet. In this research, the process conditions for a twin roll caster are analyzed by thermal flow simulation. The effect of type and dimension of delivery nozzles on production of Mg alloy are studied. A proper match of the setback distance of thin nozzle and casting speed is studied by thermal flow simulation, based on the characteristics of Mg melt handling, flow dynamics control and solidification.
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de Pádua Lima Filho, Antonio, Rafael Shoiti Ikeda, Tales Paschoalino de Castro, and Ricardo Luiz Pugina Filho. "Continuous Production of a Multi-Filament Reinforced Metal Matrix Composite Strip from the Semisolid State." Solid State Phenomena 217-218 (September 2014): 265–73. http://dx.doi.org/10.4028/www.scientific.net/ssp.217-218.265.
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Continuous metal matrix composite strip casting (MMCS-ing) composed of six 0.3-mm diameter annealed bare copper wires in a eutectic SnPb matrix was manufactured by a two-roll melt dragged processing (TRMD-ing) method at a rate of 0.3 m/s. The wires were dragged through a semisolid pool with a fibre contact time of approximately 0.2 s. The required gap between rolls to thixoforge the semisolid material around the wire filaments was approximately 1.4 mm. A successful continuous composite strip casting was achieved with a notably good degree of wire alignment. No cracks were observed at the copper wire/matrix interface. However, regions of porosity occurred in the matrix; their possible formation mechanisms are discussed. The solidification structure of the matrix was analysed, and the analysis results indicated the formation of small globular grains measuring approximately 3 μm in diameter. The specimens were evaluated for their tensile properties and compared with the rule of mixtures. The surface fracture analysis indicated a good matrix/fibre union. MMCS-ing is an economically viable process and has significant advantages over other metal matrix composite (MMC) fabrication methods.
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Haga, T., and K. Miyazaki. "Semi-continuous caster for plate." Journal of Achievements in Materials and Manufacturing Engineering 2, no. 84 (October 1, 2017): 58–67. http://dx.doi.org/10.5604/01.3001.0010.7782.
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Purpose: Development of a semi-continuous caster that can cast a single plate and a clad plate of Al-40%Sn-1%Cu alloy used for sliding bearings. Design/methodology/approach: A semi-continuous caster to cast a single plate and a clad plate directly from molten metal was designed and assembled. The cast single plate has a thickness ranging from 10 mm to 30 mm, a width of 400 mm, and a length of 500 mm to 1,000 mm. The cast clad plate has a thickness ranging from 10 mm to 30 mm, a width of 50 mm, and a length of 300 mm. Findings: The semi-continuous caster successfully produced both a single plate and a clad plate of Al-40%Sn-1%Cu alloy. Influence of casting conditions on the properties of the plate, including the thickness, porosity, and surface quality were investigated in the single plate casting. The mixing and diffusion of the alloy elements at the interface was also investigated in the clad plate casting. Research limitations/implications: The cast Al-40%Sn-1%Cu alloy plate has not yet been tested as a sliding bearing material, so the efficacy of the material still requires investigation. Practical implications: The semi-continuous caster described in this paper enables the “small lot” production made from single and clad plates of aluminium alloy. Originality/value: Development of a semi-continuous caster that can cast both single and clad plates of aluminium alloy. Investigation of the relationship between the casting conditions and plate quality.
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Du, Zhi Ming, Shui Sheng Xie, Ping Wu, and Yan Ying Zhang. "Numerical Simulation of Semi-Solid Roll Strip-Casting Process for AZ91D Magnesium Alloy." Solid State Phenomena 141-143 (July 2008): 617–22. http://dx.doi.org/10.4028/www.scientific.net/ssp.141-143.617.
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High quality magnesium alloy sheets with non-dendritic microstructure can be manufactured by the technique which incorporates semi-solid processing with continuous roll stripcasting. In particular, the process is believed to be cost-effective in mass production of magnesium sheet products. The processing parameters, such as roll speed and temperature, have significant influence on roll strip-casting process. In this paper, the commercial software, DEFORM-3D, for deformation simulation of bulk materials was used to carry out the simulation of roll strip-casting process for AZ91D magnesium alloy in semi-solid state, and the distribution of equivalent stress, equivalent strain and temperature was obtained. Based on the results, the optimization of processing parameters was discussed.
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Warzecha, Marek. "Modeling of the Steel Flow and Non-Metallic Inclusion Separation due to Flotation in a Six-Strand cc Tundish." Materials Science Forum 706-709 (January 2012): 1556–61. http://dx.doi.org/10.4028/www.scientific.net/msf.706-709.1556.
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Constantly increasing customers’ demands for the production of high and very high-quality steels, promote the intensive technological development of their production. Today, the dominating method of global steel production is continuous casting. A continuous casting plant includes the ladle turret, several steel ladles, a tundish, and a mold followed by a framework of rolls to support the strip. The tundish has become a very important metallurgical unit in the continuous casting process. Nowadays its role is not only to guaranty the link between the process of secondary metallurgy and the continuous casting process in the mould but it becomes an active metallurgical reactor. Therefore in recent years a lot of researches were done to establish a better understanding of the physical phenomena accompanying the steel flow through the tundish and non-metallic inclusion separation into the top slag cover. The article presents computational studies of the three-dimensional turbulent steel flow and non-metallic inclusions separation in a multi-strand tundish for steady-state casting conditions. Simulations of the steel flow in the tundish are performed with boundary conditions that are derived from the real casting process. The mathematical model used for simulations, was partly validated with experimental measurements. Numerical calculations are carried out by the finite-volume code Fluent using k-ε standard turbulence model. With the calculated flow field, micro-inclusions removal due to flotation to the coving slag is investigated numerically. For the particle separation at the interface a modified boundary condition is implemented.
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Karsten, Ole, Kai Schimanski, Axel von Hehl, and Hans Werner Zoch. "Challenges and Solutions in Distortion Engineering of an Aluminium Die Casting Component." Materials Science Forum 690 (June 2011): 443–46. http://dx.doi.org/10.4028/www.scientific.net/msf.690.443.
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The demand for increased efficiency of resources in industrial manufacturing processes requires continuous developments of materials and production processes. Aluminium components especially used in automotive applications meet the requirements of weight optimised and energy efficient solutions. In this context vacuum die casting enables the production of complex weight optimised components. However, in view of ensuring the needed dimensional accuracy, the productivity potential of the process is still restricted. Hence, the distortion behaviour within the whole process chain of a die casting structural part made of alloy AlSi10Mg was systematically investigated. Starting with the initial state after casting the analysis was focused on the quenching, punching, precipitation hardening and machining of the components. Contour deviations were recorded via a photogrammetry system and a coordinate measuring machine. Especially after die casting and solution annealing significant contour deviations were observed. Residual stress measurements along the process chain pointed out that residual stresses from die casting were released by solution annealing. By the knowledge of distortion sensitive component areas and the understanding of distortion mechanisms compensation strategies were derived based on the investigated processes. Within the paper these deduced strategies and the way to reduce expensive straightening processes and to raise efficiency will be given for industrial applications.
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Grimes, Roger, R. J. Dashwood, A. Dorban, M. Jackson, S. Katsas, I. Pong, and G. Todd. "Development of Superplastic Properties in Quasi Single Phase Alloys." Materials Science Forum 551-552 (July 2007): 357–64. http://dx.doi.org/10.4028/www.scientific.net/msf.551-552.357.
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The early view of superplasticity was that it was a phenomenon that could only be exhibited by fine grained, two phase alloys. This effectively ruled out most alloys that possessed attractive service properties. The first material to demonstrate good superplastic properties from a virtually single phase microstructure was the Al-6%Cu-0.5%Zr, AA 2004 but this was followed by superplastic versions of AA7475, AA8090 and AA5083. Superplasticity was also demonstrated in magnesium based alloys at an early stage. More recently different grain control additions, such as scandium or erbium have been investigated and it has also been demonstrated that, in certain circumstances, aluminium simply with the addition of a grain controlling element can exhibit good superplastic behaviour. While conventional wisdom teaches that large fabricating strains are required to confer good superplastic properties in the sheet product, recent results with both aluminium and magnesium alloys cast doubt on this belief. Although, for many years, strip casting has appeared to provide an attractive semi-fabricating route for superplastic sheet problems with centre line segregation in alloys with a wide freezing range have precluded its use. It has been demonstrated that recent developments in strip casting enable production of alloys with as wide a freezing range as AA5182 to be cast with a fine, equiaxed grain structure across the strip thickness. The paper will review the state of these various developments and their implications for the manufacture of superplastic sheet materials.
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Pérez-Ilzarbe, J., J. Fernández Carrasquilla, and C. J. Luis-Pérez. "A Study of the Mechanical Properties and Recrystallization of Two Types of Foil of Aluminium 1050 A." Key Engineering Materials 423 (December 2009): 137–45. http://dx.doi.org/10.4028/www.scientific.net/kem.423.137.
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An experimental study of the variation of the mechanical properties of sheets of aluminium alloy 1050A due to heat treatment has been carried out. For this purpose, sheets and foils rolled from continuous casting strip (CCS) and from hot rolling strip (HRS) have been prepared in the laboratory. Initially, CCS and HRS had a thickness of 7,5 mm and 3,0 mm respectively. The final thickness achieved in both cases was 0,20 mm. In order to obtain hardening curves for CCS and HRS sheets and foils, specimens of different thickness were taken during the rolling process. Oven treatments were carried out for drawing softening curves of foils. Foil proceeding from CCS presents hardening due to the precipitation of Al3Fe particles at a temperature range of 160°C to 220 °C. HRS foil has a lower hardening in the same range of temperatures owing to its low supersaturation of Fe. Correlation between ultimate tensile strength Rm and Vickers hardness is studied. Micrographies of optical microscopy are offered at hard and recrystallized conditions.
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Kurz, Gerrit, Jan Bohlen, Dietmar Letzig, and Karl Ulrich Kainer. "Influence of Process Parameters on Twin Roll Cast Strip of the Alloy AZ31." Materials Science Forum 765 (July 2013): 205–9. http://dx.doi.org/10.4028/www.scientific.net/msf.765.205.
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Reducing vehicle weight and emissions by lightweight design is a major goal of the automotive industry. Magnesium as the lightest structural metal offers a significant weight saving potential compared to steel and aluminium. Cast magnesium components are widely used, e.g. as engine blocks or gear box housings. The application of magnesium sheets is currently hampered by the low formability of magnesium which means that a large number of rolling passes is required to roll a DC cast slab to final gauge sheet. This large number of rolling steps is the main reason for the high cost of magnesium sheets. Twin-roll casting (TRC) is an alternative, economic production process for the generation of fine-grained feedstock materials that subsequently can be warm rolled to thin sheets. It therefore receives attention in actual research and development projects for the application of magnesium alloys as prospective light metal solutions. This production process for thin strips combines solidification and rolling into one single production step and therefore saves a number of rolling and annealing passes in comparison to the conventional rolling process. The main goal of the activities at the Magnesium Innovation Centre MagIC of the Helmholtz-Centre Geesthacht (HZG) is the development of wrought magnesium alloys and their introduction into industrial, structural applications. The current focus of the research work is on alloy design and their processing for magnesium sheets produced by twin roll casting. In order to understand the influence of process parameters on the microstructure and texture the first twin roll casting experiments were performed with the alloy AZ31 (Mg-3Al-1Zn-Mn) as benchmark. As an example, the influence of melt temperature on the microstructure of the strip is presented and discussed with respect to arising material properties. Optimisation of process parameters of twin roll casting and the subsequent rolling of the sheets, offers the possibility to produce high quality sheet material.
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Larouche, André, Malcom Lane, Massimo DiCiano, Daan M. Maijer, Steve CockCroft, and Roger Thiffault. "Understanding T-Ingot Horizontal DC Casting Using Process Modelling." Materials Science Forum 519-521 (July 2006): 1461–66. http://dx.doi.org/10.4028/www.scientific.net/msf.519-521.1461.
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Horizontal continuous casting process has been successfully implemented in Alcan for the production of T-ingots of primary aluminium and foundry alloys. Ability to achieve increased productivity targets and reduce production costs relies on a fundamental understanding of key process characteristics and operating parameters. Thanks to the long-standing experience in vertical DC Casting, numerical modelling appeared as a powerful approach to understand phenomena related to metal flow, solidification and ultimately defect formation. As part of a collaborative R&D program, a global model of horizontal casting process, integrating specialized sub-models on critical aspects of the process such as meniscus dynamics, is being developed. Experimental characterization of primary and secondary cooling is performed in parallel with modelling work to provide the information necessary to properly characterize mould heat transfer. This paper will present the development of a 3D process model of T-ingot casting along with its application to solve specific process challenges that have emerged during the first years of production in the plant.
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ISHIKAWA, Katumi, Teruo HIRAMATU, Hideyuki OHNISI, Toshimitu KITANO, and Hidekazu YASUDA. "The Integrated Control System of the Directly Connected Production Process between Continuous Casting Machines and Hot Strip Mill." Tetsu-to-Hagane 74, no. 7 (1988): 1331–37. http://dx.doi.org/10.2355/tetsutohagane1955.74.7_1331.
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Szymański, W., M. Bigaj, M. Gawlik, M. Mitka, and M. Szymanek. "Consolidation by Continuous Rotary Extrusion of Aluminium Alloys Cast by the Melt Spinning Process." Archives of Metallurgy and Materials 59, no. 1 (March 1, 2014): 309–12. http://dx.doi.org/10.2478/amm-2014-0050.
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Abstract One of the methods to produce aluminium alloys of an uncommon composition and structure is by the combined process of casting with rapid solidification and the following plastic forming. When modern advanced methods of rapid cooling of the melt are used, the alloy structure solidifies as a powder in the atomiser or as ribbons when cast onto a rapidly rotating copper wheel. If optimum conditions for the process of casting and rapid consolidation are satisfied, it is possible to control some structure parameters like the size of the particles, the size of the precipitates, etc. Additionally, the production of aluminium alloys by rapid solidification allows introducing the alloying constituents that are incompatible with the state of equilibrium. The consolidation of material made by rapid solidification is achieved in one of the numerous variations of the plastic forming processes, among which the most commonly used are the direct extrusion and continuous rotary extrusion (CRE). This paper presents the results of the consolidation in the process of continuous rotary extrusion (CRE) of selected aluminum alloys with an unusually high content of alloying elements cast in the process of rapid solidification by melt spinning and crushed in a high-speed cutting mill to as ”chips”.
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Knych, T., M. Piwowarska-Uliasz, P. Uliasz, and J. Wiecheć. "Comparative Characteristics of the AlZr Alloy Materials Electrical and Mechanical Properties." Archives of Metallurgy and Materials 59, no. 2 (June 1, 2014): 633–39. http://dx.doi.org/10.2478/amm-2014-0104.
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Abstract The subject of the present article consists in obtaining the wire production material with the controlled, during the heat treatment, level of electrical and mechanical properties. In the case of the AlZr alloys the appropriate strength properties are obtained in the technological process through the introduction of the specified value of the cold working (work-hardening). In turn,the AlZr alloy resistivity value is dependent on both the amount of the zircon additive and its placement characteristics in the aluminium structure (solid solution or emissions). The paper presents comparative resistivity and hardness tests of the AlZr alloy material with the zircon content ranging from 0.05 to 0.32% mas. Zr produced in the continuous casting technology as well as in the continuous casting and rolling technology.
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You, Dali, Christian Bernhard, Andreas Viertauer, and Bernd Linzer. "Simulation of the Refining Process of Ultra-Low Carbon (ULC) Steel." Crystals 11, no. 8 (July 30, 2021): 893. http://dx.doi.org/10.3390/cryst11080893.
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The standard production route for mild steels for automotive purposes is still based on conventional continuous casting (CC) and hot strip rolling (HSR). The current trend towards the “zero-carbon car” will demand the abating of material emissions in the future. Thin slab casting and direct rolling (e.g., Arvedi endless strip production (ESP)) is an approach to reduce CO2 emissions by 50% compared to CC and HSR. One of the main limitations in applying ESP for the production of ultra-low carbon/interstitial free (ULC/IF) steels is clogging. Clogging is the blockage of the submerged entry nozzle due to the build-up of oxide layers or an oxide network. The high clogging sensitivity of IF steels results most probably from the FeTi addition, and hence, a general change of the deoxidation practice might be an option to overcome these problems. In the present work, the thorough refining process of ULC steel was simulated by addressing the different deoxidation routes and the influence of titanium (Ti) alloying on steel cleanness. The developed ladle furnace (LF) and the Ruhrstahl Heraeus (RH) refining models were applied to perform the simulation. Before the simulations, the models are briefly described and validated by the published industrial data.
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Bamberger, Menachem, and Esther Kiperwasser-Karbian. "Plasma Treatment Casting of Cast Aluminum 6XXX Wrought Alloys." Materials Science Forum 765 (July 2013): 200–204. http://dx.doi.org/10.4028/www.scientific.net/msf.765.200.
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The Plasma Treatment Casting (PTC) process is an advanced stirring process that stirs molten metals and alloys during solidification in conductive and nonconductive dies. The intensive stirring has several major benefits: finer microstructure, better chemical homogeneity and much more efficient feeding in both macro and micro scales. Today the casting industry is continuously pursuing methods to improve casting quality, and to save time, energy and materials, which together result in price reduction and environmental benefits. Direct-chill (DC) casting is currently the most common semi-continuous casting practice in production of 6XXX aluminium alloys. This method results in course and non-homogenous microstructures. This requires homogenization treatment to follow the casting process in order to give 6XXX DC cast billets workability in extrusion and the required mechanical properties. The PTC process can be the solution to improve the microstructure in terms of refining the microstructure, reducing porosity and creating a more homogenous microstructure.
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Storck, Joakim, and Bengt Lindberg. "Assessment of Best Scheduling Practice in Continuous Casting and Hot Rolling of Stainless Steel Strip by System Dynamics Simulation." Key Engineering Materials 344 (July 2007): 897–904. http://dx.doi.org/10.4028/www.scientific.net/kem.344.897.
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A rapid flow of materials with little intermediate buffering between steel mill and hot strip mill has many benefits. One is energy savings due to raised charging temperature in the reheat furnaces of the hot strip mill. Another is that tied capital is freed up, thereby improving mill economy. Still, it is not unusual that average lead-time is in the order of days, or even weeks. The aim of the present work was to show how lead-times from casting to rolling could be improved by changes in the scheduling function. A System Dynamics model of a stainless steel strip production facility with continuous caster and hot rolling mill was created. The model was used to study the dynamics of the system in response to changes in parameters that defined the scheduling configuration. More frequent schedule updating generally resulted in less work in process (WIP) and shorter lead times from casting to rolling, with resulting higher charging temperatures. The amount of oscillation in the system was also reduced. More frequent work roll changes were required when scheduling frequency increased, resulting in an increased fraction of setup time in relation to total processing time. Therefore, a development towards increased scheduling frequency may have to be complemented by efforts to reduce changeover times. The conclusion was that dynamic scheduling routines with frequent schedule updating result in better overall performance of the system due to lower WIP and better heat utilization. Dynamic scheduling routines with frequent updates make the system respond better to changes in the system and give better overall performance. The result is lower WIP, increased energy efficiency and less oscillation in the system.
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Xuan, Mingtao, and Min Chen. "Optimal Design of the Submerged Entry Nozzle for Thin Slab Continuous Casting Molds." Metals 11, no. 8 (July 31, 2021): 1223. http://dx.doi.org/10.3390/met11081223.
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For the purpose of increasing the capacity of an Angang Strip Production (ASP) continuous caster and the surface quality of a medium-thin slab with mold sections of 150 × (1020–1540) mm2, the present work investigated the influences of the submerged entry nozzle (SEN) structure and main operating parameters on the flow characteristic and temperature distribution in the mold by physical and numerical simulations. The results showed that the typical “double-roll” flow and a central jet were formed through the three-port SEN. With the original SEN, the mean wave height exceeded the critical value of 5.0 mm after the casting speed was increased due to the strong upper recirculation flow. By the slight increment of the bottom port area and the side port angle of SEN, the mean wave height was obviously decreased below 4.4 mm due to the depressing of the upper recirculation flow after the casting speed increased. Meanwhile, the temperature distribution was slightly changed by using the optimized SEN. The practical application showed that the breakout rate decreased from 0.349% to 0.107% and the surface defect rate decreased from 0.54% to 0.19% by using the optimized SEN, while throughput reached the new level of 3.96 t/min.
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de Pádua Lima Filho, Antonio, Márcio Iuji Yamasaki, Leandro Akita Ono, Lourenço Nampo, and Alcides Padilha. "A Comparison of Deep Drawing and Ironing of Metal Alloy Strip Produced Conventionally and Non-Conventionally via Semi Solid Material Processing." Solid State Phenomena 141-143 (July 2008): 49–54. http://dx.doi.org/10.4028/www.scientific.net/ssp.141-143.49.
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A semi solid thin strip continuous casting process was used to obtain 50%wt Pb/50%wtSn strip by single and twin roll processing at speed of 15 m/min. A 50%wt Pb/50%wtSn plate ingot was also cast for rolling conventionally into strips of 1.4 mm thickness and 45 mm width for comparison with those achieved non-conventionally. This hypoeutectic alloy has a solidification interval and fusion temperature of approximately 31°C and 215°C respectively. The casting alloy temperature was around 280°C as measured by a type K immersion thermocouple prior to pouring into a tundish designed to maintain a constant melt flow on the cooling slope during semi solid material production. A nozzle with a weir ensures that the semi solid material is dragged smoothly by the lower roll, producing strip with minimum contamination of slag/oxide. The temperatures of the cooling slope and the lower roll were also monitored using K type thermocouples. The coiled semi solid strip, which has a thickness of 1.5 mm and 45 mm width, was rolled conventionally in order to obtain 1.2 mm thick strip. The coiled thixorolled strip had a thickness of 1.2 mm and achieved practically the same width as the conventional strips. Blanks of 40 mm diameter were cut from the strips in a mechanical press, ready for deep drawing and ironing for mechanical characterization. All the strips achieved from non-conventional processing had the same mechanical performance as those achieved conventionally. The limiting drawing ratio (LDR) achieved was approximately 2.0 for all strips. Microscopy examination was made in order to observe phase segregation during processing.
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Grigor’ev, A. M., M. S. Kuznetsov, D. S. Shepelev, E. M. Alekseev, and K. V. Grigorovich. "Optimization of production technologyof continuous cast rail steel for increasing its purity by non-metallic inclusions." Izvestiya. Ferrous Metallurgy 64, no. 5 (June 3, 2021): 345–52. http://dx.doi.org/10.17073/0368-0797-2021-5-345-352.
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The purpose of the work was to examine the reasons for formation of non-deformable non-metallic inclusions in rail steel and ways to reduce the rejection of finished rails due to the defects revealed during ultrasonic testing. The study was conducted at the steelmaking plant of JSC “Ural Steel”. In the central laboratory of the combine, a chemical analysis of non-metallic inclusions was carried out in the samples of finished rails produced from blanks manufactured by JSC “Ural Steel” and rejected at the ultrasonic test unit during the rail production at the “Aktobe Rail and Section Works” LLP. Non-metallic inclusions by their composition are represented by aluminium oxides. The most probable reasons for their formation have been determined as following: the use of aluminium containing ferroalloys and interaction of the melt components with refractory materials and casting powder. The authors made analysis of the ferroalloys used in production of rail steel. Industrial trials of the manufacturing process of continuously cast blanks from rail steel were carried out, where FS65 ferrosilicon, which contains aluminium, was replaced with silicon carbide. An increasing degree of silicon and carbon recovery in trial heats was noted. Evaluation of contamination with non-metallic inclusions and mechanical properties of the rail steel manufactured using the experimental technology showed that the service characteristics of the rail steel meet requirements of the state standard GOST R 51685 – 2013. The full-scale experiment has confirmed that the technology of alloying E76F rail steel with silicon carbide at JSC “Ural Steel” is technically feasible. The yield of 100-meter rails was increased by 17 % on a trial batch produced from JSC “Ural Steel” continuously cast blanks.
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Feng, Rui, Rui Tang Zhang, Sheng Li Li, Guan Hong Kong, and Xin De Zhu. "Study on Forming Mechanism of Lamination Defect of AH36 Shipbuilding Plate Steel." Advanced Materials Research 562-564 (August 2012): 106–10. http://dx.doi.org/10.4028/www.scientific.net/amr.562-564.106.
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The lamination defect makes the mechanical properties deterioration along the thickness of steel plate and therefore finding out the forming mechanism is of great significance for production of shipbuilding plate steel. The tensile fracture and microstructure characteristics on AH36 shipbuilding plate steel of lamination defect were studied with Scanning Electron Microscope (SEM), Transmission Electron Microscopy (TEM), etc. The results show that the strength-toughness properties vary widely at different thickness of the steel plate due to different ferrite grain size, and the center zone firstly yields and steps into plastic deformation stage due to coarse ferrite grain subjected to tensile stress, while the surface zone is still in elastic deformation stage due to relatively fine ferrite grain. The inconsistency of deformation and fracture leads to fracture separation, namely lamination. The continuous banded Widmanstätten structure, strip-shaped sulphide inclusions and mixed ferrite grain distributed at the center of shipbuilding plate steel create conditions for the lamination defect, which are important reasons for fracture separation. Widmanstätten structure at the center of steel plate has relationship with coarse austenite grain, and strip-shaped sulphide inclusions have relationship with centerline segregation of continuous casting slab during solidification process.
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Jabłoński, Michał, Tadeusz Knych, and Beata Smyrak. "Effect of Iron Addition to Aluminium on the Structure and Properties of Wires Used for Electrical Purposes." Materials Science Forum 690 (June 2011): 459–62. http://dx.doi.org/10.4028/www.scientific.net/msf.690.459.
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Eight hypoeutectic aluminium alloys with iron content within the range of 0.07-1.09% by weight, were examined. The structure, the mechanical and electrical properties of wires used for electrical purposes were studied. The batch material for the drawing process was wire rod obtained from the continuous casting and rolling line by Continuus-Properzi method. It has shown a linear relationship between mechanical properties of wire rod, a higher plasticity of wire after drawing process and an increase in thermal resistance of the material with increasing iron content. The findings enable to draw conclusions of basic and application characteristics, pointing to the possibility of using aluminium with higher iron content in the wire drawing process of small diameter and microwires for the production of automotive bundles, accumulator cables and winding wires.
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Osuch, Piotr, Beata Smyrak, and Tadeusz Knych. "Effect of Precipitation Hardening on the Structure and Properties of Al-Mg-Si Conductor Alloys in Different Technological Routes." Materials Science Forum 765 (July 2013): 823–26. http://dx.doi.org/10.4028/www.scientific.net/msf.765.823.
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The Al-Mg-Si alloys, due to their unique combination of lightweight, mechanical and electrical properties and excellent corrosion resistance, are used as a material for the production of overhead power conductors, commonly known as AAAC (All Aluminium Alloy Conductor). Wires intended for conductor manufacturing are obtained from the wire rod produced by a continuous casting and rolling line (CCR, e.g., Continuus-Properzi). The Al-Mg-Si wire rod can be processed into ready-made wires by different technological routes, which mainly consist of different combinations of strain hardening as well as precipitation hardening of wire rod or wires. In Europe the conventional technological route comprises solution heat treatment of wire rod coils (heated at temperatures over ~500 °C, followed by quenching into water), then natural ageing of wire rod at ambient temperature for a couple of days, next wire drawing, and finally artificial ageing.This paper discusses results of investigations on developing an alternative technological route. In this process heat from the continuous casting and rolling process by Continuus-Properzi is used for heat treatment of the wire rod. The new technological route allows the abandonment of the high temperature heat treatment as well as natural ageing of the wire rod, making the production process less energy consuming, cheaper and faster than the conventional one. The current paper presents research results identifying the structure of materials from different Al-Mg-Si wires production process routes. It also focuses on electrical and mechanical properties.
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Lekhov, O. S., A. V. Mikhalev, and M. M. Shevelev. "Stressed state of striker – bimetall system at production of three-layer steel bimetallic strips in the unit of continuous casting and deformation." Izvestiya. Ferrous Metallurgy 63, no. 2 (April 29, 2020): 140–45. http://dx.doi.org/10.17073/0368-0797-2020-2-140-145.
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The article presents the initial data for calculation of stress-strain state of a three-layer bimetallic strip. The regularities of distribution of axial and tangent stresses in the zone of cyclic deformation are considered. The main loads acting on the mold strikers are described for the unit of combined continuous casting and deformation at production of steel three-layer bimetallic strips. The authors describe the method for determining total stresses in the installation strikers from the efforts of compression and temperature loads. Also temperature boundary conditions for determining the temperature fields are considered. The procedure for determining temperature fields and thermoelastic stresses in the strikers is shown using the ANSYS package. The calculation results of temperature fields and thermoelastic stresses were made in five sections of the striker and are given for characteristic lines. The nature of temperature distribution over the thickness of the striker is shown when it is cooled with water at idling and in contact with a bimetallic ingot during its compression. For the calculated temperature fields, the authors have determined the axial and equivalent stresses occurring in the strikers without channels when the ingot is compressed and cooled with water during idling. The magnitudes and patterns of distribution of total axial stresses from the compression and thermal loads are also given along the thickness of the contact layer, along the height and thickness of the strikers.
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Ochuokpa, Ezekiel Otor, D. S. Sumaila, and Abdulmumin Adebisi. "Development of Aluminium Based Mango Seed Mangiferaindica Shell Ash (MSSA) Particulate Metal Matrix Composite." International Journal of Engineering Materials and Manufacture 6, no. 3 (July 15, 2021): 176–86. http://dx.doi.org/10.26776/ijemm.06.03.2021.09.
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A composite material is a combination of two or more chemically distinct and insoluble phases; its properties and structural performance are superior to those of the constituents acting independently. MMCs are made by dispersing a reinforcing material into a metal matrix to improve their properties. They are prepared by powder metallurgy and casting, although several technical challenges exist with casting technology. Achieving a homogeneous distribution of reinforcement within the matrix is one such challenge, and this affects directly on the properties and quality of composite. In this work a composite is developed by adding Mango seed shell Ash (MSSA) particulate in Al- Si-Mg Alloy by mass ratio 5%, 10%, 15% and 20%. The composite was prepared by stir casting technique. It is proposed to use this material for production of motorcycle wheel hub which are subjected to continuous wear as the hubs are in direct contact with the brakes and rotating sprockets. The MSSA, was characterized using X- ray fluorescent (XRF). The result reveals SiO2, has the highest percentage composition followed by CaO, Al2O3, Fe2O3 and Mg2O as major phases. The presents of these hard constituent compounds suggests that the mango seed shell ash can be used as particulate reinforcement in various metal matrices since the chemical composition has similarity with the XRF analysis of Periwinkle shell ash, rice husk, fly ash, and bagasse ash currently used in metal matrix composite. Mechanical tests such as hardness test and impact test were conducted. The results revealed that increase in the percentage of MSSA progressively increased the hardness of the material from 5% wt to a maximum hardness of 43.2 HV at 15% addition of MSSA. This represents a 26.16% improvement over the unreinforced alloy. However, the impact energy progressively decreases of the material from 5%wt of MSSA and later increased to optimum energy at 15% addition of MSSA. From the results it is concluded that composite material such as Al- Si-Mg/ MSSA is one of the options as a material for production of motorcycle hub. The wear test of the composite was then carried out using Taguchi design to optimize the range of MSSA from 5% wt -15% wt., Sliding speed of 5cm/s -20cm/s, sliding distance from 50m to 200m, and the load of 2N, 4N, 6N, & 8N respectively. Analysis of the result of SN ratio for wear rate shows the optimum wear resistant value is in the combination of Load=4N, sliding speed = 10cm/s sliding distance=200m and MSSA=15 wt% These also correspond with the analysis of wear maps & wear rate presented in the diagrams of dynamic friction coefficient (COF) for Al-Si- Mg/ MSSA Composite.
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Wilkinson, David S., Xin Jian Duan, Ji Dong Kang, Mukesh K. Jain, and J. David Embury. "Modeling the Role of Microstructure on Shear Instability with Reference to the Formability of Automotive Aluminium Alloys." Materials Science Forum 519-521 (July 2006): 183–90. http://dx.doi.org/10.4028/www.scientific.net/msf.519-521.183.
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This paper addresses the effect of microstructure on the formability of aluminium alloys of interest for automotive sheet applications. The bulk of this work has been on the alloy AA5754 – both conventional DC cast alloys and continuous cast alloys made by twin belt casting. It is known that alloys such as these contain Fe as a tramp impurity which results in Fe-based intermetallic particles distributed through microstructure as isolated particles and in stringers aligned along the rolling direction. It is thought that these particles are the cause, both of the reduced ductility that is observed as the Fe level rises, and the relatively poor formability of strip cast alloys, as compared with those made by DC cast. Conventional wisdom suggests that the reduction of ductility is due to the effect of particles as nucleating sites for damage. However, most studies show that these materials are resistant to damage until just before fracture. We now believe that effect is actually related to the development of shear bands in these materials. We present experimental data which supports this conclusion. We then show how the FE models we have developed demonstrate the role of shear instability on fracture and the role played by hard particles. We show how a unit cell approach can be used to incorporate the effect of particle density and morphology on shear localization in a way that includes statistical variability due to microstructural heterogeneity. This leads to a set of constitutive equations in which the parameters are distributed from one region to another. These are then fed into a macroscopic FE model at the level of the specimen or the component in order to determine the effect of microstructural variability on shear instability and ductility.
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Cwudziński, Adam. "New Insight on Liquid Steel Microalloying by Pulse-Step Method in Two-Strand Slab Tundish by Numerical Simulations." Crystals 11, no. 4 (April 20, 2021): 448. http://dx.doi.org/10.3390/cryst11040448.
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Developing a technology for introducing alloy addition to liquid steel during the course of continuous casting process seems to be an interesting approach to enhancing the steelmaking process, especially as the effective introduction of micro-additives or non-metallic inclusion modifiers to the liquid steel is the key to the production of the highest-quality steel. This paper presents the results of investigation describing the process of liquid steel chemical homogenisation in the two-strand slab tundish. The alloy was fed to liquid steel by pulse-step method. Five tundish equipment variants with different flow control devices and alloy addition feeding positions were considered. The paper includes fields of liquid steel flow, alloy concentration vs. time curves, dimensionless mixing time, minimum time values and alloy concentration deviations at tundish outlets. The results pointed much more effectively with liquid steel mixing nickel than aluminium. For aluminium obtaining a 95% chemical homogenisation level requires three-fold more time. Moreover, it is definitely beneficial for chemical homogenisation to initiate the alloying process simultaneously in two sites. This procedure generates, among others, the least alloy deviation of concentration at tundish outlets.
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Singamneni, Sarat, Nicholas McKenna, Olaf Diegel, Darius Singh, and A. Roy Choudhury. "Rapid Manufacture in Light Metals Processing." Materials Science Forum 618-619 (April 2009): 387–90. http://dx.doi.org/10.4028/www.scientific.net/msf.618-619.387.
Full textAbstract:
As several of the free form fabrication processes progress with continuous process and material improvements, the feasibility of Rapid Manufacturing becomes more and more of a reality. Defined as the use of a Computer Aided Design (CAD) based automated additive manufacturing process to construct parts that are used directly as finished products and components, some of the rapid manufacturing processes are already competing with traditional processes such as injection moulding and progress is being made in applying the new technologies to the processing of metals, envisioning additive manufacture of high strength parts of unlimited complexity. While there have been quite a few successful attempts in the rapid production of complex medical implants using titanium alloys, 3D printing of sand moulds opens up yet another rapid manufacturing front, allowing for the rapid casting of aluminium and magnesium alloys. The effectiveness of such processes is yet to be researched in terms of process and product characteristics and the overall economy. This paper attempts to review some of the promising rapid manufacturing technologies for light metals processing and presents results of experimental investigations conducted to evaluate the effectiveness of the rapid casting process currently researched at the Rapid Product Development Centre of AUT University.