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。     

High Temperature Mechanical Properties of Micro‐alloyed Carbon Steel in the Mushy Zone

The tensile strength of a micro‐alloyed carbon steel in the mushy zone is investigated as well as the influence of temperature, strain rate and thermal histories. The parameters varied comprised thermal histories of both solidifying and reheating type and strain rates from 1 × 10^?4 to 1 × 10^?2 s^?1 were tested using the physical simulation system Gleeble‐1500D. The measured results showed that tensile strength decreased with increasing test temperature in the mushy zone. The tensile strength with solidified type thermal history was lower than that with the reheated type, and the difference of tensile strength derived from the two thermal histories decreased with increasing cooling rate and increasing temperature. The tensile strength decreased with decreasing strain rate in the mushy zone. A viscoplastic constitutive equation with variables of deformation temperature, stress, strain rate, solid fraction and deformation activation energy was constructed. Moreover, the measured thermo‐mechanical parameters, such as zero strength temperature (ZST) and zero ductility temperature (ZDT), were consistent with those predicted according to the corresponding solid fractions.     

Theoretical model for determining optimum soft reduction zone of continuous casting steel

Abstract

A theoretical model for determining the optimum soft reduction zone of continuous casting steel was developed. According to the theoretical analysis of the solute segregation behaviour in the mushy zone with the soft reduction by one pair of pinch rolls, there is an optimum soft reduction position for each element of steel, and all optimum soft reduction positions of different solute elements should be included in order to eliminate the centreline segregation effectively. The theoretical analysis shows that the carbon content has a great effect on the optimum soft reduction zone, and the cooling rate could affect both the optimum soft reduction positions of the segregation prone elements (P, S) and the optimum soft reduction zone of continuous casting steel. Plant trials of steel SWRH82B with soft reduction were carried out to validate the theoretical model, and the results show that the solute element segregation in the centreline of the strand has been improved with the optimum soft reduction zone.     

Study on Mitigating Center Macro‐Segregation During Steel Continuous Casting Process

In the current paper, Methods of enlarging the area for the distribution of segregation solutes were introduced to mitigate center macro‐segregation in steel billets and steel slabs during continuous casting process, which cost less and have significant effect. The location of center macro‐segregation is relative to the shape of liquid‐core at the solidification end during steel continuous casting. A method of dissymmetrical cooling on different surfaces, by which the area for the precipitation of segregation solutes was enlarged, was introduced to mitigate the center macro‐segregation in billets during continuous casting process. Method of optimizing the uniformity of solidified shell in the transverse direction was introduced to mitigate the center macro‐segregation in steel slabs. The uniform cooling intensity along the transverse direction guaranteed a regular solidification end in the continuous casting slab, which aided in the effective application of dynamic soft reduction technology. A relevant 2‐D heat transfer model was developed for the optimization of uniform solidification. The current method was applied to the industrial slab continuous casting using the heat transfer model. The results indicated a better industrial slab quality with much less center macro‐segregation after the use of the method.     

Using a Two-Phase Columnar Solidification Model to Study the Principle of Mechanical Soft Reduction in Slab Casting

A two-phase columnar solidification model is used to study the principle of mechanical soft reduction (MSR) for the reduction of centerline segregation in slab casting. The two phases treated in the model are the bulk/interdendritic melt and the columnar dendrite trunk. The morphology of the columnar dendrite trunk is simplified as stepwise growing cylinders, with growth kinetics governed by the solute diffusion in the interdendritic melt around the growing cylindrical columnar trunk. The solidifying strand shell moves with a predefined velocity and the shell deforms as a result of bulging and MSR. The motion and deformation of the columnar trunks in response to bulging and MSR is modeled following the work of Miyazawa and Schwerdtfeger from the 1980s. Melt flow, driven by feeding of solidification shrinkage and by deformation of the strand shell and columnar trunks, as well as the induced macrosegregation are solved in the Eulerian frame of reference. A benchmark slab casting (9-m long, 0.215-m thick) of plain carbon steel is simulated. The MSR parameters influencing the centerline segregation are studied to gain a better understanding of the MSR process. Two mechanisms in MSR modify the centerline segregation in a slab casting: one establishes a favorable interdendritic flow field, whereas the other creates a non-divergence-free deformation of the solid dendritic skeleton in the mushy region. The MSR efficiency depends not only on the reduction amount in the slab thickness direction but also strongly on the deformation behavior in the longitudinal (casting) direction. With enhanced computation power the current model can be applied for a parameter study on the MSR efficiency of realistic continuous casting processes.     

Phase Evolution and Mechanical Behavior of 0.36 wt% C High Strength TRIP‐Assisted Steel

Phase evolution in a 0.36 wt% C steel has been studied by thermodynamic calculation and dilatometric analysis with an aim to achieve high strength TRIP‐assisted steel with bainitic microstructure. The equilibrium phase fraction calculated as the function of temperature indicated the formation of δ‐ferrite (≈98%) at 1417°C. In contrast, similar calculation under para‐equilibrium condition exhibited transformation of δ‐ferrite to austenite at the temperature below 1300°C. During further cooling two‐phase (α+γ) microstructure has been found to be stable at the intercritical temperature range. The experimentally determined CCT diagram has revealed that adequate hardenability is achievable in the steel under continuous cooling condition at cooling rate >5°C s^?1. In view of the aforesaid results, the steel has been hot rolled and subjected to different process schedule conducive to the evolution of bainitic microstructure. The hot rolled steel has exhibited reasonably good tensile properties. However, cold deformation of the hot rolled sample followed by intercritical annealing and subsequent isothermal bainitic transformation has resulted in high strength (>1000 MPa) with attractive elongation due to the favorable work hardening condition during plastic deformation offered by the multiphase microstructure.     

GCr15轴承钢连铸冷却速率下凝固原位观察

GCr15轴承钢在连铸凝固过程中的组织生长与溶质偏析是碳化物液析的重要诱因,成为产品质量提升的关键.为此,针对国内某钢厂240 mm×240 mm GCr15轴承钢的连铸过程,选取方坯表面下方40、80和120 mm位置处的坯样为研究对象,首先建立二维凝固传热模型,结合红外测温试验,求解它们在糊状区的平均冷却速率,然后...     

Investigation of Centreline Segregation and Centreline Porosity in CC ‐ Slabs

Improvements of solidification processing in conventional or near net shape casting depend on sophisticated methods of macroscopic examination of central unsoundness and inhomogeneity of the cast material. As long as remarkable deviations referring to the quality features exist between the slab centre and the bulk material such methods should be looked after. Two semi‐macroscopic methods of segregation analysis are discussed in this paper: firstly, the potential of the emission spectral analysis combined with sectioning of a sample and secondly, the computer aided micro‐probe analysis. Both methods are restricted to small local areas. The proneness of elements and steel grades with respect to micro‐ and macrosegregation as well as distribution‐ and segregation coefficients are determined. The effect of a diffusion anneal on homogenisation of segregation is studied. Last not least the precipitation of sulphides, phosphides or carbonitrides is estimated. Ultrasonic detection of the central unsoundness of conventional slabs or thin slabs is a new approach towards a quantitative macroscopic examination. The sample size is 400 mm x 300 mm x 30 mm. To achieve a low ultrasonic noise using a 5 MHz‐transducer the samples are heat treated for grain refinement. “Dog bone porosity”, macroscopic topographical misfit between the upper and lower solidifying shells, periodical corner cracks or systematic transverse centre cracks are detected. Obviously, segregations do not reflect the ultrasonic beam. However, it can be presumed that an interrelation exists between porosity and segregation, although these might be locally apart from each other. This new ultrasonic test of the central unsoundness of continuous cast (c.c.) slabs gives valuable arguments to machine builders and maintenance people to decide on the right concepts for strand guidance, support rollers and secondary cooling. Soft reduction can be optimized and variations in casting speed counteracted by dynamic means. R&D service of this kind can help steelmakers when decisions are impending to build new casting machines or revamp old ones.     

Multiphase Flow and Thermo-Mechanical Behaviors of Solidifying Shell in Continuous Casting Mold

 The metallurgical phenomena occurring in the continuous casting mold have a significant influence on the performance and the quality of steel product. The multiphase flow phenomena of molten steel, steel/slag interface and gas bubbles in the slab continuous casting mold were described by numerical simulation, and the effect of electromagnetic brake (EMBR) and argon gas blowing on the process were investigated. The relationship between wavy fluctuation height near meniscus and the level fluctuation index F, which reflects the situation of mold flux entrapment, was clarified. Moreover, based on a microsegregation model of solute elements in mushy zone with δ/γ transformation and a thermo-mechanical coupling finite element model of shell solidification, the thermal and mechanical behaviors of solidifying shell including the dynamic distribution laws of air gap and mold flux, temperature and stress of shell in slab continuous casting mold were described.     

Research on Key Metallurgical Technology of 350Km/h High‐Speed Rail Steel

Requirements like higher cleanliness and better quality of casting blooms are proposed for 350km/h higher speed rail steel. Present paper focuses on technical measures on improving the steel cleanliness and strand quality of 350km/h high‐speed rail steel in Panzhihua Iron & Steel Group Company. By means of series of packaging technology like dephosphorization in BOF, ladle refining, mold electromagnetic stirring and dynamic soft reduction, dephosphorization rate cleanliness and morphology control are greatly improved, with [S]≤0.015%, [P]≤0.025%, [H]≤1.5 × 10^?6, Al_s ≤ 0.004%, T[O] ≤20 × 10^?6, the grade of central porosity and segregation ≤1.0, the grade of central crack and middle crack ≤0.5, index of central carbon segregation ≤1.05, severity level of type‐A and type‐B inclusions ≤2.0 and 1.0, respectively. The optimized process meets the technical requirements on producing 350 km/h high‐speed rail steel and stable production is realized.     

Modeling of solute redistribution in the mushy zone during solidification of aluminum-copper alloys

A mathematical model has been established to predict the formation of macrosegregation for a unidirectional solidification of aluminum-copper alloys cooled from the bottom. The model, based on the continuum formulation, allows the calculation of transient distributions of temperature, velocity, and species in the solidifying alloy caused by thermosolutal convection and shrinkage-induced fluid flow. Positive segregation in the casting near the bottom (inverse segregation) is found, which is accompanied by a moving negative-segregated mushy zone. The effects of shrinkage-induced fluid flow and solute diffusion on the formation of macrosegregation are examined. It is found that the redistribution of solute in the solidifying alloy is caused by the flow of solute-rich liquid in the mushy zone due to solidification shrinkage. A higher heat-extraction rate at the bottom increases the solidification rate, decreasing the size of the mushy zone, reducing the flow of solute-rich liquid in the mushy zone and, as a result, lessening the severity of inverse segregation. Comparisons between the theoretical predictions from the present study and previous modeling results and available experimental data are made, and good agreements are obtained.     

ND钢连铸坯两相区内的微观偏析模型

通过构建ND钢连铸坯凝固两相区内溶质的微观偏析模型, 不仅研究了C、S和P元素对固液两相区内钢的高温力学参数以及溶质再分配的影响, 还对P元素偏析比随冷却速率(C_R) 的变化规律进行了探究.通过分析模型结果表明: 初始C的质量分数在0.075%~0.125%之间时, 随着初始C含量的增加, P、S元素的偏析加剧, 凝固末端温度下降幅度变大, 导致脆性温度区间增大; 增加P和S元素的初始含量, P、S元素的偏析比降低, 但会加剧其在枝晶间残余液相中的富集, 直接导致零塑性温度(ZDT) 下降; ND钢中的Cu含量低于显著提高裂纹敏感性的临界含量, 且凝固过程中Cu元素的偏析比较低, 因此在ND钢凝固过程中Cu元素不能主导裂纹的诱发; 在一定的冷却速率波动范围内, P元素的偏析比随着冷却速率(C_R)的提高略有下降.      

The influence of temperature and strain rate on the stress-strain behaviour of “in-situ solidified” steel during tensile test

The stress-strain behaviour of a low-carbon low-alloyed steel after solidification in-situ was studied at four temperatures (1000°C, 1150°C, 1300°C and 1400°C) and at four deformation rates (6 mm s^?1, 0,6 mm s^?1, 0,06 mm s^?1 and 0,006 mm s^?1) by tensile tests. The resulting microstructures after solidification and deformation were examined by scanning electron microscope and optical microscope. The results showed that the crystals developed after solidification in the melted part of the tensile specimen are cellular dendritic, similar to the crystallization mode of steel in continuous casting. It was also shown that slip in the dendritic crystals is the main mode of deformation mechanism in the tensile tests within the temperature range mentioned above, but at higher levels within this temperature range (i.e. 1400°C) and at a low deformation rate (i.e. 0,006 mm s^?1) grain boundary migration takes part in the deformation process. The data from the tensile test were analysed.     

Study on Solidification Structure of Wheel Steel Round Billet Using FE‐CA Coupling Model

Solidification structure of wheel steel round billet during the continuous casting process was simulated using FE (Finite Element)–CA (Cellular Automaton) coupling model. Variation of thermo‐physical parameters during solidification was considered based on a thermodynamic database. Meanwhile effect of electromagnetic stirring (EMS) was reflected by increasing both the thermal conductivity and crystal formation rate in liquid phase. It was found that the cooling curves and solidification structure calculated by this model agreed well with that in experiments. Optimum casting temperature range was discussed based on the simulation results and actual conditions in plant. An optimized casting superheat will be no more than 25 °C in order to obtain at least 50% equiaxed crystal ratio, while the degree of segregation in the billet is less than 1.05 correspondingly.     

Influence of Strain Rate on Hot Ductility of a V‐Microalloyed Steel Slab

The hot ductility and malleability of a vanadium‐microalloyed steel is investigated by means of tensile and compression tests at temperatures ranging from 700 to 850°C and strain rates of 3 × 10^?4 to 0.3 s^?1. The deformation tests are performed after austenitization and cooling to test temperature. The so‐called second ductility minimum is located around 750°C for all strain rates except for the highest one, where no ductility trough is observed. Ductility steadily increases with strain rate at a given temperature, and the fracture mode progressively changes from intergranular to transgranular. In the region of minimum ductility, intergranular cracking occurs at low strain rates by void nucleation, growth and coalescence within thin layers of deformation induced ferrite covering the austenite grain boundaries. Cracking is favoured by V(C,N) precipitation associated with the γ/α phase transformation. Ductility remains low above the temperature of minimum ductility, where no apparent ferrite formation is observed (790 °C). Void formation takes place as a result of grain boundary sliding in combination with matrix and grain boundary precipitation. These voids are able to grow and link up forming intergranular cracks. Ductility increases with strain rate mainly due to the short time available for precipitation as well as for intergranular void growth and coalescence.     

Ultra Fast Cooling of a Hot Steel Plate by Using High Mass Flux Air Atomized Spray

In the current research, the ultra fast cooling (UFC) of a hot stationary AISI‐304 steel plate has been investigated by using air atomized spray at different air and water flow rates. The initial temperature of the plate, before the cooling starts, is kept at 900°C or above. The spray was produced from a full cone internal mixing air atomized spray nozzle at a fixed nozzle to plate distance; and the average spray mass flux was varied from 130 to 370 kg m^?2 s by selecting different combinations of air and water flow rates. The surface heat flux and surface temperature calculations have been performed by using INTEMP software and the calculated results have been validated by comparing with the measured thermocouple data. The heat transfer analysis indicates that the cooling occurs in the transition boiling regime up to surface temperature of 500°C and thereafter it changes to nucleate boiling regime. The superposed flow of air on the hot plate enhances the cooling in the temperature range of 900–500°C by sweeping the partially evaporated droplets from the hot surface. However, due to the high percentage of fine water droplets in the resultant spray produced at higher air flow rates, the maximum cooling rate is achieved at the medium air flow rate of 30 N m³ h^?1. The cooling rate (182°C s^?1) produced by an air atomized spray is found to be in the UFC regime of a 6 mm thick steel plate. The findings of this research can be considered as the basis for the fabrication of cooling system in the run‐out table of a hot strip mill.     

Analysis of the Strain‐Induced Martensitic Transformation of Retained Austenite in Cold Rolled Micro‐Alloyed TRIP Steel

The stability of retained austenite and the kinetics of the strain‐induced martensitic transformation in micro‐alloyed TRIP‐aided steel were obtained from interrupted tensile tests and saturation magnetization measurements. Tensile tests with single specimens and at variable temperature were carried out to determine the influence of the micro‐alloying on the M_s^σ temperature of the retained austenite. Although model calculations show that the addition of the micro‐alloying elements influences a number of stabilizing factors, the results indicate that the stability of retained austenite in the micro‐alloyed TRIP‐aided steels is not significantly influenced by the micro‐alloying. The kinetics of the strain‐induced martensitic transformation was also not significantly influenced by addition of the micro‐alloying elements. The addition of micro‐alloying elements slows down the autocatalytic propagation of the strain‐induced martensite due to the increase of the yield strength of retained austenite. The lower uniform elongation of micro‐alloyed TRIP‐aided steel is very likely due to the presence of numerous precipitates in the microstructure and the pronounced ferrite grain size refinement.     

Strain‐Rate‐Dependent Flow Stress and Failure of an Mg‐PSZ Reinforced TRIP Matrix Composite Produced by Spark Plasma Sintering

A composite consisting of 5 vol% MgO‐partially stabilized ZrO₂ particles (Mg‐PSZ) and a TRIP‐steel‐matrix (CrNiMn steel; transformation induced plasticity) was produced through Spark Plasma Sintering. The processed material was tested under compression at various nominal strain rates (4 × 10^?4 s^?1; 10^?3 s^?1; 1 s^?1, 10² s^?1). Both, the pure steel and the composite showed a considerable plasticity and high strength due to the very fine grained steel matrix. The addition of 5 vol% ceramic particles led to a rise in the offset yield strength of 60 MPa till 90 MPa according to the applied strain rate. Up to a strain rate of 1 s^?1, no change in offset yield strength was measured. A strain‐rate of 100 s^?1 leads to a rise in the offset yield strength of approx. 100 MPa. Both, the ceramic and an increase in the strain rate implicate to an early generation of microdeterioration. Limited by the interfacial strength of steel and Mg‐PSZ, failure occurs early at the interfaces, which is shown in a decrease in the work hardening. During the compression, especially at higher strain‐rates, adiabatic heating occurred and counteracted to the martensitic transformation.     

10CrNiCu钢连铸坯中心偏析的原位分析

采用金属原位分析(OPA)方法研究了连铸10CrNiCu钢中心偏析的状况及其对材料性能的影响.分析表明,采用二冷电磁搅拌后,铸坯中大部分元素的最大偏析度均有不同程度的降低,C、Cr、Ni、Si等主要元素的最大正偏析降低了50%以上.该工作也表明,OPA技术对指导连铸工艺优化、提高产品质量是十分有效的方法和监测工具.