Optimisation of ladle slag composition by application of sulphide capacity model

Abstract

The sulphur distribution ratio for ladle slags at Ovako Steel AB has been determined by calculating the sulphide capacity using the Royal Institute of Technology (KTH) model and the alumina activity via an empirical expression suggested by Ohta and Suito, and by using the well established theories for sulphur refining. A parameter study was carried out based on plant data from a previous study on desulphurisation. The effect of carbon and aluminium in the steel, the temperature of the steel, and alumina and lime in the slag on the sulphur distribution ratio was investigated. It was shown that the Al₂ O₃ /CaO ratio had the largest influence on the conditions studied, and that when it increased the sulphur distribution ratio decreased. Based on these results, new plant trials were carried out, in which the alumina content in the slag was changed. The calculated sulphur distribution ratios for these trials were found to be in good agreement with experimentally determined sulphur distribution ratios. It is concluded that the present approach can be used to optimise multicomponent ladle slags with respect to sulphur refining.     

New structure of automatic torch and new approach for controlling drop transfer in rotating spray welding arc

Abstract

Using computer aided design/computer aided manufacturing technology, an automatic welding system is designed and manufactured for high current, high speed, and high deposition metal arc active gas (MAG) welding. The welding torch structure is evaluated and optimised via the finite element method and practical welding technology experiments. Finally, the process of high deposition MAG welding is investigated, and it is highlighted that on application of a longitudinal magnetic field to the high deposition MAG welding process, a steady metal transfer and drop deposition condition can be achieved, which is suited to the demands of high current, high speed welding technology.     

Grain growth of zircon pigment in tile glaze

Abstract

Glazes for ceramic materials are often opacified by a zircon pigment. The increase in optical density is related to the number and size of pigment particles, which are well dispersed in the glass. Mechanical dispersion by grinding of a fine zircon powder in a raw glaze mixture results in an unoptimised pigment dispersion in the melted glassy phase at high temperature. A significant reduction in the number of particles and a simultaneous large increase in their size is observed. In this case the optical glaze density does not attain the expected value and a very large quantity of zircon must be added. In the present work it is shown that a large part of the zircon reacts with the glass phase during firing. Simultaneously, the remaining zircon grains undergo a large increase in grain size by Ostwald ripening through the liquid phase. This process is characterised by a low activation energy (79 ± 1 kJ mol^-1) and a short diffusion path for Zr through the liquid phase between neighbouring grains. The path length is shorter than the size of the larger grains. In the usual firing range, both populations of smaller and larger grains vary in size, the smaller grains favouring growth of the larger grains.     

Periodic reverse current electrodeposited nickel pigmented anodised aluminium

Abstract

Aluminium anodically oxidised in sulphuric acid electrolyte was pigmented by an electrolytic colouring process with the use of alternating and periodic reverse current. The applied pigmentation electrolytes were based on nickel. The study reports on resistance against humidity of a selective Ni–Al₂O₃ layer. The samples before and after testing were analysed and compared. The quality of the coating, optical properties and influence of humidity on morphology and composition of the coatings were investigated. The influence of moisture on the quality of the selective Ni–Al₂O₃ layer is comparable to the commercial solar absorber type.     

Stress Generated on Aluminum During Anodization as a Function of Current Density and pH

Anodic oxidation is accompanied by stressgeneration during the growth of the oxide. The presentstudy focuses on the stress-generation mechanism onaluminum as a function of the applied current density in acidic solutions of sulfuric acid ofdifferent strengths giving variable pH. Abeam-deflection technique was utilized for thedetermination of the magnitude and direction of stressesgenerated during the anodic oxidation process. Generally,thickness of the oxide determines whether the stress iscompressive or tensile in nature. The results have beeninterpreted in terms of the formation and annihilation of anion (O^2-) and cation(Al³⁺) vacancies. A reduction in thealuminum-ion vacancy concentration (V Al ³ ) results in a compressive stressdeflection, whereas tensile-stress deflection isintroduced by an increase in the oxygen vacancy(Vo²⁺) concentration. The mechanism isfurther elucidated by current-density jump/dropexperiments. The results show that stress in this caseis affected by the dissolution of the oxide at the oxide-electrolyteinterface.     

Welding of Ti–6Al–4V and TiB2–Ni cermet using pulsed current heating

Abstract

Ti–6Al–4V alloy was joined with TiB₂–Ni cermet by using pulsed current heating and hot pressing. The properties were found to be better with the pulsed current process, because the current enhanced the growth of Ni–Ti phase at the junction between the two materials. Furthermore, the heat affected zone is localised in the pulsed current process relative to that in the hot pressed material.     

基于控制策略的变压器励磁涌流分析

介绍了一个计及合闸角和剩磁效应的三相变压器模型 ,通过该模型推导出励磁涌流与合闸角和铁心剩磁通间的相互关系。在此基础上提出了基于DSP的分相合闸控制策略并给出相应的软、硬件设计思想。仿真结果表明 :该方法可大幅减小励磁涌流的冲击 ,使变压器各电磁参数迅速进入稳态     

Electrodeposition of high performance multilayer coatings of Zn–Co using triangular current pulses

Abstract

Compositionally modulated alloy (CMA) coatings of Zn–Co were electrodeposited on to mild steel from an acid chloride bath containing thiamine hydrochloride, as an additive. Electroplating was carried out galvanostatically from a single bath containing Zn²⁺ and Co²⁺ ions. Gradual change in composition in each layer was effected by triangular current pulses, cycling between two cathode current densities. Compositionally modulated alloy coatings were developed under different conditions of cyclic cathode current density and number of layers, and their corrosion resistances were evaluated by potentiodynamic polarisation and electrochemical impedance spectroscopy. The formation of multilayer and corrosion mechanism was analysed using scanning electron microscopy. The corrosion resistances of CMA and monolithic alloy coatings were compared with that of the base metal. Compositionally modulated alloy coating at optimal configuration, represented as (Zn–Co)_{2·0/4·0/300}, was found to exhibit ～80 times better corrosion resistance compared with monolithic (Zn–Co)_3·0 alloy, deposited for the same length of time from the same bath. Improved corrosion resistance was attributed to the formation of n-type semiconductor film at the interface, supported by Mott–Schottky plots. Decrease in corrosion resistance at high degree of layering was found, and is due to lower relaxation time for redistribution of solutes in the diffusion double layer, during plating.     

Prediction of weld quality in pulsed current GMAW process using artificial neural network

Abstract

Weld joint dimensions and weld metal mechanical properties are important quality characteristics of any welded joint. The success of building these characteristics in any welding situation depends on proper selection-cum-optimisation of welding process parameters. Such optimisation is critical in the pulsed current gas metal arc welding process (GMAW-P), as the heat input here is closely dictated by a host of additional pulse parameters in comparison to the conventional gas metal arc welding process. Neural network based models are excellent alternatives in such situations where a large number of input conditions govern certain outputs in a manner that is often difficult to adjudge a priori. Six individual prediction models developed using neural network methodology are presented here to estimate ultimate tensile strength, elongation, impact toughness, weld bead width, weld reinforcement height and penetration of the final weld joint as a function of four pulse parameters, e.g. peak current, base current, pulse on time and pulse frequency. The experimental data employed here are for GMAW-P welding of extruded sections of high strength Al–Zn–Mg alloy (7005). In each case, a committee of different possible network architectures is used, including the final optimum network, to assess the uncertainty in estimation. The neural network models developed here could estimate all the outputs except penetration fairly accurately.     

Effects of torch configuration and welding current on weld bead formation in high speed tandem pulsed gas metal arc welding of steel sheets

Abstract

Undercut and humping bead are the common defects that limit the maximum welding speed of tandem pulsed gas metal arc (GMA) welding. In order to increase the maximum welding speed, effects of the inclination angle, interwire distance and welding current ratio between the leading wire and trailing wire on bead formation in high speed welding are investigated. The undercut and humping bead is attributed to the irregular flow of molten metal towards the rear part of the weld pool. This irregular flow can be prevented by the trailing wire with a push angle from 5° to 13° , which provides an appropriate component of arc force in the welding direction. The irregular flow is also related to the distance between the leading wire and the trailing wire, and the flow becomes regular when the distance is in the range 9–12 mm. Moreover, the stabilisation of the bulge of the weld pool between the two wires, the presence of enough molten metal below the trailing arc, and the reduced velocity of molten metal flow towards the rear part of the weld pool, are essential to increase the maximum welding speed. These conditions can be obtained by adjusting the ratio of the leading arc current to the trailing arc current. A maximum welding speed as high as 4–4·5 m min^?1 is achieved by setting the current ratio to a value ranging from 0·31 to 0·5.