连铸坯表面纵裂纹的产生原因及控制措施

介绍了连铸坯表面纵裂纹的成因及特征,从钢水成分、连铸机拉速、保护渣液渣层厚度和结晶器液面波动、结晶器冷却效果和二次冷却方面,提出了防止连铸坯表面纵裂纹的具体措施。     

钢的软接触电磁连铸技术的研究进展

钢的软接触电磁连铸技术(SoftContactElectromagneticContinuousCasting)是利用高频交变电磁场在结晶器内铸坯初始凝固区施加电磁压力来减少钢液与结晶器壁的接触压力,从而减小结晶器振动对铸坯表面质量的影响,降低拉坯阻力和减弱初始凝固点的传热来提高铸坯表面质量。分析了实现钢的软接触电磁连铸在结晶器结构、材质以及电磁场参数等方面需要解决的问题,并介绍了该技术的最新研究成果:高频调幅磁场及无结晶器振动的电磁连铸技术。     

合金钢连铸结晶器保护渣的基本功能

分析了合金钢连铸结晶器保护渣对钢水的保温和避免钢液氧化功能、吸收夹杂物的能力、以及润滑铸坯和控制传热的功能。改善保护渣的保温性能，有利于减轻振痕缺陷和铸坯皮下夹渣，提高保护渣吸收夹杂能力，防止高合金钢连铸时的漏钢和减少铸坯夹渣缺陷；而协调保护渣传热与润滑的功能对避免粘结漏钢和减少铸坯表面纵裂纹和微裂纹有着不可低估的作用。     

外加液态保护渣连铸生产实践与前景展望

 外加液态保护渣可以提高铸坯质量和可浇性。在某厂板坯连铸机上,分别采用液态保护渣和固态保护渣进行多钢种浇注试验,对比液态保护渣和固态保护渣消耗量、结晶器温度分布、拉坯摩擦力及铸坯质量,并对液态保护渣的应用前景进行展望。结果显示,液态保护渣比固态保护渣消耗量增加60%左右,结晶器温度分布更均匀,连铸拉坯摩擦力降低约15%,铸坯质量有所提高。这说明在连铸过程中,液态保护渣使结晶器和铸坯间传热更均匀;液态保护渣润滑效果更好,可以提高铸坯质量。同时,有望不添加F-、Na+等有害离子,改善环保问题。     

Modeling transient slag-layer phenomena in the shell/mold gap in continuous casting of steel

Mold-slag friction and fracture may cause heat-transfer variations in continuous casting, which leads to steel shell temperature and stress variations, resulting in surface cracks. Analytical transient models of liquid slag flow and solid slag stress have been coupled with a finite-difference model of heat transfer in the mold, gap, and steel shell to predict transient shear stress, friction, slip, and fracture of the slag layers. The models are validated by comparing with numerical models and plant measurements of mold friction. Using reported slag-fracture strength and time-temperature-transformation (TTT) diagrams, the models are applied to study the effect of casting speed and mold-powder viscosity properties on slag-layer behavior between the oscillating mold wall and the solidifying steel shell. The study finds that liquid-slag lubrication would produce negligible stresses. A lower mold-slag consumption rate leads to high solid friction and results in solid-slag-layer fracture and movement below a critical value. Crystalline slag tends to fracture near the meniscus and glassy slag tends to fracture near the mold exit. A medium casting speed may be the safest to avoid slag fracture, due to its having the lowest critical lubrication consumption rate. The high measured friction force in operating casters could be due to three sources: an intermittent moving solid slag layer, excessive mold taper, or mold misalignment. Other symbols are defined in Table I     

中碳钢连铸方坯内部角裂机制研究与优化

 分别选取西钢某厂实际生产中易发生内部角裂缺陷的40Cr和45钢连铸坯为研究对象,通过对缺陷采用热酸浸低倍试验、金相法和探针能谱分析,发现缺陷处不存在明显的组织异常和质点沉淀。运用ANSYS软件对连铸结晶器凝固过程进行热模拟。研究结果表明,缺陷形成于结晶器内的凝固过程,根本原因是铸坯在结晶器中凝固传热不均导致出现铸坯偏角区热节区效应,从而诱导产生热应力,致使沿柱状晶晶间铁素体开裂,并伴随一定量的铸坯鼓肚现象。通过重新设定结晶器铜管圆角半径和优化生产部分工艺后,最终使连铸坯内部角裂评级在10级以上的比例下降到1042%。     

低碳高硫易切削钢冷拔纵裂纹分析和改进工艺措施

对100t BOF-LF—165 mm×165 mm方坯连铸-热轧至Φ14 mm-冷拔至Φ12 mm的低碳高硫易切削钢(/%:0.07C,1.24Mn,0.06P,0.39S)冷拔材开裂现象进行系统分析,得出该钢在冶炼连铸过程中由于卷渣、氧化等原因造成钢坯内部缺陷是材料冷拔纵裂纹形成的主要原因。通过控制连铸过程结晶器冷却水量,二冷区采用弱冷工艺,比水量0.83 L/kg,拉速1.5 m/min,无氧化保护浇铸及采用1300℃粘度为0.6 Pa·s专用保护渣等工艺措施,有效避免冷拔纵裂纹的发生。     

Study of the Effects of the Mold Surface and Solid Mold Flux Crystallization on Radiative Heat Transfer Rates in Continuous Casting

Radiative heat transfer plays a crucial role in the meniscus area of a steel continuous casting machine. However, the study of radiation across the mold flux and copper molds is very difficult due to the harsh environment and highly transient nature of the phenomena in continuous casting molds. By using an infrared radiation emitter, a radiative heat flux was able to be applied to a copper mold with different top surfaces to observe their effects on the radiative heat transfer. The mold surface was covered with solid slag disk subjected to the radiative heat flux to simulate the radiative heat transfer phenomena in continuous casting. The solid slag disk could either be glass or a mixture of glass and precipitated crystals. The effect of full crystallization of a slag disk was to reduce the heat transfer rate by 20.5%, as compared with a completely glassy sample.     

连铸结晶器内渣膜形成及传热的研究现状

介绍了模拟结晶器内渣膜形成的实验方法, 综述了国内外学者在保护渣传热方面所做的研究工作, 包括固态渣膜的界面热阻、保护渣的导热系数、辐射传热以及渣膜的光学性质, 并提出了今后在渣膜形成及传热研究中有待进一步完善的内容和方向.现有的研究结果表明利用热丝法可以对渣膜的形成过程进行原位观察, 采用水冷铜探头法可以获取用于研究渣膜微观组织的固态渣膜样品.渣膜的界面热阻在0.0002~0.002 m2·K·W-1之间.在800℃以下, 保护渣的导热系数在1.0~2.0 W·m-1·K-1范围内, 且随温度的升高而逐渐增加.渣膜中的晶体一方面可以增加渣膜的界面热阻, 另一方面可以提高固态渣膜的反射率, 起到降低辐射热流的作用.此外, 过渡族金属氧化物的加入以及固态渣膜中弥散分布的微小颗粒也能改变渣膜的光学性质, 从而影响通过渣膜的辐射传热.      

Thermomechanical finite-element model of shell behavior in continuous casting of steel

A coupled finite-element model, CON2D, has been developed to simulate temperature, stress, and shape development during the continuous casting of steel, both in and below the mold. The model simulates a transverse section of the strand in generalized plane strain as it moves down at the casting speed. It includes the effects of heat conduction, solidification, nonuniform superheat dissipation due to turbulent fluid flow, mutual dependence of the heat transfer and shrinkage on the size of the interfacial gap, the taper of the mold wall, and the thermal distortion of the mold. The stress model features an elastic-viscoplastic creep constitutive equation that accounts for the different responses of the liquid, semisolid, delta-ferrite, and austenite phases. Functions depending on temperature and composition are employed for properties such as thermal linear expansion. A contact algorithm is used to prevent penetration of the shell into the mold wall due to the internal liquid pressure. An efficient two-step algorithm is used to integrate these highly nonlinear equations. The model is validated with an analytical solution for both temperature and stress in a solidifying slab. It is applied to simulate continuous casting of a 120 mm billet and compares favorably with plant measurements of mold wall temperature, total heat removal, and shell thickness, including thinning of the corner. The model is ready to investigate issues in continuous casting such as mold taper optimization, minimum shell thickness to avoid breakouts, and maximum casting speed to avoid hot-tear crack formation due to submold bulging.     

60Si2Mn弹簧钢150 mm x 150 mm铸坯缺陷分析与工艺优化

针对60Si2Mn弹簧钢(/%:0.56～0.64C,1.50～2.00Si, 0.70～1.00Mn,≤0.025P,≤0.020S)的150 mm×150 mm连铸坯角部存在横向表面裂纹缺陷问题,通过采用金相显微镜和扫描电镜对铸坯角部横向表面裂纹缺陷进行分析及试验比对。结果表明：结晶器铜管锥度过大、拉坯阻力大、保护渣润滑效果差以及二次冷却不均匀导致角部产生横向表面裂纹。通过将结晶器铜管锥度从2.2 mm降到1.6 mm、保护渣熔化温度从1182℃降到1072℃、粘度从0.76 Pa·s降到0.52 Pa·s以及二次冷却比水量从0.45L/kg降到0.32L/kg等措施,降低铸坯在铜管内拉坯阻力,改善结晶器冷却传热和二冷段喷淋冷却效果,提高铸坯冷却均匀性,使得铸坯缺陷得到有效控制,铸坯表面探伤合格率从35%提高到92%。     

基于无网格伽辽金法的连铸坯凝固计算方法

为考察无网格方法求解铸坯凝固过程的可行性,本文依据移动最小二乘和变分原理,推导并建立了基于无网格伽辽金法的结晶器内铸坯凝固过程二维非稳态传热/凝固数学模型。以小方坯凝固过程为对象,分别采用节点均匀布置、加密布置、随机布置方式,模拟分析了小方坯凝固过程的温度场变化,并将计算结果与参考解、有限元法数值解进行了对比,结果证实无网格伽辽金法在计算精度、自适应性、网格依赖性等方面均优于有限元法。研究结果为无网格方法应用于连铸过程的传热、凝固以及应力/应变行为的数值计算提供参考。      

方坯连铸过程中拉速波动对结晶器液面波动影响的研究

通过从现场S20C中碳钢小方坯24 h连铸生产的结晶器液面波动和拉速波动数据,绘制了结晶器液面即时位置、液面波动曲线和拉速波动曲线,并用薄铁片测量了结晶器液渣层的厚度和形状。讨论了拉速波动对结晶器液面波动的影响。结果表明,结晶器液面波动随拉速的增加或降低而变剧烈,拉速变化在一定程度上影响了结晶器液面波动,但不是惟一的影响因素。     

Formation of longitudinal cracks on slabs

The heat transfer in the mold of a continuous slab-casting machine is analyzed, in order to understand the source of longitudinal cracks on continuous-cast billet. Recommendations are outlined for predicting crack formation and minimizing billet defects.     

特大圆坯连铸用新型浸入式水口的设计与研究

 针对特大截面圆坯连续浇铸的特点,基于依靠浸入式水口自身结构减小钢流冲击深度,同时保证流动与传热沿周向分布均匀的思想,首次提出了新型浸入式伞形水口设计方案,并建立了结晶器内钢水的流-热-固耦合模型,对钢水的流动、传热和凝固行为进行了数值耦合模拟分析,验证了此水口的优越性与合理性：伞形水口的射流在结晶器内形成上下两个回流区,不仅有利于夹杂物、气体等的上浮分离,还能有效降低钢流冲击深度,使过热钢液均匀分布在结晶器上部,可提高弯月面温度和化渣效果;沿周向凝壳生长均匀,减轻了纵裂纹的萌生概率;在0.35m/min拉速下,出结晶器凝壳厚度达到31.2mm,满足安全生产要求。     

低碳钢薄板坯高速连铸保护渣研究与优化

 针对低碳钢薄板坯高速连铸过程中保护渣液渣层过薄、黏结报警频发、铸坯表面纵裂纹过多等问题,在充分考虑高拉速下低碳钢凝固收缩特性的基础上,确定了保护渣润滑与传热性能的优化方向并开展了工业试验。将保护渣碱度从1.10提高到1.30,Li₂O质量分数从0.57%提高到1.06%,Na₂O质量分数从5.48%提高到8.16%,碳质量分数由7.71%降低到6.72%。对2种保护渣的流变性能和渣膜3层结构进行了深入研究,发现优化后保护渣渣膜中的液渣层比例增加,渣膜润滑系数α增大;同时,渣膜中的结晶层比例也有一定程度的提高,渣膜热阻系数β增大,从而使保护渣的润滑性能和控制传热能力均得到改善。从矿相分析结果看出,保护渣碱度的提高在一定程度上会促进硅灰石的析出,导致渣膜结晶率提高、热阻增大,进而起到控制传热的目的。生产实践表明,在拉速提高后,使用新型保护渣基本避免了黏结和裂纹的产生,生产效率和铸坯质量均得到显著提高。     

板坯结晶器钢液流动传热和摩擦行为的数值模拟

结晶器摩擦力对连铸顺行非常重要,而钢液流动行为会影响铸坯温度场和保护渣分布,可能对铸坯摩擦力产生一定的影响.利用Fluent软件建立结晶器内钢液流动、传热三维数学模型,并将温度场数据导入Ansys计算铸坯应变,然后根据铸坯-保护渣-结晶器摩擦行为数学模型讨论了渣膜润滑情况,对比了不同水口底部形状下结晶器内液态、固态和总摩擦力.结果表明:不考虑水口射流时结晶器总摩擦力比考虑水口时增大约29.4％;浸入式水口底部形状分别为凸底、平底和凹底3种情况下铸坯窄面中心温度依次降低,凝固壳厚度依次增大,固态摩擦力依次增大,总摩擦力依次增大,液态摩擦力相差较小.     

Mathematical Modeling of Hot Tearing in the Solidification of Continuously Cast Round Billets

Billets produced by continuous casting sometimes show the presence of subsurface cracks that can compromise the quality of the final product. The presence of these cracks is revealed by Baumann prints of billet cross sections in which the chill zone is visible and the short radial cracks are located only where the chill zone thickness is thinner. This experimental finding induces the hypothesis that cracks are formed as a result of the presence of unevenness in the mold heat extraction around the billet perimeter. Cracks start to open in the dendritic front in regions where the shell growth in the mold is slower. The study presented in this article focused on steels with a sulfur content of about 300 ppm. The Baumann prints taken from billet samples of numerous different heats allowed detecting the presence of subsurface cracks and their location nearby visible chill zone thinning areas. To understand the mechanisms of crack formation and to define the possible corrections, a modeling activity has been carried out using the finite element technique on 148-mm diameter billets continuously cast at TenarisDalmine (Dalmine, Italy). The model performs a two-dimensional thermomechanical analysis of the solidification in the mold and within about 4 cm below the mold exit, along which the shell surface is cooled only by radiation to the environment, before the sprays of the first ring impact on the strand. The model includes the contact of the shell with the mold inner surface, which moves according to taper and distortion (this last part is calculated by means of a separate mold model); the steel creep behavior; the calculation of the heat transfer through the gap depending on the local mutual distance between the two surfaces; the effect of the liquid steel fluid dynamics on the solidification growth as a result of the temperature distribution; and the calculation of a hot tearing indicator represented by the porosity fraction caused by mechanical strains applied at the dendrite roots. From the simulation results, it is concluded that subsurface cracks are generated in the space between the mold exit and the first cooling ring; the involved mechanisms of formation also are withdrawn. Nucleation of MnS precipitates of large dimensions is an additional cause of defectiveness in controlled sulfur steels. As a final conclusion of this work, the most important actions to eliminate subsurface cracks are derived.     

SS400连铸坯纵向裂纹研究

分析了SS400出现纵向裂纹的原因为晶粒粗大,组织疏松,浇铸温度过高,浇铸过程中形成了成分偏析,拉速与保护渣粘度匹配不合理,浇铸过程中水口插入太深,导致保护渣被卷入板坯形成夹杂物,结晶器铜板厚度不合理。通过控制钢中[C]、[P]、[S],稳定拉速,浇铸速度,选择合适的结晶器及保护渣,控制二冷水的水量及强度,保持水口插入深度在钢液面10 mm以下,控制浇铸温度和板坯宽度等措施,纵向裂纹得到有效控制。     

Mold Simulator Study of Heat Transfer Phenomenon During the Initial Solidification in Continuous Casting Mold

In this paper, mold simulator trials were firstly carried out to study the phenomena of the initial shell solidification of molten steel and the heat transfer across the initial shell to the infiltrated mold/shell slag film and mold. Second, a one-dimensional inverse heat transfer problem for solidification (1DITPS) was built to determine the temperature distribution and the heat transfer behavior through the solidifying shell from the measured shell thickness. Third, the mold wall temperature field was recovered by a 2DIHCP mathematical model from the measured in-mold wall temperatures. Finally, coupled with the measured slag film thickness and the calculations of 1DITPS and 2DIHCP, the thermal resistance and the thickness of liquid slag film in the vicinity of the meniscus were evaluated. The experiment results show that: the total mold/shell thermal resistance, the mold/slag interfacial thermal resistance, the liquid film thermal resistance, and the solid film thermal resistance is 8.0 to 14.9 × 10^?4, 2.7 to 4.8 × 10^?4, 1.5 to 4.6 × 10^?4, and 3.9 to 6.8 × 10^?4 m² K/W, respectively. The percentage of mold/slag interfacial thermal resistance, liquid film thermal resistance, and solid film thermal resistance over the total mold/shell thermal resistance is 27.5 to 34.4, 17.2 to 34.0, and 38.5 to 48.8 pct, respectively. The ratio of radiation heat flux is around 14.1 to 51.9 pct in the liquid slag film.