Showing papers in "Metallurgical and Materials Transactions B-process Metallurgy and Materials Processing Science in 2019"

Additive Manufacturing of a Steel–Ceramic Multi-Material by Selective Laser Melting

Abstract: Most techniques employed for powder bed additive manufacturing (AM) only can handle a single material. However, additional functionality of the structures built, e.g., local insulation, is desirable for more sophisticated applications. In the present work, a multi-material process allowing for realization of a ceramic coating on a steel substrate and a novel sandwich system are introduced. Both were manufactured by selective laser melting (SLM). As a first step, the microstructure of a bulk zirconia–alumina ceramic, directly manufactured by SLM, was examined and its tensile strength determined. Afterwards, the ceramic was manufactured directly on the as-built surface of a tool steel processed by SLM. For this compound, the adhesive strength was determined. Finally, an open porous structure, made of the same tool steel, was built on top of the ceramic layer. The results clearly prove that the SLM process can be used for direct manufacturing of a multi-material sandwich structure made from metal and ceramic, providing an important step towards complex structures functionalized for electric insulation.

A Review of Physical and Numerical Approaches for the Study of Gas Stirring in Ladle Metallurgy

Abstract: This article presents a review of the research into gas stirring in ladle metallurgy carried out over the past few decades. Herein, the physical modeling experiments are divided into four major areas: (1) mixing and homogenization in the ladle; (2) gas bubble formation, transformation, and interactions in the plume zone; (3) inclusion behavior at the steel–slag interface and in the molten steel; and (4) open eye formation. Several industrial trials have also been carried out to optimize gas stirring and open eye formation. Approaches for selecting criteria for scaling to guarantee flow similarity between industrial trials and physical modeling experiments are discussed. To describe the bubble behavior and two-phase plume structure, four main mathematical models have been used in different research fields: (1) the quasi-single-phase model, (2) the volume of fluid (VOF) model, (3) the Eulerian multiphase (E–E) model, and (4) the Eulerian–Lagrangian (E–L) model. In recent years, the E–E model has been used to predict gas stirring conditions in the ladle, and specific models in commercial packages, as well as research codes, have been developed gradually to describe the complex physical and chemical phenomena. Furthermore, the coupling of turbulence models with multiphase models is also discussed. For physical modeling, some general empirical rules have not been analyzed sufficiently. Based on a comparison with the available experimental results, it is found that the mathematical models focusing on the mass transfer phenomenon and inclusion behaviors at the steel-slag interface, vacuum degassing at the gas–liquid interface, dissolution rate of the solid alloy at the liquid–solid interface, and the combination of fluid dynamics and thermodynamics need to be improved further. To describe industrial conditions using mathematical methods and improve numerical modeling, the results of physical modeling experiments and industrial trials must offer satisfactory validations for the improvement of numerical modeling.

High-Temperature Properties and Microstructural Stability of the AISI H13 Hot-Work Tool Steel Processed by Selective Laser Melting

Abstract: The microstructural stabilities, softening resistance, and high-temperature tensile properties of the H13 hot-work tool steel by selective laser melting (SLM) were systematically studied. A series of tempering procedures were performed on the as-SLMed specimens. Afterwards, the mechanism of softening resistance behavior was discussed based on the XRD, SEM, EBSD observations, hardness measurements, and high-temperature tensile tests. It was found that the as-SLMed H13 consisted of α-iron and γ-iron. The carbide-stabilizing elements aggregated as the cell-like substructures for the rapid solidification of the SLM process. After the softening resistance treatment, the retained austenite transformed to ferrite and carbide mixtures. The cell-like substructures dissolved slowly into the matrix when the temperature was below 550 °C. These factors increased the hardness and retarded the softening of the material. When the temperature was 600 °C, the microstructural constituents transformed to soft ferrite and globular carbides, which lead to a considerable decrease of the hardness. Due to the grain refinement, solid solution strengthening, and residual stress, the as-SLMed H13 exhibited better mechanical properties than that of the wrought counterparts.

Novel Cooling Rate Correlations in Molten Metal Gas Atomization

Abstract: The cooling rate in molten metal gas atomization is the key determining factor for the microstructure of metal powders. Mathematical expressions for cooling rates often include the melt droplet diameter and a pre-exponential factor describing the materials and gas properties. A new mathematical cooling rate correlation for rapidly solidified melt droplets is proposed based on heat flow considerations during gas atomization. The model approach takes process conditions such as gas-to-melt mass flow ratio and the initial gas temperature into account. The mathematical formulation was experimentally developed using secondary dendrite arm spacing method. For this purpose, a Cu-6wt pct Sn alloy was atomized with close-coupled (CCA) and free-fall atomization (FFA). A novel approach was made to predict the pre-exponential factor that allows the transferability to other materials. Our correlation for the cooling rate and the pre-exponential factor was validated by experimental data from the literature. The novel correlation type is valid for two different atomizing systems (FFA and CCA), suggesting that it may be applicable to entirely different gas atomization systems.

Transformation of Inclusions in Linepipe Steels During Heat Treatment

Abstract: The effect of heat treatment on the transformation of inclusions in linepipe steels was investigated experimentally and theoretically. During heat treatment, CaO-Al2O3 type of inclusions in steels before heating transformed into Al2O3-CaS type, and in the form of CaS-Al2O3-MgO eventually with CaS formed on the surface of Al2O3-MgO phase, depending on the heating temperature, heating time, size of inclusions, and components such as T.Ca and T.O in steels. The transformation details were revealed by thermodynamic calculations and kinetics analysis; what is more, the coefficients kinc of each composition in inclusions such as Al2O3, MgO, CaO, and CaS at 1473 K (1200 °C) were calculated, respectively. The theoretical results in this paper are in good agreement with the experimental observations.

Dendritic Growth Under Natural and Forced Convection in Al-Cu Alloys: From Equiaxed to Columnar Dendrites and from 2D to 3D Phase-Field Simulations

Abstract: The interaction between convection and solute transport during solidification has significant influence on the dendritic evolution. By employing the phase-field lattice-Boltzmann approach together with the parallel and adaptive-mesh-refinement algorithm, the dendritic evolution under convection is simulated in both 2D and 3D cases. The flow-induced redistribution of the solute alters both tip velocity and the development of dendritic arms. The effect of both convection and undercooling is quantified and compared using the length ratio of the dendritic arms. The effect of convection behavior (i.e., natural and forced) and domain dimension (i.e., 2D and 3D) on dendritic growth is discussed. Results show that the convection effect is mainly dominated by the convection mode, and the melt flow in 2D can produce biased results comparing with those in 3D.

Effect of Nozzle Port Angle on Transient Flow and Surface Slag Behavior During Continuous Steel-Slab Casting

Abstract: Undesirable flow variations can cause severe instabilities at the interface between liquid mold flux and molten steel across the mold top-region during continuous steel casting, resulting in surface defects in the final products. A three-dimensional Large Eddy Simulation (LES) model using the volume of fluid method for the slag and molten steel phases is validated with plant measurements, and applied to gain new insights into the effects of nozzle port angle on transient flow, top slag/steel interface movement, and slag behavior during continuous slab casting under nominally steady conditions. Upward-angled ports produce a single-roll flow pattern with lower surface velocity, due to rapid momentum dissipation of the spreading jet. However, strong jet wobbling from the port leads to greater interface variations. Severe level drops allow easy entrapment of liquid flux by the solidifying steel shell at the meniscus. Sudden level rises may also be detrimental, leading to overflow of the solidified meniscus region. Downward-angled ports produce a classic double-roll pattern with less jet turbulence and a more stable interface everywhere except near the narrow faces. Finally, the flow patterns, surface velocity, and level predicted from the validated LES model are compared with steady-state standard k-e model predictions.

Insight into the Relationship Between Viscosity and Structure of CaO-SiO2-MgO-Al2O3 Molten Slags

Abstract: This article elucidates the quantitative relationship between viscosity and structure in a basic slag system of CaO-SiO2-MgO-Al2O3 and focuses on the role of Al2O3. Slag viscosity was measured by the rotating cylinder method, and structural information was obtained using Fourier transformation infrared, Raman and magic angular spinning nuclear magnetic resonance (MAS-NMR) techniques. The results show that, as the Al2O3 content increased, slag viscosity increased initially and decreased afterwards, directly indicating that Al2O3 had an amphoteric effect on slag viscosity. The Raman spectra verified that with increasing Al2O3 content, the concentrations of Q0(Si) and Q2(Si) decreased first and then increased, while that of Q1(Si) kept increasing and that of Q3(Si) increased first and then decreased. The 27Al MAS-NMR spectra proved that the mole ratios of AlO5 and AlO6 to AlO4 kept increasing with the increase of Al2O3 content, and, overall, Al2O3 changed from a network former to a network modifier. The relationship between the viscosity and structure of the molten slags was further analyzed quantitatively based on the modified (NBO/T), denoted as (NBO/T)′, and we found a fine linear correlation between the logarithm of viscosity and (NBO/T)′. Moreover, the variations of thermodynamic properties of this system also indirectly supported the present experimental results.

Iron Ore Reduction by Hydrogen Using a Laboratory Scale Fluidized Bed Reactor: Kinetic Investigation—Experimental Setup and Method for Determination

Abstract: The reduction kinetics of hematite iron ore fines to metallic iron by hydrogen using a laboratory fluidized bed reactor were investigated in a temperature range between 873 K and 1073 K, by measuring the weight change of the sample portion during reduction. The fluidization conditions were checked regarding plausibility within the Grace diagram and the measured pressure drop across the material during experiments. The apparent activation energy of the reduction was determined against the degree of reduction and varied along an estimated two-peak curve between 11 and 55 kJ mol−1. Conventional kinetic analysis for the reduction of FeO to metallic iron, using typical models to describe gas–solid reactions, does not show results with high accuracy. Multistep kinetic analysis, using the Johnson–Mehl–Avrami model, shows that the initial stage of reduction from Fe2O3 to Fe3O4, and partly to FeO, is controlled by diffusion and chemical reaction, depending on the temperature. Further reduction can be described by a combination of nucleation and chemical reaction, whereby the influence of nucleation increases with an increasing reduction temperature. The results of the kinetical analysis were linked to the shape of the curve from apparent activation energy against the degree of reduction.

Molecular Dynamics Simulation on the Effect of MgO/Al2O3 Ratio on Structure and Properties of Blast Furnace Slag Under Different Basicity Conditions

Abstract: The SiO2-Al2O3-CaO-MgO is the basic structural system of blast furnace slag and the composition directly affects the performance of the slag. Molecular dynamics simulations were carried out to analyze the local structure, structural unit, bond angle, transport properties, and enthalpy of the slag with the increase of MgO/Al2O3 mass ratio under different basicity conditions. It was found that the change of MgO/Al2O3 ratio does not affect the short-range order structure, but it will reduce the overall stability of the network structure. Through the analysis of the structural unit of the slag, it was found that the polymerization degree of the system decreases with the increase of MgO/Al2O3 ratio, indicating that the complex network structure of the system is partially depolymerized. Besides, the self-diffusion coefficients of each ion were concluded and the magnitudes were observed to be in the following order: Mg2+>Ca2+>Al3+>O2->Si4+. The diffusivity of the slag increases with the increase of MgO/Al2O3 ratio and the corresponding viscosity decreases. And the enthalpy of the slag is increased with the increase of MgO/Al2O3 ratio or basicity, therefore the fuel consumption should also be properly adjusted during the operation of blast furnace to ensure the target temperature.

Recovery of Carbon and Valuable Components from Spent Pot Lining by Leaching with Acidic Aluminum Anodizing Wastewaters

Abstract: A three-step process was employed to separate cryolite from used carbon cathodes, known as spent pot lining (SPL), and obtain valuable carbon. The process comprised leaching of NaF from the imbedded electrolyte with water, followed by leaching of Na3AlF6, CaF2, and NaAl11O17 with acidic anodizing wastewater, and then precipitating the electrolyte components from the mixed filtrate from the previous two steps. The influences of stirring rate, liquid–solid ratio, temperature, and time on the extent of leaching of cryolite and recovery of carbon were studied. Additionally, the effects of pH value, F/Al ratio, temperature, and time on the recovery of valuable components in the mixed filtrate were evaluated. The results showed that most NaF in the SPL was dissolved by water leaching. The residual electrolyte in SPL was mainly cryolite and contained approximately 0.95 pct NaF. The purity of the carbon obtained reached 95.5 pct under optimal experimental conditions (leaching temperature: 80 °C; stirring rate: 300 rpm; liquid–solid ratio: 8 mL/g; leaching time: 180 minutes). The recovery of cryolite and the purity of the sodium sulfate crystal from the mixed filtrate were 98.4 and 92.0 pct, respectively, under suitable conditions (pH 9; 75 °C; 4 hour; F/Al ratio of 6:1).

Evolution of Oxide Inclusions in Si-Mn-Killed Steel During Protective Atmosphere Electroslag Remelting

Abstract: The current study was motivated to reveal the evolution of MnO-SiO2-Al2O3 inclusions during protective atmosphere electroslag remelting (P-ESR), and the effect of slag composition on the inclusion evolution. The oxide inclusions in the consumable steel electrode were ternary (7.1-26.4 mass pct) MnO-(53.3-82.8 mass pct) SiO2-(8.3-23.1 mass pct) Al2O3 without exception, which were fully removed during the P-ESR in two ways: a portion of these inclusions were dissociated in its individual chemical species into liquid steel, whereas the others were removed by absorbing them into molten slag before liquid metal droplets collected in liquid metal pool during P-ESR. The oxide inclusions both in liquid metal pool and in remelted ingots are mostly MgAl2O4 (containing about 3 mass pct MgO) and Al2O3 inclusions, irrespective of the SiO2 contents (1.9 to 9.0 mass pct) in the slag. These inclusions readily formed in the liquid metal pool as a result of the reaction between alloying elements and the dissolved oxygen in liquid steel that dissociated from MnO-SiO2-Al2O3 inclusions.

Deoxidation of Titanium Using Mg as Deoxidant in MgCl 2 -YCl 3 Flux

Abstract: To reduce the oxygen level in titanium (Ti) to less than 1000 mass ppm O, using magnesium as the deoxidant at 1300 K (1027 °C), the activity of the deoxidation product (MgO), i.e., aMgO, in the system must be reduced to less than 0.04, from a thermodynamic viewpoint. In this study, we developed a new deoxidation technique for Ti, by adding yttrium chloride (YCl3) to magnesium chloride (MgCl2) flux, which effectively decreases and maintains the aMgO in the system at a low level, via the formation of yttrium oxychloride (YOCl). Through thermodynamic assessment using a $$ p_{{{\text{O}}_{ 2} }} {\text{-}}p_{{{\text{Cl}}_{ 2} }} $$ diagram, as well as experiments, the deoxidation of Ti to an oxygen level below 1000 mass ppm O, via the reaction O (in Ti) + Mg + YCl3 → MgCl2 + YOCl, was confirmed. Furthermore, using the E-pO2− diagram of the M-O-Cl system (M = Y, Mg), the possibility of electrochemical deoxidation is discussed. In the MgCl2-YCl3 flux, Mg deposits on the Ti cathode and simultaneously deoxidizes it. The activity of the deoxidation product, MgO, decreases due to the formation of YOCl and/or the electrochemical oxidation of oxide ions on the carbon anode; thus, the deoxidation of Ti becomes feasible. This new deoxidation technique using rare-earth-containing MgCl2 flux can be applied to the recycling of Ti scraps, in the future.

A Novel Shim-Assisted Resistance Spot Welding Process to Improve Weldability of Medium-Mn Transformation-Induced Plasticity Steel

Abstract: Medium-Mn transformation-induced plasticity steels have great potential to significantly reduce vehicle weight and improve fuel economy due to their outstanding combination of high strength and excellent ductility. One bottleneck to the application is their poor weldability resulting from their high Mn contents. In this paper, three resistance spot welding set-ups, including no shim, an interstitial-free steel shim at the faying interface (shim-in) and shims against the electrodes (shim-out), were incorporated to investigate the weldability of Fe-7Mn-0.14C medium-Mn steel. Tensile-shear, cross-tension, and microhardness tests were used to evaluate the mechanical properties of the welds. Experimental results demonstrated that the failure mode of the welds transitioned from the interfacial fracture in the case of no shim to the desired nugget pull-out fracture in the shim-out set-up, resulting in dramatical improvements in both peak loads and their corresponding extensions during the tensile-shear and cross-tension tests. In contrast, the shim-in set-up made no improvement. What can contribute to such improvement was then discussed on the basis of observed morphologies and microstructures of welds.

Increased Use of Natural Gas in Blast Furnace Ironmaking: Mass and Energy Balance Calculations

Abstract: In blast furnace ironmaking, coke can be partially replaced by injected natural gas. Tuyere injection of cold natural gas is commonly practiced in North America. In this work, limits to the tuyere injection rate have been quantified with mass and energy balances. The fundamental origin of the limits is the endothermicity of methane injection. In principle, shaft injection of preheated and partially combusted methane would obviate the endothermic effect. However, the thermal and chemical energy parameter indicates that the energy requirement in the lower part of the furnace—to melt hot metal and slag—might not be met in the case of shaft injection. Tuyere injection of preheated methane might be a feasible alternative. Calculated combustion kinetics support the feasibility of partial combustion of preheated methane (with sub-stoichiometric oxygen) before injection.

Characterization of Inclusions in 3rd Generation Advanced High-Strength Steels

Abstract: Samples taken from laboratory-produced 3rd generation advanced high-strength steels, solidified at a low cooling rate, have been investigated to study the characteristics of non-metallic inclusions. Two steels, containing 2 and 5 pct Mn content, were produced for this purpose. A higher number of total inclusions were observed in 5 pct Mn steel. The four main types of inclusions observed were Al2O3, AlN, MnS, and AlSiMn-oxide. These classes were divided into subclasses according to variations in their chemistry. The major subclasses of AlN inclusions are either plate-like or regular in shape and have different size distributions. Thermodynamic calculations suggest that plate-like AlN inclusions are formed at the initial stage of solidification, while faceted/regular-shaped inclusions are precipitated toward the end of solidification. Moreover, it was found that the size of nitride inclusions is related to their N content. This phenomenon is discussed from the viewpoint of nucleation theory.

Novel Approach to Studying Influences of Na 2 O and K 2 O Additions on Viscosity and Thermodynamic Properties of BF Slags

Abstract: The present work calculated the heat capacity, enthalpy change, and slag temperature of CaO–MgO–Al2O3–SiO2 slags after adding Na2O or K2O, and investigated the influences of Na2O and K2O on the slag viscosity under given temperatures and heat quantities. It was found that the slag viscosity decreases with the addition of Na2O and tends to increase with K2O additions at the same temperature. The heat capacity of the slag increases, while the enthalpy change decreases obviously with the increasing addition of Na2O or K2O. Under the constant heat quantity, an increase in content of Na2O or K2O of the slag leads to an appreciable increase in slag temperature, whereas the viscosity decreases significantly. Besides, the Na2O or K2O additions also help to stabilize the slag fluidity and lower energy consumption of blast furnace.

Tuning Weld Metal Mechanical Responses via Welding Flux Optimization of TiO 2 Content: Application into EH36 Shipbuilding Steel

Abstract: A series of TiO2-containing basic-fluoride-type agglomerated fluxes was applied to join EH36 shipbuilding steel under high heat input SAW. The effects of TiO2 content on composition, microstructure features, inclusions characteristics, and mechanical properties of ensuing weld metals (WMs) were systematically investigated. 6 wt pct TiO2 leads to the most optimal mechanical properties. Such behaviors were elucidated via transfer of alloying elements, which enables a good combination of acicular ferrites (AFs) and accompanying microstructures.

A Review on Friction Stir Processing of Titanium Alloy: Characterization, Method, Microstructure, Properties

Abstract: In the past two decades, friction stir processing (FSP) technology has received considerable attention. FSP can be used to adjust and control the microstructure of materials, including eliminating defects, destroying dendrites and controlling fractions in the second stage, and is therefore widely used in titanium and its alloys for biomedical, aerospace and automotive applications. This article comprehensively reviews the methods of studying FSP, the microstructure evolution of materials and the summary of material properties. It begins with the introduction of the FSW system, characterization, structure and elemental analysis, and simulation and performance testing methods, and then introduces the microstructure evolution mechanism of various titanium materials and discusses in detail the material properties of titanium alloy, namely hardness and wear resistance, elasticity and plasticity, corrosion resistance and biocompatibility. Finally, this review presents unresolved issues and outstanding challenges in FSP technology and reveals the direction of this emerging field of research.

Characteristics of Bi-metallic Interfaces Formed During Direct Energy Deposition Additive Manufacturing Processing

Abstract: Various additive manufacturing processes are being evaluated to reduce the time and cost for fabrication of low volume, complex, and multifunctional assemblies. This study evaluated two direct energy deposition processes for the fabrication of large bi-metallic structures. The materials evaluated were Inconel 625 and copper alloy C18150, which are used in various high heat flux applications. Inconel was deposited onto the C18150 substrate using blown powder and wire-fed processes. Complete bonding was obtained in both processes and the resulting interfaces were evaluated using microscopy and indentation testing. Differences were observed in the interface region suggesting the kinetic energy of the blown powder process resulted in more residual stress at the interface, promoting recrystallization and enhanced diffusion. This created a broader interface in the blown powder specimens compared to a narrower mechanically mixed interface with the wire-fed process.

Finding the Most Efficient Way to Remove Residual Copper from Steel Scrap

Abstract: The supply of end-of-life steel scrap is growing, but residual copper reduces its value. Once copper attaches during hammer shredding, no commercial process beyond hand-picking exists to extract it, yet high-value flat products require less than 0.1 wt pct copper to avoid metallurgical problems. Various techniques for copper separation have been explored in laboratory trials, but as yet no attempt has been made to provide an integrated assessment of all options. Therefore, for the first time, a framework is proposed to define the full range of separation routes and evaluate their potential to remove copper, while estimating their energy and material input requirements. The thermodynamic, kinetic, and technological constraints of the various techniques are analyzed to show that copper could be removed to below 0.1 wt pct with relatively low energy and material consumption. Higher-density shredding allows for greater physical separation, but requires proper incentivization. Vacuum distillation could be viable with a reactor that minimizes radiation heat losses. High-temperature solid scrap pre-treatments would be less energy intensive than melt treatments, but their efficacy with typical shredded scrap is yet unconfirmed. The framework developed here can be applied to other impurity-base metal systems to coordinate process innovation as the scrap supply expands.

Microstructural Modeling of the α + β Phase in Ti-6Al-4V: A Diffusion-Based Approach

Abstract: Complex heat treatment operations and advanced manufacturing processes such as laser or electron-beam welding will see the metallic workpiece experience a considerable range of temperatures and heating/cooling rates. These intrinsic conditions will have a significant bearing upon the microstructure of the material, and in turn upon the thermo-mechanical properties. In this work, a diffusion-based approach to model the growth and shrinkage of precipitates in the alpha + beta field of the common titanium alloy Ti-6Al-4V is established. Further, the numerical model is extended using a JMA-type approach to explore the dependency of the beta-transus temperature on extremely high heating rates, whereby dissolution alone is too slow to accurately describe the alpha to beta-phase transformation. Experimental heat treatments at rates of 5, 50, and 500 °C/s were performed, and metallographic analysis of the samples was used to validate the numerical modeling framework predictions for lamellar shrinkage, while data from the literature has been used to evaluate the numerical modeling framework for the growth of equiaxed microstructures. The agreement between measurements and numerical predictions was found to be good.

Effects of B 2 O 3 on Crystallization, Structure, and Heat Transfer of CaO-Al 2 O 3 -Based Mold Fluxes

Abstract: The reaction between traditional CaO-SiO2-based mold fluxes and high-Al steel inevitably changes flux composition, and, consequently, flux properties. This problem can be mitigated by using CaO-Al2O3-based mold fluxes. To maintain appropriate melting properties, CaO-Al2O3-based mold fluxes contain B2O3, which is an effective fluxing agent that decreases the liquidus temperature. In this article, the effects of B2O3 on crystallization behavior, structure, and heat transfer of CaO-Al2O3-based mold fluxes were studied using single/double hot thermocouple technique, Raman spectroscopy, and infrared emitter technique. The increase of B2O3 content from 7.6 to 13.1 mass pct suppressed the crystallization tendency of mold fluxes in continuous cooling experiments and isothermal experiments conducted over 1273 K (1000 °C). The isothermal crystallization below 1273 K (1000 °C) was also inhibited when B2O3 content increased from 7.6 to 9.6 mass pct; but a further increase of B2O3 content to 13.1 mass pct did not show a visible effect on the crystallization tendency. The increase of B2O3 content from 9.6 to 13.1 mass pct improved the heat fluxes under an incident thermal radiation of 1.6 MW/m2; however, the increase of B2O3 content from 7.6 to 9.6 mass pct slightly decreased the heat transfer rate. Crystallization of fluxes and heat transfer were discussed in relation to flux structure.

A Comprehensive Analysis of Macrosegregation Formation During Twin-Roll Casting

Abstract: A two-phase Eulerian–Eulerian volume-averaged model is used to predict the formation of macrosegregation during the twin-roll casting of inoculated Al-4 wt pct Cu alloys. For low solid fractions, the equiaxed crystals are modeled according to the submerged object approach. However, above a given transition limit, they are assumed to behave like a viscoplastic material. This means that the solid phase behaves as a coherent structure that can influence the motion of the liquid. Such approach allows one to take into account the flow dynamics arising from the occurrence of both solidification and hot rolling simultaneously, which usually occurs in twin-roll casting. Therefore, it is possible to explain the origin of the macrosegregation patterns obtained in the simulations based on the relative motion between the phases. Compression-induced expulsion of segregated melt is observed as a result of the deformation of the solidifying shells. Such occurrence leads to a negative macrosegregation region in the outer part of the as-cast strip. Then, because the solute-enriched melt is squeezed out toward adjacent regions, two positively segregated bands can be found near the center of the domain. Furthermore, it is shown how solidification-induced feeding weakens the absolute value of the negative and positive segregation bands.

The Importance of Viscous and Interfacial Forces in the Hydrodynamics of the Top-Submerged-Lance Furnace

Abstract: The purpose of this work is to focus on the hydrodynamics of a Top-Submerged-Lance (TSL) smelting furnace, understanding how liquid properties and operational parameters act on key factors of a TSL process, such as splashing, mixing, mass transfer area, and bubble development. A deep knowledge of all those aspects is needed since they all influence the smelting reaction rates; hence the efficiency of the reactor. The characterization and scaling of the TSL gas injection are commonly based on the modified Froude number, the ratio of dynamic and gravitational forces. Detailed literature research reveals a potential weakness of this approach, since it does not consider the effects of viscosity and surface tension. To investigate this question an extensive parametric study was performed applying computational fluid dynamics to cold and non-reactive flows, which provided a broad overview of the physics of the flow. The analysis was performed on fluid dynamic properties (liquid density, liquid viscosity, surface tension) and operational variables (gas volume flow, lance immersion depth). The coupled Level Set—Volume of Fluid model, available in the commercial solver ANSYS Fluent®, was used to resolve the gas–liquid interface in the multiphase flow. The results of the work underscore the significance of the viscous and interfacial forces for gas injection in smelting slags, confirming the incompleteness of applying only the Froude number to describe such flows.

Model Study of Blast Furnace Operation with Central Coke Charging

Abstract: Blast furnace (BF) remains the dominant ironmaking process worldwide. Central coke charging (CCC) operation is a promising technology for stabilizing BF operations, but it needs reliable and quantified process design and control. In this work, a multi-fluid BF model is further developed for quantitatively investigating flow-thermal-chemical phenomena of a BF under CCC operation. This model features the respective chemical reactions in the respective coke and ore layers, and a specific sub-model of layer profile for the burden structure for the CCC operation. The simulation results confirm that the gas flow patterns and cohesive zone’s shape and location under the CCC operation are quite different from the non-CCC operation. Under the CCC operation, the heat is overloaded at the furnace center while the reduction load is much heavier at the periphery regions; the profiles of top gas temperature and gas utilization show bell-shape and inverse-bell-shape patterns, respectively. More importantly, these differences are characterized quantitatively. In this given case, when the CCC opening radius at the throat is 0.35 m, the cohesive zone top opening radius is around 0.50 m, and the isotherms of CCC operation become much steeper (~ 80 deg) than those of non-CCC operation (~ 60 deg) near BF central regions. In addition, it is confirmed that carbon solution-loss reaction rate can be decreased significantly at BF central regions under CCC operation. The model helps to understand CCC operation and provides a cost-effective method for optimizing BF practice.

In Situ Observation of Acicular Ferrite Nucleation and Growth at Different Cooling Rate in Ti-Zr Deoxidized Steel

Abstract: The effects of cooling rate on acicular ferrite (AF) nucleation, growth, and inclusion characteristics in Ti-Zr deoxidation steel were studied by utilizing the high temperature confocal laser scanning microscope (HT-CLSM). The results indicated that with the increase of cooling rate, the ferrite start nucleation temperature decreased, and the difference of first nucleation temperature between AF and ferrite side plate (FSP) reduced. When the cooling rate increased to 10.0 °C/s, AF and FSP simultaneously nucleated at 564.5 °C. In addition, the AF actual growth rate rose with the increase of cooling rate and reached 30.13 µm/s at 10.0 °C/s cooling rate. The AF ratio in microstructure increased first and then decreased with the cooling rate increase and was up to the maximum 45.83 pct at 1.0 °C/s cooling rate. For inclusion characteristics, cooling rates had no obvious effect on inclusion types, but had a great influence on inclusions size distribution. With the cooling rate increase, the inclusion average diameter reduced, and diminished to 1.39 µm at 10.0 °C/s cooling rate. Finally, the AF nucleation on the Ti-Zr-Mn-O-S + TiN inclusion could be explained by the low lattice misfit between ferrite and TiN that precipitated on the Ti-Zr-Mn-O-S inclusion surface.

Effects of Nozzle Radial Position, Separation Angle, and Gas Flow Partitioning on the Mixing, Eye Area, and Wall Shear Stress in Ladles Fitted with Dual Plugs

Abstract: Mixing time, slag eye area, and wall shear stress in a ladle fitted with dual plugs have been studied as a function of operating variables, namely, gas flow rate, radial nozzle position, separation angle between nozzles and flow rate partitioning. While the mixing time and slag eye area have been experimentally investigated in a scaled water model (with and without a top slag layer), the shear stress on the vessel wall has been studied computationally via a RANS-based turbulent, three-dimensional coupled Eulerian–Lagrangian (VOF-DPM), multiphase flow model. Experimental and computational results have indicated that the mixing, eye area, and wall shear stress depend on the gas flow rate, i.e., while mixing efficiency increases with the increasing gas flow rate, the slag eye area, and wall shear stress, in contrast, become more pronounced with the increasing gas flow, leading to an undesirable operating regime. The radial nozzle position, separation angle between the nozzles and flow rate partitioning at any given flow rate also influence the ladle process performance, influencing the mixing, eye area, and wall shear stress, albeit to a varied degree. Within the range of operating conditions studied, an expected inverse correspondence between mixing time and shear behavior was observed. Experimental and computational results in conjunction have indicated that the best arrangement of porous plugs or gas injection nozzles for superior ladle process performance is dependent on the gas flow rate and is specific to the desired objective (i.e., decreasing the mixing time, or slag eye area and wall shear stress). Hence, a unique gas injection practice cannot and should not be suggested as the optimum for ladle metallurgy in steelmaking. Nevertheless, if the mixing time is the parameter of primary interest, a nozzle configuration with equal flow partitioning (1:1) between the nozzles and identical nozzle radial positions (0.7R/0.7R, 45 deg) should suffice for both low and high gas flow rates. In contrast, a nonidentical nozzle radial position (0.7R/0.5R, 90 deg) and an unequal gas flow rate per nozzle (1:3) appear preferable if both ladle eye and shear stresses, rather than mixing, are the issues of concern.

Effects of Fluorine on Solidification, Viscosity, Structure, and Heat Transfer of CaO-Al 2 O 3 -Based Mold Fluxes

Abstract: To mitigate the chemical reaction between mold fluxes and high-Al steel, CaO-Al2O3-based mold fluxes were proposed to replace the conventional CaO-SiO2-based mold fluxes. However, the high viscosity of CaO-Al2O3-based mold fluxes is harmful to the lubrication to the strand. In this article, the effects of fluorine on solidification, viscosity, structure, and heat transfer of CaO-Al2O3-based mold fluxes were evaluated. The addition of fluorine increased the break temperature and decreased the heat transfer rate of mold fluxes. It also reduced the flux viscosity at 1673 K (1400 °C) when fluorine content increased from 4.0 to 6.9 mass pct; but a further increase of fluorine to 12.5 mass pct did not notably change the flux viscosity. This phenomenon was correlated to the synergic effects of the dissociation of flux network and the increased potential of nucleation at high temperature with the fluorine addition.

Evolution Mechanism of Inclusions in Medium-Manganese Steel by Mg Treatment with Different Aluminum Contents

Abstract: To investigate the effect of magnesium addition on the evolution of inclusions in medium-manganese steel with different aluminum contents, both thermodynamic calculation and high-temperature simulation experiments were carried out in the present work. The in situ observation experiments were used to clarify the related evolution process of inclusions. The samples taken from the melts were analyzed by scanning electron microscopy and energy dispersive spectroscopy. The compositions of steel were determined by inductively coupled plasma-optical emission spectrometer. The results show that the aluminum content in steel has a certain influence on the magnesium content, under the same conditions, magnesium content increases with increasing aluminum content. The inclusions transformed from MnO·Al2O3 to Al2O3 when the aluminum content was higher than 0.0076 mass pct. After magnesium treatment, the inclusions gradually transformed into MgO·Al2O3, and the MgO/Al2O3 mole ratio in inclusions decreased with the increase of aluminum content. The diameter of the inclusions decreased, and number density of inclusions increased in steel after magnesium addition. The phenomenon that large-sized cluster-like Al2O3 inclusions transform into finely dispersed Mg-containing inclusions was firstly observed in situ by confocal laser scanning microscope.