拉速波动对GCr15轴承钢250 mm×280 mm连铸坯内部质量的影响

试验用GCr15轴承钢的生产工艺为100 t BOF-LF-RH-250 mm×280 mm连铸坯-Φ70 mm轧材。用碳截面偏析检验、射钉试验及高倍检验等分析检测方法,研究了结晶器冷却水2 530 L/min,钢水过热度33~37℃,二冷比水量0.12 L/kg,M-EMS 530 A/2.5 Hz,F-EMS 400 A/3.0 Hz参数下,GCr15轴承钢连铸坯拉速0.52~0.58m/min对连铸坯轴承钢碳偏析、坯壳厚度及末端凝固位置和Φ70 mm轧材带状的影响。结果表明,随着连铸拉速的提升,铸坯的宏观碳偏析先呈现下降后呈现上升趋势,凝固末端位置后移,液相穴长度变长,拉速控制在0.55m/min,有利于降低铸坯的宏观碳偏析和轧材球化退火后的带状组织级别。     

结晶器电磁搅拌对轴承钢大方坯碳偏析的影响

针对南钢大方坯连铸机轴承钢连铸电磁搅拌冶金效果不明显的问题,开展了优化轴承钢连铸结晶器电磁搅拌工艺参数的试验,对不同电磁搅拌参数及搅拌方式下铸坯和轧材碳偏析进行了研究。结果表明:大方坯心部和边部均为负偏析,1/4处为正偏析,320 mm×480 mm大方坯碳偏析指数基本在0.87～1.05,轧材碳偏析指数基本在0.94～1.03;正反交替的电磁搅拌有利于降低碳偏析,电磁搅拌的电流参数较大时,心部的负偏析较严重,随着搅拌电流的增大,产生的白亮带向铸坯中心移动并且白亮带宽度增大;轴承钢铸坯中的碳偏析会遗传到轧材上。     

国内外2205双相钢连铸坯凝固组织及碳偏析分析

以国内外两家先进不锈钢生产企业的2205双相不锈钢连铸方坯为研究对象,对比分析了其相应的凝固组织特征和宏观碳偏析分布。研究发现,国外2205连铸坯凝固组织柱状晶较为发达,柱状晶比例为76%,宏观碳偏析总体较低;而国内2205连铸坯等轴晶占主要部分,等轴晶比例为58%,存在严重的中心碳偏析。通过进一步对比国外样品柱状晶区和等轴晶区的致密度得出,柱状晶区平均致密度为0.89,高于等轴晶的0.84,高致密度的凝固组织对降低宏观偏析有利。因此,为了获得较为均匀的连铸坯成分和较低的宏观偏析度,合理的柱状晶和等轴晶比例非常重要。     

GCr15轴承钢大方坯凝固过程微观偏析模型及应用研究

建立了考虑δ/γ相变的GCr15轴承钢大方坯连铸凝固两相区溶质微观偏析模型,并应用于220 mm ×260 mm铸坯的凝固传热。结果表明:通过模型可以获得高碳钢精确的固液相线温度,以及温度与固相率的关系;GCr15轴承钢大方坯凝固过程仅析出γ相,凝固末期S、P和C元素的偏析严重;固相率越大,冷却速率对偏析度的影响更明显;S和P元素含量以及冷却速率对零塑性温度（ZDT）影响较大;采用基于凝固传热模型优化的连铸工艺后,铸坯中心碳偏析指数控制在0.961.05,且铸坯未产生内裂纹。     

连铸轻压下技术对轴承钢中心碳偏析的影响

介绍了连铸轻压下技术在江阴兴澄特种钢铁有限公司GCr15轴承钢上的应用,通过对连铸坯上的碳硫分析和心部区域的原位分析,研究了不同轻压下参数下轴承钢中心碳偏析的变化趋势。     

连铸凝固过程宏观偏析的形成机理及预防措施

连铸坯的宏观偏析是影响钢材质量的重要原因之一,宏观偏析形成的本质原因是凝固过程固、液两相发生对流。对连铸凝固过程引起钢液流动的原因如外力强制对流、鼓肚、凝固收缩等进行了总结,并对这些原因造成宏观偏析的机理进行了分析。低过热度浇注、电磁搅拌、凝固末端液芯压下等技术是解决连铸坯宏观偏析的有效措施,然而单一的方法无法完全消除连铸坯宏观偏析,要完全解决铸坯宏观偏析应针对不同类型的偏析,采取相应的方法提高铸坯成分均匀性。     

4孔浸入式水口结晶器钢水流场的仿真分析及其在连铸生产中的应用

为减少轴承钢300 mm×300 mm连铸坯的碳偏析,通过CFX-4.4软件仿真分析了连铸结晶器内钢水流动和传热凝固过程,探讨了有关工艺参数和浸入式水口结构的关系。实践表明,通过4孔水口替代直孔水口,铸坯的碳偏析级别由1.0～2.0级降至1.0～1.5级,采用4孔水口中心碳偏析≤1.0级占79%,直孔水口仅为50%。     

GCr15连铸坯中心碳偏析原位分析研究

采用原位分析方法对不同拉速下、有(无)电磁搅拌等因素下的冷却连铸坯进行原位分析,得到大面积钢材料中化学成分分布情况并给出宏观、微区表征图谱和一些统计参数;再通过正交法找出最优的连铸工艺参数,使轴承钢GCr15连铸坯中心碳偏析控制得到优化。     

小方坯齿轮钢连铸过程中的宏观偏析模拟

基于国内某厂齿轮钢小方坯连铸生产过程,利用ProCAST软件建立移动切片模型,能够高效模拟连铸过程中的宏观偏析,模型分别模拟研究了不同过热度、二冷水量和拉坯速度等对宏观偏析的影响。模拟结果与碳偏析检测结果吻合良好,验证了移动切片模型模拟连铸坯宏观偏析的准确性。由于溶质浮力的影响,内弧侧的宏观偏析强于外弧侧。随着过热度的增加,铸坯中心碳偏析度从1.06增加至1.15。过热度控制在25 ℃范围内,可以保证铸坯的宏观碳偏析度控制在1.10范围内。随着连铸二冷水量的增加,铸坯中心偏析改善程度较小,铸坯中心碳偏析度从1.16降低至1.13。随着拉坯速度的增加,铸坯中心偏析呈现加重的趋势,铸坯中心碳偏析度由1.14增加至1.21,拉坯速度控制在1.4 m·min–1范围内,可保证铸坯中心碳偏析度低于1.15。      

中心偏析原因、危害、评定及预防(上)

偏析是液态钢凝固时各部位发生凝固不同时性和温度不均匀性而出现程度之差，它是由于物理作用引起的。连铸坯中心偏析是指位于铸坯中心部位的碳、磷、硫、锰等元素集聚变化而使含其突然升高（成分出格）的偏析出象。它基本上是一种宏观偏析或称半宏观偏析，与钢锭中存在的...     

The 3-dimensional structure of macrosegregation in continuously cast high-carbon steel

Three-dimensional segregation maps were obtained by serially sectioning rolled billets of high carbon steel. The sections were macroetched to reveal phosphorus segregation then digitised and combined using a computer. Volume rendering software was used to create images that represented views of continuously cast blooms with unsegregated steel transparent and macrosegregation opaque. The images showed the overall V-structure of macrosegregation and channel like morphology of individual macrosegregates. Samples with a fully columnar structure and a mixed columnar-equiaxed structure were compared. A large equiaxed zone disperses the macrosegregation over a wider area and increases the angle and length of channels. The observed structures suggest that macrosegregation forms through a combination of internal hot tearing and erosion of solid by flowing segregated liquid.     

Some effects of electromagnetically induced fluid flow on macrosegregation in continuously cast steel

Electromagnetically induced and controlled flow of the molten metal inside the solid shell has been found to be a technique for controlling solidification structures and centerline segregation in continuously cast steel billets. Measurements of centerline segregation in steel billets solidified under induced flow indicate a reduction of centerline segregation by a factor of two for carbon, phosphorus, sulfur, chromium, and nickel, and somewhat smaller improvements for other elements. The type of induction stirring technique applied was found to have a substantial effect on the macrosegregation patterns found in the billets solidified under induced flow.     

A Study of Surface Deformation during Wire‐Rod Rolling of High Speed Steels using Experimental and Computational Techniques

The evolution of surface defects during shape rolling of high‐speed steel billets is studied using longitudinal surface defects prepared by machining and welding. The reduction of the defects during rolling in a production mill is compared to the total area reduction of the billets. Samples are collected after pass 4, 6, 8, 14, 19 and the final pass, 28, representing the finished 5.5mm wire. By inspecting the cross sections, the rotation of the billets from pass to pass is evaluated. Results from FE simulations on solid billets are compared to the experimental results. Generally, simulations predict less reduction than observed experimentally. In most cases cracks reduce most effectively followed by carbon steel welds and stainless steel welds.     

Effect of permanent magnet stirring on internal quality of steel

Permanent magnet stirring (PMS) featuring low power dissipation and high-intensity magnetic field was investigated as a means of decreasing internal solidification defects. In this study, the magnetic Taylor number (Ta) was used to quantify the melt ?ow. Initial research of PMS involved a laboratory study of the solidification of Sn–20 wt-% Pb alloy. An industrial plant trial with continuously cast tire cord steel confirmed that PMS, in accord with the laboratory findings, produced an improvement in central cavities in the cast product. Moreover, it was established that PMS is an alternative method for reducing carbon macrosegregation in tire cord steel billets with different section sizes. It was also found that PMS (Ta?=?8.97?×?10⁷) was more effective for improving central carbon macrosegregation of tire cord steel than electromagnetic stirring (Ta?=?6.33?×?10⁷) due to the larger Ta related to the driven-flow intensity of the residual melt.     

工艺参数对连铸轴承钢坯碳偏析的影响

研究了二次冷却带电磁搅拌和冷却强度对高碳铬轴承钢连铸坯偏析的影响,并对“白亮带”及中心碳偏析的形成机理及其影响因素进行了较为系统的分析,提出了改善偏析的措施。试验结果表明,采用搅拌电流为１３０Ａ、搅拌方式为“左旋１０ｓ停７ｓ右旋１０ｓ”快频交替间歇式弱搅拌和适当的二冷制度（０．４Ｌ／ｋｇ左右）,轴承钢坯的质量将得到明显的改善     

重轨混钢区钢坯碳含量分布及轨性能研究

以包钢5#铸机对称六流中间包结构为研究对象,通过对上下炉成品中间包碳差大于0.03%的中包混钢区部分的钢坯及所轧钢轨横、纵向断面上的碳含量分布情况、波动范围及力学性能的研究,解析了上下炉碳差大于0.03%对重轨钢混钢区钢坯、钢轨的碳含量分布范围及其对钢轨性能的影响。     

On the formation of pipes and centerline segregates in continuously cast billets

Centerline macrosegregation in continuously cast steel billets, blooms, and slabs is a significant problem. Thermal contraction of the solidified shell at the final end of the liquid pool causes a separation in the central portion of the strand and formation of a pore. When this pore fills with liquid, centerline macrosegregation results. Segregation formation is influenced by the cooling and casting conditions. The effects of those parameters are discussed in this article. Thermal contraction also causes formation of a large pipe in the very last portion of the strand. The casting parameters that control the centerline macrosegregation also control the size of the pipe.