连铸坯横向断裂影响因素的分析

 对含Si低碳钢连铸坯发生的横向断裂缺陷进行了金相、扫描电镜检验分析及加热工艺模拟试验;对铸坯从钢水凝固到轧前加热断裂的热历程中所受外力及其与裂纹形成的关系进行了分析。检验分析结果表明：引起铸坯横向断裂的主要原因是浇注时钢水过热度高,凝固组织冷却慢,晶粒发生了严重的粗化,柱状晶间界的强度大大降低,使铸坯在弯曲矫直过程中形成内部裂纹,当再加热时,其热应力使内部裂纹进一步扩展而开裂。所以,控制好铸坯的浇注温度,提高铸坯中心等轴晶率,是防止含硅低碳钢连铸坯横向断裂的有效途径。     

连铸坯中心裂纹发生的原因

连铸板坯可能在板坯厚度的中央有一些裂纹,这些裂纹被称为中心裂纹。本文根据中心裂纹的调查研究和有关操作条件的分析结果,对中心裂纹的形成机理进行了论述,其结果概述如下：（１）中心裂纹是通过钢水凝固过程中被封闭在液态中心最后阶段的附近而形成的缩孔。（２）由模腔数据计算的封闭的钢水的厚度大约是６ｍｍ。（３）铸坯的缺陷周期间隔与在矫直点附近的辊子圆周相吻合。（４）当铸坯是在裂纹敏感区铸造时,中心裂纹是易于发     

天钢连铸板坯中心裂纹的成因分析

针对天钢炼钢厂在连铸生产中出现的中心裂纹,结合VAI动态辊缝模拟软件、铸坯凝固过程应变理论及天钢炼钢厂的生产实践,分析了产生铸坯中心裂纹的影响因素.在设备方面,辊缝超差,特别是凝固末端辊缝超差是造成中心线裂纹的主要原因.在工艺方面,铸坯在冷却过程中,由钢水成分、浇注温度以及拉速变化引起的相变降低了钢的高温塑性.在外力作用下,坯壳承受的应力之和超过了钢的允许强度和应力时,铸坯就会产生裂纹.     

连铸坯裂纹成因及预防

分析了钢的高温力学性能和作用在连铸坯上的各种应力以及化学成分对铸坯产生裂纹的影响，指出裂纹产生的外因是钢水的静压力，热应力，组织收缩应力和其它外力的作用，当这些应力之和超过了钢的高温临界强度和变形量时，就在凝固前沿或凝固壳中产生裂纹，在二冷区凡是增加共内应力，降低强度和塑性的因素将促进裂纹的发生和扩展，裂纹产生的因是钢的高温力学性能和化学成分，提出了防止连铸坯产生裂纹应从两方面考虑，一是工艺参数和设备运转状态，设法降低连铸坯承受的应变和应变速率，二是钢的化学成分，提高钢水纯净度。     

低碳含铌钢表面裂纹的研究与改进措施

 主要研究了低碳含铌钢的表面裂纹形成的原因。通过对表面裂纹缺陷部位进行金相组织观察、SEM(EDS)、金属原位分析,得知低碳含铌钢表面裂纹附近存在夹杂物,铌元素的含量富集。钢水中的氮过高、连铸二冷水强度是影响铌提前凝固析出富集的主要原因。通过降低钢水的氮含量,适当提高热矫温度等工艺的优化措施,明显降低了低碳含铌钢的表面裂纹。     

中低碳钢方坯中间裂纹的成因分析与控制

天钢炼钢厂2~#连铸机在投产初期,在生产10~#、20~#、Q235B等中低碳钢时,铸坯内部质量较差,中间裂纹问题较突出。分析了裂纹形成机理、钢水成分、过热度、铸坯拉速等因素对裂纹形成的影响。结果表明方坯中间裂纹的产生是钢水在浇注凝固过程中不均匀冷却的必然结果。对钢水成分、温度控制和浇注工艺进行了优化,取得了稳定铸坯的内部质量的效果。     

采用电磁搅拌技术改善铸坯质量的探讨

一、前言电磁搅拌技术早在1922年Mcneill就论述了熔融金属的流动对凝固组织、中心偏析和夹杂物分布的影响。1934年Bruchanov利用电转磁场研究了钢水的流动对凝固组织形态的影响,以及对减少钢中气体含量、改善     

钢水流动对凝固组织影响的模型

在大方坯、小方坯铸造中，为了防止中心偏析和中心疏松，在结晶器内和凝固末端，采用电磁搅拌使凝固组织等轴晶化，在凝固末期采用轻压下技术来防止凝固收缩时的钢水流动。但是对偏析晶粒影响很大的等轴晶率和等轴晶粒大小，因钢种、铸坯尺寸、铸造速度、钢水过热度及流动条件等会发生怎样的变化，目前还未建立定量的推定方法。     

连铸板坯裂纹成因及预防措施研究

针对宁钢生产连铸板坯的中心裂纹和三角区裂纹缺陷,分析缺陷产生原因。结果表明:连铸坯宽度方向冷却不均匀,在凝固最后阶段,当较低温度区已基本凝固或接近完成凝固时,相邻的较高温度区尚有部分钢液未完成凝固,未凝固钢液膨胀,将较低温度区域刚结束或基本结束凝固的部分拉开,形成裂纹。通过试验确定了裂纹的预防措施,即严格控制夹送辊开口度、增加二冷区后程冷却水量等,将连铸板坯的中心裂纹和三角区裂纹发生几率降至最低。     

P20中厚板中心裂纹产生原因分析

从P20中厚板的低倍组织、显微组织、低倍制样以及生产工艺等方面对中心裂纹产生的原因进行了分析。结果表明,钢板中心偏析严重、热切割制样时产生较大组织应力和热应力是产生钢板中心裂纹的主要原因。通过降低连铸钢水过热度、在连铸过程中采用电磁搅拌、连铸坯轻压下等技术措施,有效改善了连铸坯中心偏析状况。     

Study on Improving Solidification Structure of Rare Earth Al-Si Alloys with Electropulse Acting on Liquid Alloy

Electropulse modification (EPM) process, a new physical field method for improving the solidification structure of metals was introduced.Different from other research, EPM is only acting pulse current on melt under liquid state.The solidification structure of Al-Si alloys, A1-Cu alloys,cast iron and steel can be modified obviously with this method: the solidification structure of ZL101 alloy presented the Na and Sr modification and the mechanical properties were enhanced; a large number of primary silicon appeared in the microstructure of ZL109 alloy; the equiaxed grain zone was expanded and the grains were fined in Al-5.0wt% Cu alloy; the graphitization took place in solidification process of molten cast iron; the grain sizes of solidification structure of T8 steel were reduced significantly and the shape of steel pearlites also changed; the equiaxed grain zone increased to 88% from original untreated 19%, the equiaxed grains were fined and the intercrystalline crack was avoided in concasting billet by continuously treating liquid electrical sheet steel in tundish.Effects of rare earths on casting Al-Si alloys were also summarized.The method of modifying the solidification structure of rare earth Al-Si alloys with EPM in producing the alloys was proposed.     

Solidification Structure of Continuous Casting Large Round Billets under Mold Electromagnetic Stirring

The solidification structure of a continuous casting large round billet was analyzed by a cellular-automaton-finite-element coupling model using the ProCAST software.The actual and simulated solidification structures were compared under mold electromagnetic stirring (MEMS)conditions (current of 300 A and frequency of 3 Hz).There-after,the solidification structures of the large round billet were investigated under different superheats,casting speeds,and secondary cooling intensities.Finally,the effect of the MEMS current on the solidification structures was obtained under fixed superheat,casting speed,secondary cooling intensity,and MEMS frequency.The model accurately simulated the actual solidification structures of any steel,regardless of its size and the parameters used in the continuous casting process.The ratio of the central equiaxed grain zone was found to increase with decreasing su-perheat,increasing casting speed,decreasing secondary cooling intensity,and increasing MEMS current.The grain size obviously decreased with decreasing superheat and increasing MEMS current but was less sensitive to the casting speed and secondary cooling intensity.     

模具钢电渣重熔铸坯凝固组织形貌的分形特征

为了更为精细化地表达及控制铸坯质量,以H13模具钢电渣重熔铸坯凝固组织为研究对象,引入分形维数对其主体形貌特征进行定量描述。结果表明,基于数盒子法计算得到的分形维数可定量表征凝固组织形貌的自相似复杂程度,其值从柱状晶向中心等轴晶先减小后增大;凝固组织分形维数可作为衡量铸坯偏析程度（偏析率大小）的指标,且分形维数越大,对应区域偏析率越小,偏析越轻;通过凝固组织分形维数、偏析率和偏析点平均面积与二次枝晶间距关系的研究发现,使用二次枝晶间距表征铸坯凝固组织形貌差异并由此反映偏析程度的方法存在局限性。     

Numerical simulation of solidification structure of high carbon SWRH77B billet based on the CAFE method

Abstract

Based on the coupled method of cellular automaton (CA) and finite element (FE), the solidification structure of 160×160 mm cast billet of high carbon SWRH77B steel was simulated. The nucleation density, kinetics of the dendrite tip growth, crystallographic orientation and coupling of CA and FE methods are discussed. In the current study, the influence of superheat on the solidification structure of the billet is researched in detail. The results show that for an increase in superheat extent from 20 to 30°C, the density of grain in billet decreased from 4·662×10⁶ to 3·087×10⁶ m^?2, and the grain mean radius increased from 295·1 to 346·3 μm. The three-dimensional microstructure of high carbon SWRH77B steel was simulated by the CAFE method, and there was good agreement with the results from industrial billet.     

连铸工艺参数对20CrMnTi齿轮钢150 mm x 150 mm铸坯凝固组织影响数值模拟和生产应用

为改善20CrMnTi钢小方坯凝固组织,基于ProCAST软件中的CAFE模型,对其凝固组织进行数值模拟,研究了不同钢水过热度、铸坯拉速、二冷比水量对凝固组织的影响。模拟结果表明,降低钢水过热度、提高铸坯拉速、降低二冷比水量均可达到增大铸坯等轴晶率和细化晶粒的目的,其中过热度对其影响最大。过热度每降低10℃,等轴晶率平均增加3.7%;拉速每增加0.1 m/min,铸坯等轴晶率平均增加1.8%;比水量每降低0.1 L/kg,铸坯等轴晶率平均增加1.65%。生产应用表明,钢水过热度30℃时,当拉速由原2.2 m/min降低至2.1 m/min,二冷比水量由0.6 L/kg提高至0.7 L/kg,铸坯中心疏松明显减少。     

Effect of Induction Heat on Initial Solidification During Electromagnetic Continuous Casting of Steel

 Aiming at the process of electromagnetic continuous casting (EMCC), a three dimensional finite element model on electromagnetic field and temperature field was developed through the commercial software ANSYS to investigate the effects of induction heat of high frequency electromagnetic field on the early solidification process of molten steel in soft contact mold under various conditions of exciting current parameters. The results show that the induction heat has significant effects on the early solidification process, which appear as increasing the billet surface temperature, thinning the initial solidified shell and lowering the starting point of the initial solidification. The increases of exciting current frequency and density make the effects of induction heat on solidification process increased remarkably. Especially, with the increase of exciting current frequency, the early solidification process and shell growth become non-uniform in billet circumferential direction. Morever, if the exciting current density exceeds a certain value, there occurs a high temperature region in the top of molten steel column, and then the initial solidification rate is decreased greatly.     

Effect of M-EMS on the solidification structure of a steel billet

Effects of mold electromagnetic stirring (M-EMS) on the solidification structure of 45# steel billet were investigated by examination of interdendritic corrosion The results show that the primary and secondary dendrite arm spacings increase from the edge of the billet to the center and decrease obviously with increasing electromagnetic torque, which will be beneficial to refine the solidification structure and enlarge the equiaxed crystal zone. The ratio of equiaxed crystal increases by 15.9% with the electromagnetic torque increasing from 230 to to the central area, where the cooling rates are similar at different torques. The closer to the central area, the less the influence of M-EMS on the cooling rate is. The ratio of the primary to secondary dendrite arm spacing is approximately 2.0, namely, λ1 ≈2λ2, and is constant irrespective of the stirring intensity and position of the billet. Original position analysis (OPA) results indicate that the center segregation of the billet is greatly improved, and the more uniform and compact solidification structure will be obtained with the increase of stirring intensity.     

中心偏析控制对型钢低温韧性的影响

 为了研究不同凝固组织形态(等轴晶比例)对连铸方坯宏观偏析及型钢力学性能的影响,通过工业试验改进连铸工艺改变连铸坯凝固组织结构。结果表明,大幅提高柱状晶比例可以有效控制连铸坯中心偏析并降低中心偏析影响区域面积,同时明显减少轧材中珠光体体积分数,提高组织均匀性,断后伸长率提高10%,韧脆转变温度从0降低到-40 ℃,因此,控制连铸坯偏析程度可实现优良低温韧性,这表明通过控制铸坯均匀性发展E级或更高韧性级别的技术可行。     

含硫易切削钢连铸坯低倍裂纹的成因及控制

对300 mm×360 mm大方坯连铸含硫易切削钢（保硫钢）铸坯低倍的皮下、中间裂纹缺陷进行分析,认为 是由于钢中加S后,凝固过程中晶界容易析出FeS、MnS等夹杂物,导致晶界的抗应变能力降低,在外应力的作用 下容易沿晶界扩张形成皮下、中间裂纹。降低结晶器冷却水量及改善结晶器保护渣性能能够消除铸坯低倍皮下、 中间裂纹缺陷。     

合金元素对20CrMnTi钢凝固组织影响的模拟

 为了改善20CrMnTi小方坯的凝固组织,采用移动边界法先对20CrMnTi钢的温度场进行模拟,在此基础上,采用元胞自动机有限元法（CAFE法）对其凝固组织进行了数值模拟。当模拟结果与实际结果基本吻合时,进一步探讨了硅、铬、锰、钛等合金元素对20CrMnTi钢凝固组织的影响规律。模拟结果表明,在该钢号的合金元素规定范围内,适当减少硅元素的质量分数,能够提高铸坯中心等轴晶比例,使晶粒数目增加,晶粒平均半径减小。适当添加铬元素能够扩大铸坯中心等轴晶区,从而减小晶粒平均半径,增加晶粒数量。增加锰元素质量分数可以提高铸坯的中心等轴晶率。最后根据所得模拟结果对该钢种的合金元素进行调整,达到了扩大铸坯中心等轴晶区和细化晶粒的目的。