低碳钢连铸板坯表层凝固钩的特征

对不同浇铸条件下的低碳钢连铸板坯进行了凝固钩（Hook）的特征研究,根据凝固钩的形貌概括了凝固钩的不同类型,统计了凝固钩周围气泡和夹杂物的分布,讨论了不同浇铸参数对铸坯凝固钩深度的影响,并通过Bikerman方程和弯月面凝固理论对凝固钩的不同特征进行了解释.结果表明：按形貌可将凝固钩分为完整叶状、双凝固钩、弯曲截断型和二次凝固型四种类型,其中二次凝固型的凝固钩出现的概率最高为46.8%,而完整叶状、弯曲截断型和二次凝固型的凝固钩出现概率分别为25.3%、7.6%和6.3%;研究发现,凝固钩周围的夹杂物数量明显多于其他区域的夹杂物数量,说明凝固钩能够捕获结晶器内上浮的夹杂物;对比不同浇铸参数发现,采用结晶器电磁制动装置（FC-Mold）、减小结晶器水口浸入深度、增大浇铸拉速均能够减小凝固钩的深度;Bikerman方程的计算结果和弯月面凝固理论能在机理上解释凝固钩的形貌特征.     

Modeling superheat removal during continuous casting of steel slabs

To investigate superheat dissipation in a continuous slab casting machine, mathematical models have been developed to compute fluid flow velocities, temperature distribution within the liquid pool, heat transfer to the inside of the solidifying shell, and its effect on growth of the shell. Three-dimensional (3-D) velocity and heat-transfer predictions compare reasonably with pre-vious experimental measurements and two-dimensional (2-D) calculations. The results indicate that the maximum heat input to the shell occurs near the impingement point on the narrow face and confirm that most of the superheat is dissipated in or just below the mold. Superheat tem-perature and casting speed have the most important and direct influence on heat flux. The effects of other variables, including mold width, nozzle jet angle, and submergence depth, are also investigated. Calculated heat flux profiles are then input to a one-dimensional (1-D) solidifi-cation model to calculate growth of the shell. Shell thickness profiles down the wide and narrow faces are compared with the predictions of conventional heat conduction models and available measurements.     

The formation of oscillation marks in the continuous casting of steel slabs

The formation of oscillation marks on the surface of continuously cast slabs has been studied by metallographically examining slab samples and by performing a set of mathematical analyses of heat flow, lubrication, and meniscus shape in the meniscus region of the mold. The metallographic study has revealed that, in agreement with previous work, the oscillation marks can be classified principally according to the presence or absence of a small “hook” in the subsurface structure at the base of individual oscillation marks. The depth of the oscillation marks exhibiting subsurface hooks varies with the carbon content, reaching a maximum at about 0.1 pct carbon, while the oscillation marks without hooks show no carbon dependence. The analysis of heat flow at the meniscus, which is based on a measured mold heat-flux distribution, indicates that depending on the level of superheat, the meniscus may partially freeze within the period of a typical mold oscillation cycle. Lubrication theory has shown that, owing to the geometry of the mold flux channel between the solidifying shell at the meniscus and the straight mold wall, significant pressure gradients capable of deforming the meniscus can be generated in the flux by the reciprocating motion of the mold relative to the shell. A force balance on the interface between the steel and the mold flux has been applied to compute the shape of the meniscus as a function of the pressure developed in the lubricating flux at different stages in the mold oscillation cycle. This has demonstrated that the “contact” point between the meniscus and mold moves out of phase with (by π/2), and has a greater amplitude than, the mold displacement so that just at, or near, the end of the negative strip time molten steel can overflow at the meniscus. From these studies a reasonable mechanism of oscillation-mark formation emerges which involves interaction between the oscillating mold and the meniscusvia pressure gradients in the mold flux, meniscus solidification, and overflow. The mechanism is consistent with industrial observations. E. TAKEUCHI, on study leave from Nippon Steel Corporation     

Development of the continuous casting of steel at the Chelyabinsk Metallurgical Combine

In 2007, the electric steelmaking shop at the Chelyabinsk Metallurgical Combine operated with two continuous slab casters made by Uralmash, while the oxygen converter shop had two continuous section casters made by the Danieli company. It was decided that the two Uralmash casters will be replaced by a single Danieli caster. The shop has also mastered a technology for casting corrosion-resistant, reinforcement-grade, pseudo-rimming, and low-and medium-carbon steels. Plans call for further expansion of the range of grades of steel that can be cast.     

Modeling of the solidification process in a continuous casting installation for steel slabs

The development of a computational simulation system for modeling the solidification process in a continuous casting facility for steel slabs is discussed. The system couples a module for solving the direct problem (the calculation of temperatures in the steel strand) with an inverse analysis module that was developed for evaluating the steel/mold heat fluxes from the information provided by thermocouples installed in the continuous casting mold copper plates. In order to cope with the non-uniqueness of the inverse analysis, a priori information on the solution, based on the consideration of the problem physics, is incorporated. The stability of the system predictions are analyzed and the influence of the first trial used to start the evaluation procedure is discussed. An industrial case is analyzed.     

管线钢连铸板坯的半宏观偏析和凝固组织

研究了不同凝固组织下管线钢的中心偏析情况.低倍组织腐蚀结果表明,连铸板坯的中心偏析由相对独立的、大小不一的半宏观偏析点组成,且不同凝固组织的半宏观偏析特征有所差别.化学成分分析表明,中心等轴晶时板坯中心为负偏析,且贯穿于整个等轴晶区中,而中心为柱状晶时则表现为正偏析.通过对比化学成分和半宏观偏析面积比发现,板坯的半宏观偏析面积比随C和Mn最大偏析度的增加而增加,由于化学成分分析只能反应局部位置的偏析情况,因此半宏观偏析面积比的方法对生产实践更具有指导意义.对不同过热度下不同凝固组织的半宏观偏析面积比的统计结果显示,在合理使用轻压下技术的前提下,中心为柱状晶更有利于减轻半宏观偏析面积比,进而改善管线钢连铸板坯的中心偏析.     

不锈钢软接触电磁连铸的工业试验

 通过分析碳钢和不锈钢材质的电阻率差异性,以及304不锈钢软接触电磁连铸的中试试验结果,证实了不锈钢软接触电磁连铸的可行性。进而,在商业级规模铸机上分别开发了不锈钢圆坯和方坯软接触电磁连铸系统,进行了不同钢种、不同保护渣条件下的相关工业生产试验。结果表明,不锈钢圆坯和方坯软接触电磁连铸在不超过150 kW的电源输出功率条件下,均能获得较佳的振痕去除效果,改善铸坯表面质量。对获得的铸坯进行免修磨轧制成[?]8 mm线材,并经过固溶热处理以及酸洗等工序,使线材成品的综合成材率提高3%以上。多次生产试验采用不间断连浇方式,期间,软接触电磁连铸设备系统生产稳定可靠,未发现液面异常波动以及铸坯低倍组织卷渣等缺陷,使软接触电磁连铸技术向商业化生产运营迈出了关键一步。最后,讨论了软接触电磁连铸技术拓展至不锈钢板坯断面的可行性。     

Transient fluid flow and superheat transport in continuous casting of steel slabs

The turbulent flow of molten steel and the superheat transport in the mold region of a continuous caster of thin steel slabs are investigated with transient large-eddy simulations and plant experiments. The predicted fluid velocities matched measurements taken from dye-injection experiments on full-scale water models of the process. The corresponding predicted temperatures matched measurements by thermocouples lowered into the molten steel during continuous casting. The classic double-roll flow pattern is confirmed for this 132×984 mm slab caster at a 1.52 m/min casting speed, with about 85 pct of the single-phase flow leaving the two side ports of the three-port nozzle. The temperature in the top portion of the molten pool dropped to about 30 pct of the superheat-temperature difference entering the mold of 58 °C. About 12 pct of the superheat is extracted at the narrow face, where the peak heat flux averages almost 750 kW/m² and the instantaneous peaks exceed 1500 kW/m². Two-thirds of the superheat is removed in the mold. The jets exiting the nozzle ports exhibit chaotic variations, producing temperature fluctuations in the upper liquid pool of ±4 °C and peak heat-flux variations of±350 kW/m². Employing a static-k subgrid-scale (SGS) model into the three-dimensional (3-D) finite-volume code had little effect on the solution.     

Cooling systems in the continuous casting of slabs

The production of rolled bar and complex profiles from continuous-cast slab is considered. The proposed method includes water-based cooling systems and the introduction of consumable macrocooling units in the melt. This approach significantly reduces the axial segregation of chemical elements and the structural inhomogeneity of the blank, improves the plastic properties and improved strength of the rolled bar, and reduces the metal consumption.     

IF钢开浇阶段铸坯洁净度分析

由于IF钢生产过程中对开浇阶段铸坯质量判定不明确,因此在利用时容易导致产品质量问题而增加生产成本。通过对头坯不同位置进行取样,研究IF钢开浇阶段铸坯沿拉坯方向的洁净度变化。实验结果表明,IF钢开浇阶段铸坯中大型夹杂物主要来源于结晶器卷渣和中间包中来不及上浮的脱氧或二次氧化产物;从距离头坯头部2.5m位置开始,由结晶器卷渣所引入的大型夹杂物含量接近正常坯水平;距离头坯头部7.5m位置处开始N含量与正常坯含量基本持平,簇状Al_2O_3夹杂物数量及尺寸接近正常坯水平;距离头坯头部8.5m位置处开始全氧质量分数保持在20×10~(-6)左右。     

Heat flow,gap formation and break-outs in the continuous casting of steel slabs

A theoretical investigation of heat flow and gap formation in the mold of a continuous slab caster has been undertaken using a mathematical model, with the ultimate purpose of predicting the casting conditions which can lead to break-outs. The mathematical model that has been developed for this study is capable of treating the heat flow and air gap as coupled phenomena, and can accept operating variables such as slab size, casting speed, mold taper, and thermal conductivity of the mold powder, as input. Four different cases of slab casting have been investigated; and it has been found that hot spots can form on the surface of the slab within a few centimeters of the corners. Depending on their temperature, it is suggested that these hot spots may give rise to the formation of break-outs off the corners of the slab. From an examination of the behavior of the hot spots, the susceptibility of the cases studied to break-outs has been evaluated. The usefulness of the present analysis in qualitatively ascertaining the location and extent of mold wear under different casting conditions has also been examined. A. Grill was formerly affiliated.     

Advantageof anticlogging nozzles over conventional aluminographite nozzles in continuous casting of steel slabs

Abstract

The goal of this work was to establish the advantages of the application of anticlogging nozzles compared with conventional aluminographite nozzles in the continuous casting of steel slabs. Anticlogging nozzles are used in many steelmaking plants to inhibit scab formation at the internal side of the nozzle wall. The formation of aluminate-corundum scab decreases internal nozzle diameter, leading to the reduction of steel flow and eventual blocking of the nozzle. The results of monitoring the behaviour of a large number of conventional aluminographite and anticlogging nozzles in a campaign lasting two months are presented. The data reveal lower average values of internal erosion caused by the steel and reduced thicknesses of scab formed at the internal side of the anticlogging nozzle wall relative to conventional nozzles. At the same time, the average values of external erosion, caused by the action of ungranulated casting powders, were considerably increased relative to external erosion resulting from the action of granulated casting powder.     

Numerical simulation of Mo macrosegregation during ingot casting of high-Mo austenitic stainless steel

Mo macrosegregation was studied through the comparison of numerical simulation of the ingot pouring process and experiment on as-cast 500?kg high-Mo austenitic stainless steel ingot. The simulated results showed the evolution of temperature, melt velocity and the patterns of Mo macrosegregation, and revealed the effects of pouring temperature and cooling rate on macrosegregation. The predicted variation of Mo macrosegregation was compared with measurement values from an industrial ingot along the vertical centreline and horizontal direction. Severe normal and gravity segregation were observed. Although a basic agreement was obtained, the lack of a sufficiently fine numerical grid and the neglect of sedimentation for free equiaxed grains in the prediction brought about the absence of A-segregation and V-segregation. Further investigation would be needed to perform this investigation. The predicted results also confirmed that Mo macrosegregation in the ingot could be effectively diminished by improving cooling rate and decreasing pouring temperature.     

马氏体不锈钢方坯连铸工艺研究

由于马氏体不锈钢的物理特性,使得连铸过程中存在柱状晶发达、中心疏松、缩孔及表面凹陷严重等问题.针对上述情况,连铸过程中针对该钢种的凝同特点、高温物理特性等方面进行了研究,解决了马氏体不锈钢浇铸过程中的工艺问题,保证了产品的质量.     

Application of high-basicity mould fluxes for continuous casting of large steel slabs

Controlling the formation of longitudinal cracks on hypo-peritectic steel slab surfaces is one of the key challenges in continuous casting worldwide. Based on the production in Chongqing Iron & Steel Co., mould fluxes with high basicity ranging from 1.7 to 1.8 were put forward and the effects of compositions on the basic properties of mould flux were studied in the present paper. After laboratory experiments, a high-basicity mould flux with an increased crystallisation speed to abate the heat-transfer capability in the meniscus area was fully applied in the first steelmaking plant of Chongqing Iron & Steel Co. Using the high-basicity mould flux, for more than 3 million tonnes of slab production, the large longitudinal crack was eliminated and the rate of formation of small longitudinal cracks decreased greatly. During the production process, sticking that impedes the smooth running of continuous casting was infrequent, and the spot check for longitudinal cracks on micro alloy steel surface was simplified in the slab finishing process. Furthermore, since the application effect of mass production is remarkable, the hot charging process is better implemented, and the contract can be accomplished in time. In summary, the problem of longitudinal cracks on hypo-peritectic steel slab surfaces is finally resolved and the high-basicity mould fluxes have become indispensable auxiliary materials during continuous casting of hypo-peritectic steel.     

A new mechanism of hook formation during continuous casting of ultra-low-carbon steel slabs

The initial stages of solidification near the meniscus during continuous casting of steel slabs involve many complex inter-related transient phenomena, which cause periodic oscillation marks (OMs), subsurface hooks, and related surface defects. This article presents a detailed mechanism for the formation of curved hooks and their associated OMs, based on a careful analysis of numerous specially etched samples from ultra-low-carbon steel slabs combined with previous measurements, observations, and theoretical modeling results. It is demonstrated that hooks form by solidification and dendritic growth at the liquid meniscus during the negative strip time. Oscillation marks form when molten steel overflows over the curved hook and solidifies by nucleation of undercooled liquid. The mechanism has been justified by its explanation of several plant observations, including the variability of hook and OM characteristics under different casting conditions, and the relationships with mold powder consumption and negative/positive strip times.     

Surface segregation in austenitic stainless steel

We report in this paper a study of surface segregation in austenitic stainless steel. Auger electron spectroscopy was used to measure segregation as a function of time and temperature. We have found that P, N, S, Cr, and Ni will all segregate to the surface. However, their presence on the surface often depends on the competitive and attractive interactions between the various elements. We show that thermodynamic data on ternary liquid iron alloys are quite valuable in predicting these interactions. We also discuss possible applications of these studies.     

Carbon paraequilibrium in austenitic stainless steel

Carburization of austenitic stainless steels under paraequilibrium conditions—i.e., at (low) temperatures where there is essentially no substitutional diffusion—leads to a family of steels with remarkable properties: enhanced hardness, resulting in improved wear behavior, enhanced fatigue, and corrosion resistance, and with essentially no loss in ductility. These enhanced properties arise from an enormous carbon solubility, which, absent carbide formation, is orders of magnitude greater than the equilibrium solubility. Using interaction parameters from the latest CALPHAD assessment of the Fe-Cr-Ni-carbon system, the authors have calculated the equilibrium and paraequilibrium carbon solubility in a model Fe-18Cr-12 Ni (wt pct) austenitic steel (essentially a model 316L composition), as well as the carbon solubility in this austenite when paraequilibrium carbide formation occurs (i.e., when carbides form in a partitionless manner). For temperatures in the range 725 to 750 K, the calculations predict a paraequilibrium carbon solubility of ～5.5 at. pct. Carburization of 316L stainless steel at these temperatures, however, results in significantly higher concentrations of carbon in solid solution—up to 12 at. pct. Much better agreement with experimental data is obtained by calculating the paraequilibrium carbon solubility using Wagner interaction parameters, taken from the most comprehensive experimental study of this system. The discrepancy between the two predicted solubilities arises because the CALPHAD Cr-carbon interaction parameters are not sufficiently exothermic at the low temperatures used for paraequilibrium carburization. After multiple paraequilibrium carburization cycles, carbide formation can occur. The carbides that form under these conditions do so in a near-partitionless manner (there is modest Ni rejection to the austenite/carbide interface) and have an unusual stoichiometry: M₅C₂ (the Hägg or η carbide).