Semi‐Solid Rheoforging of Steel

To produce steel components with complex shapes excessive machining is necessary frequently since high pressure die casting of steel is not industrially applied. Forming steel in the semi‐solid state can in principle produce new components and geometries which cannot be realised by conventional closed die forging. Semi‐solid forging of steel combines the possibility of producing geometries not conventionally forgeable in one forming operation and of adding further functions during the same operation. In previous investigations on thixoforming of steels, the semi‐solid steel was generated by reheating precursor material billets. An alternative approach for generating semi‐solid steel from the liquid state with subsequent forging operation is presented in this paper for the first time. The steel grades X210CrW12 cold work tool steel and 100Cr6 bearing steel are molten and driven into a globular semi‐solid state using a cooling slope and a cup. By cooling the steel into the semi‐solid range instead of heating it, the required process temperatures are lower than in the process route via heating. Therefore, the load on the dies in a semi‐solid forging operation is decreased. Suggestions for the respective layout of the process are made for both steel grades. Future potentials and challenges to be solved are discussed, showing advantages especially in the field of high melting point alloys such as steels. This technique enables to produce pre‐shaped semi‐solid billets to optimise the materials flow and the homogeneity of the mechanical properties.     

Structural Morphologies and Deformaiton Characteristics of Semi‐solid Type 304 Stainless Steel during Solidificaiton and Remelting

Microstructural evolutions of type 304 stainless steel and the related mechanical property of flow stress in semi‐solid state are investigated. The evolutions of microstructure during solidification, partial remelting of a hot‐rolled billet and partial remelting of a cast billet are compared with respect to structural morphologies in the semi‐solid state. Various structural morphologies, such as the linear and multilayered liquid/austenite/δ‐ferrite structure, globular liquid/δ‐ferrite structure and dendrite structure, are characterized using optical micrographs and an EPMA (electron probe microanalyzer). The various structural morphologies in the semi‐solid state are influenced not only by the phase transformation but also by the previous treatment of type 304 steel, such as hot rolling and casting. Furthermore, a series of hot compression tests are conducted for various combinations of deformation rate and deformation temperature in the semi‐solid state, to measure the flow stress and the change in microstructure resulting from plastic deformation. Flow stress, phase segregation, microfracture and distortion of solid particles during and after the hot compression test are strongly affected by the structural morphology in the semi‐solid state, such as the dendrite structure, nonglobular structure and globular structure. Semi‐solid type 304 stainless steel with dendrite structure exhibits the highest flow stress, which is about three times that of steel with globular structure, although the testing temperature and deformation rate are controlled to be the same. This is a result of the higher bonding force between solid particles and lower fluidity of the liquid phase of the dendrite structure than those of the globular structure, which exhibits excellent fluidity of the liquid phase and rotation of solid particles.     

Effect of Rare Earth on Thermal Shock Resistance of Steel 9Cr2Mo

Ｒａｒｅｅａｒｔｈｅｌｅｍｅｎｔｓｈａｖｅｂｅｅｎａｄｄｅｄｉｎｔｏｈｏｔｒｏｌｌｅｒｓｔｅｅｌ.ＲＥｅｌｅｍｅｎｔｓｃａｎｉｍｐｒｏｖｅｔｈｅｒ ｍａｌｆａｔｉｇｕｅ[1] ,ｌｏｗｆｒｅｑｕｅｎｃｙｆａｔｉｇｕｅ[2 ] ,ｐｌａｓ ｔｉｃｉｔｙａｎｄｔｏｕｇｈｎｅｓｓ[3] ,ｒｅｆｉｎｅａｕｓｔｅｎｉｔｉｃｇｒａｉｎｓｉｚｅ[4] ａｎｄｍｏｄｉｆｙｉｎｃｌｕｓｉｏｎｓ[5 ] ｏｆｈｏｔｒｏｌｌｅｒｓｔｅｅｌ 6 0ＣｒＭｎＭｏ .Ｓｔｅｅｌ 9Ｃｒ2Ｍｏｉｓａｔｒａｄｉｔｉｏｎａｌｃｏｌｄｒｏｌｌｅｒｓｔｅｅｌ.Ｗｈｅｎ…     

Effects of Y2O3 on Thermal Shock of Al2O3／TiCN Composites

Advancedstructuralceramics ,suchasoxides ,nitridesandcarbides ,havebecomepreferredrefracto rymaterialsforaviation ,spaceflight ,energyandmet allurgybecauseoftheirchemicalstability ,creepresis tanceandhightemperaturestrength .Buttheyareaf fectedgreatlybyte…     

Evolution of Globular Microstructure in New Rheocasting and Super Rheocasting Semi‐Solid Slurries

Based on the solidification theory for metal alloys, a simple recipe for the controlled processing of globular microstructures without external stirring is presented: Firstly, small solidification nuclei must be distributed homogeneously throughout a melt. In New Rheocasting (NRC) these nuclei are formed by forced homogeneous nucleation due to partial quenching of the melt, while in Super Rheocasting (SRC) the nuclei are “second phase particles” in specially designed alloys, which are grown in a controlled fashion in a certain temperature range. Potential alloy compositions for SRC are provided. Secondly, given these melts with small particles in them, globular growth can be assured by utilizing the Gibbs‐Thomson “self healing effect” and slow further cooling to allow diffusion in the melt and to suppress constitutional supercooling. This simple recipe is applicable to various ferrous and non‐ferrous alloys. If an SRC alloy is cooled more rapidly than necessary for globular growth of the primary phase, but is held sufficiently long in the SRC range for dispersoid formation, these dispersoids can act as potent grain refiners and possibly enhance elevated temperature properties. A combination of both processes by using SRC alloys in the NRC equipment may lead to pressure tight castings with low porosity and finer grain structure than can be achieved with NRC on its own, and consequently, better mechanical properties.     

Experimental Investigations and Computer Simulation of the Liquid Fraction Evolution during the Solidification of Alloys Suitable for Semi‐Solid Processing

One important parameter for the processing of materials by semi‐solid forming is the actual distribution of the solid and liquid phases in the semi‐solid range. This parameter defines the process stability for the forming step. Therefore it is necessary to obtain information about the materials behaviour in the semi‐solid state for different materials grades. This kind of information can be obtained by experimental studies in the interesting temperature range or by calculations with simulation programs using thermodynamic data validated by experiments. This work shows the results of experimental studies and thermodynamic calculations of the solidification and heat treatment behaviour of the aluminium alloy A319 and the steel X210CrW12. The experimental studies of solidification and heat treatment of these alloys were carried out using a differential thermal analysis system (DTA). The theoretical fraction of liquid content was calculated from the DTA signal by using a software module called Corrdsc. The experimental data obtained were used to validate the thermodynamic simulations of the solidification of semi‐solid alloys. The simulations of the solidification process were carried out for equilibrium conditions, with the Scheil‐Gulliver model as well as with diffusion calculations. The equilibrium and Scheil‐Gulliver calculations were performed by the program Thermo‐Calc, and the diffusion by the program DICTRA. The required thermodynamic and mobility data for multicomponent systems were taken from the data bases COST 507 light alloys, TCFE2000 Steel/Alloys and MOB2 mobility and from newly added data. The comparison of calculated phase transformations and fractions of liquid content with experimental data revealed a good agreement.     

The Activities of FexO in {CaO‐SiO2‐Al2O3‐MgO‐FexO} Slags at 1723 K

In Japanese steelworks, hot metal is now produced by scrap melting process. With this process removal of sulphur is very much handicapped because of very high sulphur levels (0.04 to 0.09 pct by weight) and relatively low tapping temperatures (1623 to 1723 K). In order to overcome such disadvantages, the authors explored on the phase diagrams of {CaO‐SiO₂‐Al₂O₃‐MgO} slags, and this research revealed that those slags at 35 wt%‐Al₂O₃ would be good candidates as reagents for the removal of sulphur from high sulphur hot metal at relatively low temperatures. For better understanding of the thermodynamic properties of the candidate slags, in this study, activities of Fe_xO were determined by using solid‐state electrochemical cells incorporating MgO‐stabilized zirconia and Mo + MoO₂ reference electrode.     

Reoxidation of Ni‐ and Ni‐Fe‐Alloys by Al2O3‐SiO2 Refractory Materials

Reactions at the refractory/melt interface during ingot casting of Ni‐ and Ni‐Fe‐alloys were studied. The casts were performed using different alumino‐silicate bricks as refractory materials. Samples taken from the casting channel before and after casting were investigated using light and scanning electron microscopy with XPS. Thermodynamic calculations were performed with FactSage and the results were compared with the results from industrial tests. After the melt has infiltrated the surface layer of the bricks, refractory corrosion starts with an attack of Mn and Mg of the melt on SiO₂ and Fe₂O₃ of the refractory bonding matrix. Despite the presence of elements with higher oxygen affinity in the melt, low‐melting alumino‐silicate phases are predominantly built by the reaction with Mn and Mg. In a second step this liquid phase either traps non‐metallic inclusions from the melt or, at higher contents of Zr, Ti, Mg, Y etc. in the melt, causes massive reoxidation and inclusion formation. The refractory materials investigated show an increasing trend for reoxidation with an increasing amount of SiO₂ in glassy phases of the refractory bonding matrix. By the use of a refractory material with higher mullite content in the bonding matrix or by use of alumina bricks a strong reoxidation of the melt and intense inclusion formation can be avoided. These observations are also valid for other alloys with higher contents of elements with high affinity to oxygen.     

The Effect of Carbon in Slag on Steel Reoxidation by CaO‐SiO2‐Al2O3‐MgO‐MnO‐FetO Slags

An equilibrium study was carried out at 1873K to ascertain the effect of carbon in CaO‐SiO₂‐Al₂O₃‐MgO‐MnO‐Fe_tO slag systems on their Fe_tO and MnO activity coefficients, representing the slags’ thermodynamic potential for steel reoxidation. Both γf e_to and γm no showed not only a sharp increment but also a simultaneous slow decrement by increasing carbon content in slag, suggesting opposite roles of the carbon according to its stable forms. XPS (X‐ray photoelectron spectroscopy) was introduced to clarify the stable forms of carbon in slag. XPS results prove that carbon dissolves in slag as carbonate, and carbide ions under oxidizing and reducing atmospheres, respectively. It was concluded that carbonate ions increase γf e_to and γm no , but that carbide decreases them. This paper suggests an application method of the present results to actual ladle refining processes, in order to enhance steel cleanliness with maintaining (Fe_tO + MnO) in slag to some allowable amount.     

Control and Engineering of Non‐metallic Inclusions belonging to xSiO2‐yCaO‐zAl2O3 System in Ca‐treated Al‐killed and Al‐Si‐killed Steel

A model based on the fundamental principles of thermodynamics has been applied to forecast and control the precipitation of non‐metallic inclusions in Ca‐treated Al‐killed or Al‐Si‐killed steels. The engineering of the non‐metallic inclusions takes place during the period just after the tapping from the electric arc furnace until the beginning of the casting period. The construction of the model and its validation have been accomplished through a precise monitoring of the treatment of several steel grades characterized by different oxygen contents after tapping. The oxygen killing of the steel melt with an oxygen content between 750‐1200 ppm is performed by the addition of Si and Al, which produces the formation of pure Al₂O₃ but not always the formation of pure SiO₂. This is a fundamental hypothesis of the model confirmed by experimental observations. The other fundamental aspect is related to the determination of the oxygen activity in the steel bath, which is defined from experimental measurements by an electrochemical concentration cell and through the computation of the equilibrium between the steel bath and the ladle slag. The comparison between the experimental data and the non‐metallic evolution forecast by the model on the basis of the minimization of the oxygen potentials has shown very interesting performances, which makes the model a suitable and very stable tool for industrial application.