Academic literature on the topic 'Mould Flux Powders'
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Journal articles on the topic "Mould Flux Powders"
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Liu, Li Na, Xiu Li Han, Chang Cun Li, and Hui Ping Yang. "Effect of Mold Flux for Casting on Microstructe of Mould Powder." Advanced Materials Research 194-196 (February 2011): 287–91. http://dx.doi.org/10.4028/www.scientific.net/amr.194-196.287.
Full textAbstract:
The microstructe of mold fluxes of low-carbon steel and mould powders were researched by means of polarizing microscope. The result shows that the mineral compositions of the mould fluxes primarily are glass phase, wollastonite, quartz, melilite, pyroxene and feldspar. The main mineral compositions of mould powders is melilite. The quartz, pyroxene and glass phase are helpful to reduce the crystalline portion of mould powder, but the melilite, wollastonite help to improve the crystalline portion and promote crystallization of melilite. It is good for the crystalline portion when the casting speed droop.
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Hariharan, Ashok, and Samir Kumar Mozumdar. "Evolution of Mould Fluxes." Advanced Materials Research 794 (September 2013): 75–89. http://dx.doi.org/10.4028/www.scientific.net/amr.794.75.
Full textAbstract:
Mould flux was invented for bottom poured ingots using fly ash as raw material. It transited subsequently to synthetic raw materials. As continuous casting of steel developed, Fluxes in fine powder form evolved culminating to the development of environment friendly fluxes in granular form. As continuous casting of stainless steel commenced different powders were developed for different Stainless qualities like austenitic, ferritic etc. Powders developed from interface with users were not only to satisfy demand of lubrication in the mould but also for adequate heat transfer and better surface quality. Shrinkage in mould, interplay of the elements in steel during casting with mould slag, tendency of the steel grades towards cracking or sticking and influence of various casting parameters determined mould powder development and usage. In-mould Powder performance dynamically reacts to changes in casting parameters and conditions and appropriate changes in powder chemistry can overcome or minimise detrimental effects of such changes. Future demands of overall cost control, better surface quality, minimal grinding, stable meniscus will guide powder research and development alongwith focus on environmental concerns.
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Drożdż, P. "Analysis of the Equilibrium State of Flux Powders in the Mould During Continuous Casting of Steel." Archives of Metallurgy and Materials 60, no. 1 (April 1, 2015): 263–68. http://dx.doi.org/10.1515/amm-2015-0042.
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Abstract Mould fluxes in the continuous casting of steel perform a protective function against oxidizing effect of the atmosphere on liquid metal, reduce friction between the solidifying steel shell and the walls of the mould and regulate the transfer of heat to the mould walls. Their chemical composition is crucial as it impacts the determination of the characteristic temperatures. The paper presents calculation results of the equilibrium composition of the selected mould powders in thermodynamic conditions similar to the actual conditions during continuous casting of steel slabs based on FactSage. The calculations were verified by high temperature tests of mould flux powders.
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Sarkar, Rahul, and Zushu Li. "Isothermal and Non-isothermal Crystallization Kinetics of Mold Fluxes used in Continuous Casting of Steel: A Review." Metallurgical and Materials Transactions B 52, no. 3 (April 2, 2021): 1357–78. http://dx.doi.org/10.1007/s11663-021-02099-5.
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AbstractCasting powders or mold fluxes, as they are more commonly known, are used in the continuous casting of steel to prevent the steel shell from sticking to the copper mold. The powders first melt and create a pool of liquid flux above the liquid steel in the mold, and then the liquid mold fluxes penetrate into the gap between water-cooled copper mold and steel shell, where crystallization of solid phases takes place as the temperatures gradually drop. It is important to understand the crystallization behavior of these mold fluxes used in the continuous casting of steel because the crystalline phase fraction in the slag films plays a crucial role in determining the horizontal heat flux during the casting process. In this work, the existing literature on the crystallization kinetics of conventional and fluoride-free mold fluxes used in the continuous casting of steel has been reviewed. The review has been divided into two main sections viz. the isothermal crystallization kinetics and non-isothermal crystallization kinetics. Under each of these sections, three of the most widely used techniques for studying the crystallization kinetics have been included viz. thermoanalytical techniques such as differential scanning calorimetry/differential thermal analysis (DSC/DTA), the single and double hot thermocouple technique (SHTT and DHTT), and the confocal scanning laser microscopy (CSLM). For each of these techniques, the available literature related to the crystallization kinetics of mold fluxes has been summarized thereby encompassing a wide range of investigations comprising of both conventional and fluoride-free fluxes. Summaries have been included after each section with critical comments and insights by the authors. Finally, the relative merits and demerits of these methods vis-à-vis their application in studying the crystallization kinetics of mold fluxes have been discussed.
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Li, Guang Qiang, Ai Da Xiao, De Zhi Wen, Guo Hua Jiao, Bai Ping Zheng, and Jie Fu. "Study on the Production of Ti Micro-Alloyed High Strength Hot Rolled Steel by CSP Process." Materials Science Forum 654-656 (June 2010): 230–33. http://dx.doi.org/10.4028/www.scientific.net/msf.654-656.230.
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Ti micro-alloyed high strength hot rolled steel was developed in Valin Lianyuan Steel in the CSP line. The cleanliness of liquid steel was good enough for thin slab casting after LF refining. The mould powder was adjusted for stabilizing the heat flux of thin slab continuous casting mould. Homogeneous microstructure consisting of ferrite and pearlite was obtained in the hot rolled steel plates by the improving of rolling process. The nano-scale precipitates of Ti(C, N) and Nb(C, N) is the main strengthening mechanism. The yield strength of developed hot rolled plate is higher than 660 MPa and the tension strength is 760 MPa. The ductile-brittle transition temperature is below -60 degree Celsius. The developed Ti alloyed steel with designed composition fulfils the requirements of 600 MPa grade steel for engineering machinery.
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Chung, Joon Yang. "Improvements & Innovations in the Continuous Casting Process at POSCO." Materials Science Forum 561-565 (October 2007): 3–4. http://dx.doi.org/10.4028/www.scientific.net/msf.561-565.3.
Full textAbstract:
Continuous casting is the essential process converting liquid steel to solid in the form of slabs or billets/blooms in the steel plant. The economy and quality of the steel products are greatly dependent on how successfully the continuous casting is performed. New technologies have been actively developed in the process during the last decades in order to increase the productivity and, therefore, to decrease the operational cost. Since its first commissioning of a slab caster in 1976, POSCO has constructed a number of continuous slab, bloom and billet casters including a thin slab caster not only for plain carbon steels but for stainless steels. Through the operation of various types of continuous casters for more than 30 years so far, POSCO has steadily developed fundamental technologies and operational know-how and achieved the equipment innovations to improve the surface and internal qualities of cast products as well as to extend the productivity of continuous casters. Furthermore, POSCO has deepened the basic understanding on the solidification phenomena of liquid steel and also accumulated the engineering backgrounds to design the most optimal continuous casters. It has also devised the indispensable and auxiliary equipments and the key technologies to control the process precisely and efficiently in order to guarantee the quality and productivity. An innovative technology under development is the POCAST process, where controlled amount of the pre-molten mold flux instead of conventional powder mold flux is continuously fed into free surface of molten steel through the plunger-type feeding system from the flux melting furnace. In order to prevent the molten flux from freezing at the meniscus, a reflective insulation cover is installed, leading to the suppression of thermal radiation from the molten steel and flux. It is generally understood that, as casting speed increases, the occurrence of breakout increases since mold lubrication becomes insufficient due to the lack of mold flux flow from the meniscus into the solid shell/mold boundary. However, by utilizing the especially composition controlled pre-molten flux, it becomes possible to eliminate the formation of slag bear in the mold. Therefore, the mold flux consumption rate is increased even at the reduced oscillation rate & stroke and more importantly, the mold flux infiltration becomes more uniform throughout the boundary between the mold and the solidified shell. This consequently results in drastic reduction of the formation and depth of the oscillation mark and the occurrence of surface hooks without increasing the possibility of breakout, as has been proved in the casting trials carried out with the 10 ton pilot slab caster in Pohang. A key trend in the development of the continuous casting process is to reduce the thickness of cast products. Examples include thin slab casting and strip casting. In the thin slab casting process, a major drawback is the relatively low casting speed and, as a result, the inefficient equipment layout in the plant where two casters are connected to a hot rolling unit. The drawback could be resolved if the casting speed exceeds a certain limit. At the high casting speed, the productivity of casting becomes equivalent to that of hot rolling, and the thin slab casting plant is to be designed so that one strand
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Jafari, Hassan, Mohd Hasbullah Idris, Ali Ourdjini, and Saeed Farahany. "Oxidation and Melting Characterizations of AZ91D Granules during In Situ Melting." Advanced Materials Research 311-313 (August 2011): 631–34. http://dx.doi.org/10.4028/www.scientific.net/amr.311-313.631.
Full textAbstract:
In this research, the oxidation and melting behaviour of AZ91D magnesium alloy granules was investigated throughout using in-situ melting technique when the granules were covered by flux. The granules were heated inside an electrical resistance furnace at four different temperatures of 650, 700, 750 and 800 °C for 30 min. Thermal analysis was used to detect the granules characteristic temperatures during the technique. The products of the heating process were examined visually and characterized by scanning electron microscopy and energy dispersive X-ray spectroscopy. The results showed that due to occurrence of severe oxidation and combustion, particularly at 800 °C, a significant amount of the granules transformed to a powdered state. The presence of the mould materials within the oxidation residue was detected indicating that severe mould-magnesium reaction occurred during heating. It was found that the granules melted during the heating process. However, the presence of oxides on the granules prevented them from fusing to form a single melt.
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Guo, En Yu, Qiwei Zheng, and T. Jing. "Numerical Simulation of Solidification of Thick-Wall Stainless Steel Pipe in Horizontal Centrifugal Casting Process." Materials Science Forum 706-709 (January 2012): 1427–32. http://dx.doi.org/10.4028/www.scientific.net/msf.706-709.1427.
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A mathematical model of the horizontal centrifugal casting process based on the cast cylindrical coordinates for stainless steel pipe has been developed. Thermal boundary conditions, including the radiative and convective heat transfer conditions, have been taken into consideration. The model equation was solved numerically using non-uniform cylindrical grids and the finite differential method (FDM). Several parameters of casting process such as melt superheat, preheating temperature of mold, thermal conductivity of coating and flux powder, which affect the temperature distributions in both cast pipe and mold and the changed positions of melt solidifying at last are investigated. In order to verify the results of simulation, calculated temperatures were compared with the experimental data.
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Changizi, Ahmad, Mamoun Medraj, and Mihaiela Isac. "Effect of Casting Parameters on the Microstructural and Mechanical Behavior of Magnesium AZ31-B Alloy Strips Cast on a Single Belt Casting Simulator." Advances in Materials Science and Engineering 2014 (2014): 1–9. http://dx.doi.org/10.1155/2014/101872.
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Strips of magnesium alloy AZ31-B were cast on a simulator of a horizontal single belt caster incorporating a moving mold system. Mixtures of CO2and sulfur hexafluoride (SF6) gases were used as protective atmosphere during melting and casting. The castability of the AZ31-B strips was investigated for a smooth, low carbon steel substrate, and six copper substrates with various textures and roughnesses. Graphite powder was used to coat the substrates. The correlation between strip thickness and heat flux was investigated. It was found that the heat flux from the forming strip to the copper substrate was higher than that to the steel substrate, while coated substrates registered lower heat fluxes than uncoated substrates. The highest heat flux from the strip was recorded for casting on macrotextured copper substrates with 0.15 mm grooves. As the thickness of the strip decreased, the net heat flux decreased. As the heat flux increased, the grain sizes of the strips were reduced, and the SDAS decreased. The mechanical properties were improved when the heat flux increased. The black layers which formed on the strips’ surfaces were analyzed and identified as nanoscale MgO particles. Nano-Scale particles act as light traps and appeared black.
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Couture, Rex A. "An Improved Fusion Technique for Major-Element Rock Analysis by XRF." Advances in X-ray Analysis 32 (1988): 233–38. http://dx.doi.org/10.1154/s0376030800020528.
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AbstractA new apparatus and technique are described for borate flux fusion of rocks for x-ray fluorescence analysis. The method yields homogeneous, strain-free glass discs with flat, smooth surfaces that do not require polishing. The technique is adapted from several previous methods but has advantages over each in terms of sample uniformity, quality of the discs, or capital cost. The ignited rock powder is fused with flux over a burner mounted on a stock laboratory mixer, and is cast into a solid flat, polished Pt-Au mold. The very effective mixing action ensures homogeneity An oxidizing atmosphere, which is necessary to prevent loss of iron to the crucibles, is maintained by injecting air during fusion.There is no significant loss of alkali metals during fusion, and negligible loss of flux. Duplicate samples of several rock types show excellent reproducibility, approaching counting statistical errors, for 10 major elements.
Dissertations / Theses on the topic "Mould Flux Powders"
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Elahipanah, Zhaleh. "Thermo-Physical Properties of Mould Flux Slags for Continuous Casting of Steel." Thesis, KTH, Materialvetenskap, 2012. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-101270.
Full textAbstract:
Due to the high efficiency and productivity of continuous casting process, this method has been the most employed process to produce steel in past decades. The need to improve and optimize the finished product made it essential to gain more knowledge about the process, types of defects that may occur and the reasons for them. Moreover, the solutions for reducing the shortcomings in continuous casting process have been an intriguing subject to study. Many attempts have been done in order to reach this goal. Understanding, determining and optimizing the mould flux slag properties is especially important, since it plays an important and significant role in this process. For this, it is of outmost importance to acquire more knowledge about different properties of mould flux powders. Hence, there has been a world wide effort to measure and model the properties of mould flux properties, such as liquidus and solidus temperatures, heat capacity, enthalpy, thermal expansion, density, viscosity, electrical conductivity, surface tension and thermal conductivity. This thesis presents a brief review on continuous casting process, mould flux powder and its properties and characteristics. Furthermore, it focuses on the thermo-physical properties of mould fluxes. In present work, different industrial mould flux powders have been analyzed to measure their viscosity, break temperature, physical properties such as density, flowablity of powder, slag structure and chemical composition. The experimental data have been compared to some of the most commonly used models such as Riboud model, Urbain model, Iida model and KTH model.
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Pinheiro, Carlos A. M. "Mould thermal response, billet surface quality and mould-flux behaviour in the continuous casting of steel billets with powder lubrification." Thesis, National Library of Canada = Bibliothèque nationale du Canada, 1998. http://www.collectionscanada.ca/obj/s4/f2/dsk3/ftp05/nq27226.pdf.
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Pinheiro, Carlos A. M. "Mould thermal response, billet surface quality and mould-flux behaviour in the continuous casting of steel billets with powder lubrication." Thesis, 1997. http://hdl.handle.net/2429/8560.
Full textAbstract:
The main objectives of this study were to examine mould thermal response and billet
surface quality during continuous casting of steel billets with powder lubrication, and to
compare with oil lubrication. Measurements were carried out on an operating billet caster to
determine mould-wall temperature profiles for different mould-flux types, mould coolingwater
velocity, oscillation frequency and steel grade. The trial involved data acquisition on
mould displacement, casting speed, metal level and mould powder temperature field. In
addition, mould powder consumption and liquid flux pool depth were also measured.
An inverse heat conduction model was developed to determine mould heat flux from
measured mould wall temperatures. Existing mathematical models were utilized to investigate
mould/billet binding and mould taper. Results from plant measurement, mathematical models
and billet sample evaluation were used to compare mould-powder and oil casting in terms of
mould thermal response, transverse depression, rhomboidity, oscillation mark and mould level
variation. Finally, a mathematical model was developed to analyze the influence of mould-flux
properties and feeding strategies on melting behaviour.
This work has led to a very comprehensive understanding of mould thermal response and
mould-related quality problem in billet casting with powder lubrication. Transverse
depressions were found to be formed in steel grades with high coherency temperature due to
metal level fluctuation. For Boron(Ti)-alloyed medium-carbon steel cast with powder
transverse depressions were eliminated due to a substantial decrease in meniscus heat flux,
thus producing a thinner, hotter, more flexible shell, and also due to lower metal level
fluctuations on account of pouring with SEN. An understanding of the role of titanium and nitrogen on transverse depressions resulted in
the establishment of maximum values for these elements. In order to minimize transverse
depression in billet casting with oil lubrication the nitrogen content of the steel must be kept
below 60 ppm and the titanium content below 0.019%.
Mathematical modelling of billet shrinkage, corroborated by billet inspection, showed that
excessive mould taper caused the mould to squeeze the solidifying shell which led to the
formation of longitudinal depressions. To eliminate this problem a double mould taper with
1.8% m⁻¹ up to 450 mm from the mould top and 0.9% m⁻¹ for the rest of the mould is
recommended. Mathematical modelling of mould powder melting has led to further
understanding of the response of the molten-flux pool to changes in powder properties,
feeding strategies and casting speed.
Book chapters on the topic "Mould Flux Powders"
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Mills, Kenneth C., and Carl-Åke Däcker. "Effect of Casting Variables on Mould Flux Performance." In The Casting Powders Book, 147–75. Cham: Springer International Publishing, 2017. http://dx.doi.org/10.1007/978-3-319-53616-3_5.
Full textConference papers on the topic "Mould Flux Powders"
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Boutaous, M., E. Pe´rot, A. Maazouz, P. Bourgin, and P. Chantrenne. "Heat Transfer and Air Diffusion Phenomena in a Bed of Polymer Powder Using Apparent Heat Capacity Method: Application to the Rotational Molding Process." In ASME/JSME 2007 5th Joint Fluids Engineering Conference. ASMEDC, 2007. http://dx.doi.org/10.1115/fedsm2007-37181.
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The process of rotational moulding consists in manufacturing plastic parts by heating a polymer powder in a biaxial rotating mould. In order to optimise the production cycle of this process, a complete simulation model has to be used. This model should describe the phenomena of heat and mass transfer in a moving granular media with phase change, coalescence, sintering, air evacuation and crystallization during the cooling stage. This paper focus on the study of heat and mass transfer in a quiescent polymer powder during the heating stage. An experimental device has been built. It consists in an open plane static mold on which an initial thickness, e, of a polymer powder is deposited. This powder is then heated until it melts. An inverse heat conduction method is used to determine the heat flux and temperature at the interface between the mold and the powder. This interfacial heat flux is taken as a boundary condition in a numerical heat transfer model witch takes into account the heat transfer in granular media with phase change, coalescence, sintering, air bubbles evacuation and rheological behaviour of the polymer. For the numerical simulation of the heat transfer, the apparent specific heat method is used. This approach allows to solve the same energy equation for all the material phases, so one do not have to calculate the melting front evolution. This fine modelling, close to the real physical phenomena makes it possible to estimate the temperature profile and the evolution of the polymer powder characteristics (phase change, air diffusion, viscosity, evolution of the thermophysical properties of the equivalent homogeneous medium, thickness reduction, air volume fraction...). Several results are then presented, and the influence of different parameters, like the thermal contact resistance, the process initial conditions and the polymer’s rheological characteristics are studied and commented. Indeed the predictions of the temperature rises in the polymer bed, agree well with the experimental measurements.
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Pan, Yi, Jeffrey Thomas, and Chris Propes. "Heat Transfer Coefficient of a Graphite Mold Quenched by Water." In ASME 2019 Heat Transfer Summer Conference collocated with the ASME 2019 13th International Conference on Energy Sustainability. American Society of Mechanical Engineers, 2019. http://dx.doi.org/10.1115/ht2019-3731.
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Abstract Metal matrix composites (MMCs) can be manufactured by infiltrating a melting matrix alloy into hard powders — such as silicon carbide and tungsten carbide — loaded in a graphite mold and quenched to achieve a specific quenching temperature profile for proper solidification. Water quench is a widely used quenching technique within the aluminum and steel industry. It is more common to apply numerical simulation to optimize process parameters and help improve product quality, which depends upon reliable boundary conditions (e.g., heat flux or heat transfer coefficient); however, heat transfer coefficient changes with surface temperature and water flow rate. Moreover, the heat transfer coefficient in the discussed manufacturing process was never quantified. A combined experimental and simulation method to investigate heat transfer coefficient of the external surface of the graphite mold associated with water quenching is proposed. Firstly, the heat flux from the graphite mold is measured, which varies with water flow rate, mold surface temperature, nozzle arrangement, and water flow pattern. Without modifying the hardware design, this study focuses on the effects of water flow rate and mold surface temperature on surface heat flux. Secondly, the temperature distribution within the mold is used to inversely determine the heat transfer coefficient by solving an inversed optimization problem.
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Ghosh, Kalyanjit, and Srinivas Garimella. "Dynamic Modeling of Thermal Processes in Rotational Molding." In ASME 2004 Heat Transfer/Fluids Engineering Summer Conference. ASMEDC, 2004. http://dx.doi.org/10.1115/ht-fed2004-56801.
Full textAbstract:
Transient heat transfer phenomena in the rotational molding of plastic parts are modeled in this study. Natural convection and radiation from the furnace and flue gases to the mold housing are analyzed. Other models include transient heat transfer through the mold, single-phase conduction through the particulate plastic material prior to phase change, melting of the plastic, and heating of the liquid pool. Subsequent staged cooling and solidification of the mold and plastic using a combination of free and forced convection and radiation is also modeled. Information about the properties of the plastic in powder, liquid and solid forms is obtained from the literature. Assumptions about the behavior of the plastic powder and the molten plastic during the rotational operations are also made in accordance with the available literature. The mold wall, melt and solidified plastic regions are divided into a number of finite segments to track the temperature variation with time during the molding process. The corresponding variations in masses and thicknesses of the melt and solidified plastic regions are also estimated. Consequently, the energy consumption rates in the process are estimated. The model is applied to a specific molding process in a commercial rotational molding plant. Parametric studies of the effect of heating and cooling durations on the plastic temperatures and the energy consumption rates are also conducted. These analyses provide insights about opportunities for optimization of the heating and cooling schedules to reduce overall energy consumption and also improve throughput.