连铸电磁旋流水口流体流动和夹杂物行为

采用数值模拟方法对连铸电磁旋流水口内流体流动和夹杂物碰撞长大行为进行了研究.数值结果表明电磁旋流水口出口处流体流动扩张角与低熔点合金实验值相符.旋转磁场对浸入式水口内壁夹杂物沉积行为存在两个相反的作用:一方面旋转磁场作用加强了水口壁面处钢液的湍流流动,加速了夹杂物在水口内壁的沉积吸附速率;另一方面水口内壁附近夹杂物在旋转磁场产生的旋流作用下易被携带至水口中心,削弱了水口内壁对夹杂物的黏附.在上述两方面因素作用下,钢液区存在一个最佳磁感应强度可使水口内壁夹杂物沉积速率降至最低,从而减轻水口结瘤现象.      

连铸浸入式水口结瘤和堵塞的原因分析及控制措施

分析了浸入式水口结瘤物、堵塞物的结构和大致化学成分,介绍了水口内壁结瘤和堵塞的多种原因,并从改善水口材质及结构、减少夹杂物或改性夹杂物、优化局部钢水流动状态和施加外场4个方面总结了抑制水口结瘤和堵塞的措施。     

耐材壁面夹杂物稳定性研究

分析了连铸水口内夹杂物与耐材壁面的相互作用及夹杂物的稳定性,建立了夹杂物黏附模型。分析结果表明,夹杂物在耐材壁面附着时,受耐材壁面的正向吸附力,且夹杂物在平行壁面方向上的受力主要与夹杂物半径相关,随夹杂物半径的增大而增大;在垂直壁面方向上所受的力恒为正,且随夹杂物半径、润湿角的增大而增大。壁面夹杂物的稳定性随夹杂物半径的增大而减小,当夹杂物半径大于4μm时,不同夹杂物附着稳定性发生变化,且夹杂物稳定性从高到低依次为Al_2O_3TiNMgOSiO_2。当夹杂物在耐材壁面夹杂物底层吸附时,夹杂物在垂直壁面方向上受力随底层粗糙度的增大缓慢减小,随夹杂物尺寸的增大而增大。分析结果对研究连铸水口内夹杂物、钢液、耐材壁面三者之间相互作用具有指导意义。     

BOF→RH→CSP工艺生产含钛IF钢浸入式水口结瘤机理研究

针对BOF→RH→CSP工艺生产含钛IF钢浸入式水口结瘤问题,采用扫描电镜、能谱分析等方法,分析了IF钢浇铸过程水口结瘤物的组成,结合中间包夹杂物的特性,阐明了水口结瘤的机理。结果表明:钛元素的存在一方面使钢水中Al_2O_3夹杂物不易碰撞长大,另一方面减小了钢液、耐材和夹杂物之间的润湿角,容易造成水口结瘤;结瘤物初始沉积层主要为钢水与水口耐材反应生成的以Al_2O_3为主的复合氧化物;而结瘤物主体层主要来源于钢水中的夹杂物,为低变性的MgO·Al_2O_3尖晶石或Al_2O_3,且含有钢滴;夹杂物沉积进而烧结成疏松的网状层,使钢水更易粘附从而加剧了水口结瘤速度。研究结果可为优化工艺参数、提高BOF→RH→CSP工艺连浇炉数和产品质量提供可靠的理论指导。     

含钛铁素体不锈钢连铸浸入式水口结瘤机理研究

采用光学显微镜和扫描电镜,对00Cr18Ti铁素体不锈钢钢样中夹杂物类型和浸入式水口结瘤物的物相进行分析,研究水口结瘤机理。结果表明,钢液中存在大量TiO2夹杂物,并不断附着沉积在水口内壁,造成浸入式水口氧化钛型结瘤;通过控制钢中w[Al]-w[Ti]值在铝钛竞争氧化反应平衡曲线之下,使w[Ti]/w[Al]4/3273.55,能够防止大量TiO2夹杂物的生成,避免氧化钛型水口结瘤。     

连铸含钛不锈钢浸入式水口结瘤的形成机理

为了搞清连铸含钛不锈钢时浸入式水口CaO.TiO2型结瘤的机理,在实验室碳管炉中进行了铝碳质耐材棒浸入321不锈钢钢液的实验。结果表明,结瘤是由于钢中CaO.TiO2等夹杂物沉淀附着在耐材棒表面形成的。如果存在二次氧化,钢中夹杂物数量明显增加,相应形成的结瘤层也较厚。提高钢液温度50℃对钢中生成的氧化物夹杂的类型没有影响,但是,能显著减少结瘤层中的凝固金属,使结瘤层减薄。     

耐材壁面夹杂物碰撞研究

分析了钢液流经连铸水口时钢液中夹杂物与耐材质吸附杆壁面之间的碰撞行为,建立了夹杂物碰撞模型。分析结果表明,回弹系数一定时,同尺寸夹杂物与壁面碰撞,垂直于壁面方向上夹杂物速度越大,最大压缩距离越大,回弹距离也越大,碰撞后越易回弹至钢液中;当回弹系数、夹杂物初速度一定时,不同尺寸的夹杂物与壁面碰撞,夹杂物的尺寸越小,对应的最大压缩距离越小,回弹距离也越小,夹杂物越易碰撞吸附在壁面。R=20μm Al_2O_3夹杂物与光滑壁面已附着夹杂物碰撞,当夹杂物速度一定时,压缩距离越大,壁面夹杂物临界接触域尺寸越大,壁面夹杂物越易脱落、滚动;与粗糙壁面附着夹杂物碰撞,当夹杂物速度方向与耐材壁面的夹角β0.51°时,壁面夹杂物不会脱落、滚动。分析结果对研究连铸水口内耐材壁面对钢液中夹杂物的吸附具有指导意义。     

含钛不锈钢连铸水口结瘤和结晶器"结鱼"

总结了前人在含钛不锈钢方面的研究工作和工业实践进展.指出合钛不锈钢结晶器"结鱼"主要是由于钢中氮钛浓度积偏高,导致TiN夹杂物大量析出,并在结晶器弯月面聚集,与保护渣反应放出氮气,致使局部钢液温度下降凝固后形成的;TiN型水口结瘤主要由于浇铸过程中TiN夹杂物附着在浸入式水口内壁造成的;TiO2型水口结瘤主要是二次氧化造成TiO2夹杂物大量增加,并在浇铸过程中附着在连铸水口内壁形成的;CaO·TiO2型水口结瘤主要是钢中Ca＞0.001%,Al＞0.01%的情况下,加入Ti后钢中形成数量较多的CaO·TiO2-MgO·Al2O3双相夹杂物,并在浇铸过程中附着在水口内壁形成的.同时阐述了上述连铸水口结瘤和结晶器"结鱼"的控制措施和工业实践中取得的进展.     

含Ti超低碳钢浸入式水口结瘤研究

对某钢厂含钛超低碳钢连铸过程所用结晶器浸入式水口结瘤问题进行了研究,采用XRF、SEM-EDS等方法分别对水口上部内壁和底部出口处结瘤物的成分、物相进行了分析,利用Factsage热力学软件计算了造成结瘤的夹杂物析出条件。研究结果表明:水口上部内壁的结瘤物主要为Al_2O_3夹杂物和冷钢,并且结瘤物存在明显的分层现象;水口底部出口堵塞是由于上部内壁结瘤物在钢液冲刷下吸附在底部出口,进而引起冷钢堆积造成的,并由此提出一个"结瘤-冲刷-堆积-堵塞"的水口堵塞模型来描述这个过程。     

板坯连铸水口结瘤机理研究

通过对CAS-OB精炼钢水板坯连铸水口结瘤物的物相分析和钢中夹杂物的类型分析,研究了中间包浸入式水口、钢包下水口滑板处结瘤的机理,发现浸入式水口结瘤物是CaO·Al2O3和CaS;钢包下水口和滑板处结瘤物主要是CaO-2Al2O3;通过同炉钢中夹杂物检验,证明结瘤是钢水中相同类型的夹杂物沉积粘附在水口内壁造成的.讨论了m(Ca)/m(Al)和钢中S、Al含量对水口结瘤的影响,为了防止水口结瘤,钢中的S、Al含量应控制在12CaO·7Al2O3生成曲线的下方,并保持m(Ca)/m(Al)》0.13.     

Mechanism of alumina buildup in tundish nozzles during continuous casting of aluminum-killed steels

During continuous casting of aluminum-killed steels, the pouring rate through the tundish nozzle often diminishes, posing serious operating problems. This happens because a buildup of microscopic alumina particles at the nozzle orifice effectively decreases the nozzle orifice diameter and causes constriction of the liquid-steel pouring stream. There are two major aspects of the constriction problem: (1) the source of the depositing particles, and (2) the mechanism by which the particles deposit at the nozzle orifice. Detailed microscopic examination of the buildup of alumina particles in nozzles from various casting trials and petrographic examination of the nozzle refractory indicated that the particles depositing at the nozzle orifice were already present in the melt because of deoxidation and reoxidation processes. A model proposed herein explains why and how the alumina particles deposit and stay at the nozzle orifice. The model considers a microscopically thin boundary layer at the nozzle bore where the velocity of the liquid steel approaches zero. Particles passing close to the refractory surface and in the slow-moving boundary layer attach to the wall and to each other. The presence of eddy currents in and close to the turbulent boundary layer increase the particle to particle collision. Such collisions of the particles thrown from outer region of boundary layers with the already attached particles keep on dumping the particles toward the refractory surface. The high interfacial energy of alumina inclusions in steel is a driving force for particles to attach to the refractory wall and to each other, and high-température sintering then occurs to form a network of alumina particles.     

Mathematic Model of SEN Clogging During Continuous Casting of Steel

 The SEN clogging is a long term issue for all the steelmakers. In the current study, the kinetics of SEN clogging during steel continuous casting was established. The dynamic build-up of alumina inclusions to the lining refractory of SEN was analyzed. The fluid flow and inclusions motion are calculated by means of mathematic model. Effect of diameters of inclusions, roughness of nozzle, diameter of nozzle and casting speed on the entrapment probability are estimated.     

超低碳钢连铸过程中Ti和P对水口结瘤的影响

浇注含Ti超低碳钢时,浸入式水口内产生结瘤,严重影响生产效率,同时对产品质量造成危害。根据企业生产的经验,随着超低碳钢中Ti和P含量的增加,水口结瘤的问题越来越严重。通过深入分析实际生产过程的试样和实验室研究,阐明浇注超低碳钢时Ti和P对水口结瘤的影响。分析了含Ti含P的超低碳钢水口结瘤物的成分,结果表明结瘤物的主要成分是氧化铝(>90%),Ti含量较少(0.58%～3.58%)。采用脉冲分布解析原子发射光谱法(OES-PDA)测得氧化夹杂物的大小随Ti含量的增加而变小。采用液滴法测定了溶质Ti和P对钢液/Al2O3体系的润湿性影响,结果表明Ti和P使体系接触角和钢液表面张力降低,其中Ti能够降低体系的接触角只是在其具有反应湿润性的情况下。研究表明Ti和P对产生结瘤的作用有显著区别:只要形成的表层界面具有润湿性,Ti就可以降低Al2O3夹杂物的大小,而氧化铝夹杂物颗粒越小,越容易结瘤。为了不产生结瘤就必须控制好Al脱氧的时间和Ti的加入时间。P可以增加Fe-Ti-P三元体系的润湿性是因为P可以增加Ti的活度,降低钢液的粘度。与Ti相比,P对产生结瘤的影响较小。     

Prevention of overgrowth on submerged nozzles during casting of steel deoxidized by aluminum

An initial reaction layer forms on the submerged entry nozzles; this layer is followed by bulk deposits that primarily contain endogenous alumina and steel inclusions. It would therefore be of some interest to prevent the formation of this initial layer opposite the refractory wall of the submerged nozzle. The presence of carbon and SiO₂ on the surface of the nozzle facilitates formation of a loose layer of alumina deposits. Refractories with various coatings were tested in contact with nonmetallic inclusions, liquid steel, and synthetic slag. It was found that a coating of pure alumina or ZrO₂ reduces overgrowth on the submerged nozzles and shows high chemical resistance to liquid steel.     

钛处理对EH36船板钢中夹杂物及组织特征影响

 为了研究结晶器喂钛线对EH36船板钢中夹杂物的影响,采用无水有机溶液电解分离提取钢中夹杂物,结合扫描电镜和能谱仪分析其三维形貌,尺寸和成分。试验结果表明,在结晶器喂钛线后,钢中硅铝酸钙夹杂物+外包裹MnS转变为硅铝酸钙钛+MnS夹杂物,三维表面从光滑转变为粗糙多孔的形貌。在焊接热模拟后的试样中,组织形貌从未加钛试样中的晶界铁素体和侧板条铁素体转变为钛处理试样中的针状铁素体,且夹杂物周围铁素体从块状转变为针状,韧性提高了70 J。通过热力学理论计算,分析船板钢中含钛氧化物夹杂物形成条件。计算结果表明,钛、铝与氧反应生成氧化物的过程存在竞争关系,当钢中钛质量分数为0.02%时,钢液中应严格控制铝质量分数不高于0.003 5%,才能保证钢液中大量生成含钛氧化物粒子。     

Effect of electromagnetic stirring on flow field in mold under submerged entry nozzle clogging

A physical model with mercury as analog was developed to investigate the influences of electromagnetic stirring( EMS) on flow field in slab continuous casting when the submerged entry nozzle( SEN) was clogged with different clogging rates( 0,10%,25%,and 50%). The flow field in mold under different EMS currents( 0,40 A,and 60 A) was measured by an ultrasonic Doppler velocimeter. The results proved that the flow field in the mold was a typical double roll structure under non-clogging SEN. As the SEN clogging rate increased,the flow field structure was transformed from a double roll to asymmetry flow. When the clogging rate reached 50%,the up circulation disappeared on the clogged side. The zone under the meniscus near the narrow face was a non-flowing area. EMS could correct bias flowcaused by SEN clogging and improve the symmetry of the flow field during SEN clogging.     

Effect of Nozzle Base Material on the Rate of Clogging during the Continuous Casting of Aluminum‐Killed Steels

One approach to solving the problem of nozzle clogging during the continuous casting of aluminum‐killed steels is through careful selection of nozzle materials. In this study, the rate of clogging was measured while casting steel through simulated nozzles produced from alumina, zirconia, magnesia, zirconia‐graphite, and alumina‐graphite ‐ three common base materials and two common carbon‐containing nozzle materials. Spent nozzles were characterized using optical and cathodoluminescence microscopy. Interactions between the nozzles and steel were not observed in the alumina, zirconia, and zirconia‐graphite nozzles. Slight interactions were observed in the magnesia nozzles as alumina inclusions within the steel interacted with the nozzle to produce alumina‐magnesia spinel. Greater amounts of interaction were observed with alumina‐graphite nozzles. No statistical differences in the mean rate of clogging were observed between all of the pure oxide nozzles and zirconia‐graphite nozzles. However, the alumina‐graphite nozzles clogged at a much higher rate than the other nozzles. The higher rate of clogging is thought to be due to refractory‐steel interactions.     

铝锆碳浸入式水口异常堵塞原因分析

对钢液微合金化钛处理后引起堵塞的铝锆碳质浸入式水口进行分析,结果表明:堵塞物质为铝酸钙和钙钛矿。铝酸钙有变质体中的析出相,也有水口内壁处的原位反应产物,还有钢液中内生夹杂物。中包渣渗有钛处理和铝处理后的残留物,改变了原有属性,导致水口边滞留,为新生高熔点物质铝酸钙提供了物质来源,新生和内生铝酸钙及钙钛矿共同引起水口结瘤导致堵塞。