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Applications in Iron and Steel Making
Published in Nirupam Chakraborti, Data-Driven Evolutionary Modeling in Materials Technology, 2023
In continuous casting the hot metal from a ladle is poured into a tundish which acts as a reservoir of metal and where some compositional adjustments take place. It helps in inclusion control and modification, sometimes alloy addition is done there; it also helps in particulate homogenization. The tundish feeds the metal to a water-cooled copper mold where the primary cooling takes place and a solidified shell forms in the outer region of the metals. The metal is sprayed upon by a bank of sprays leading to a secondary cooling and the shell thickness continues to increase while the metal continues to move being aided by a series of guiding rolls and is ultimately cut off once the complete solidification takes place. Both slab and bloom, which differ in their dimensions, can be cast this way.
Major Melt—Crucible Systems
Published in Nagaiyar Krishnamurthy, Metal–Crucible Interactions, 2023
The tundish refractory is usually made of magnesia and forsterite (2MgO·SiO2) raw materials. The lining may thus react with Al in steel, more so if the lining is porous. At the steel/refractory interface lining, a layer composed of MgO–Al2O3 spinel forms by reaction between aluminium in steel and forsterite in the refractory. Spalling due to the mismatch of properties between the spinel layer and the MgO–forsterite refractory lining can lead to MgO–Al2O3 inclusions in the steel. The ladle shroud is usually made of alumina–graphite. The same reactions as in the submerged nozzle are also possible here.
Casting and Reheating of Steel
Published in Vladimir B. Ginzburg, Metallurgical Design of Flat Rolled Steels, 2020
Continuous casting of thick slabs is commonly performed by employing vertical plus bending casting (Fig. 6.2B). Below is a brief description of the casting process that utilizes this method [4]. In order to start the casting process, the dummy bar is inserted In the mold so that its top closes the bottom of the mold. The insertion of the dummy bar is made either from the top of the machine or through entire machine in the bottom of the mold. Liquid steel is then poured at a controlled rate from ladle into the tundish and then the metal flows through nozzles in the bottom of tundish and fills the mold.
Experimental investigation of flow control devices effect on inclusion separation in a four strand tundish
Published in Canadian Metallurgical Quarterly, 2019
Mohamad Reza Mosalman Yazdi, Ahmad Reza Faghih Khorasani, Shahram Talebi
Tundish, as a continuous metallurgical reactor, provides the steel to be used in the continuous casting molds with the desired flow rate, constant temperature, uniform chemistry, and low inclusion count. Metallurgical and fluid mechanics studies on tundish can result in not only increased steel quality, but also increased production efficiency, reduced refractory wear, increased casting sequence, and further control over operation turbulence.
Machine learning algorithms for the prediction of the strength of steel rods: an example of data-driven manufacturing in steelmaking
Published in International Journal of Computer Integrated Manufacturing, 2020
Estela Ruiz, Diego Ferreño, Miguel Cuartas, Ana López, Valentín Arroyo, Federico Gutiérrez-Solana
The fabrication of steel rods comprises four major stages, namely, electric arc furnace (EAF), ladle furnace (LF), continuous casting (CC) and hot rolling (HR). These are briefly described hereafter (Gasik 2013; Wente, Nutting, and Wondris 2019; Ruiz et al. 2019; Seetharaman et al. 2014): Steel scrap, direct reduced iron and hot briquetted iron are melted in the EAF by means of high-current electric arcs to obtain liquid steel with the required chemistry and temperature. To promote the formation of slag, lime and dolomite are included in the EAF; slag favors the refining of steel and reduces excessive heat loss. Molten steel (He et al. 2019) is poured into the transportation ladle where ferroalloys and additives are added to form a new slag layer. During the EAF stage, the chemical composition, the temperature and the time required, among other parameters, are recorded.Secondary metallurgy is conducted in the LF where the final chemical composition and the temperature of the steel are adjusted. During refining in the ladle, deoxidizers, slag formers, and other alloying agents are added. Argon stirring is employed to homogenize temperature and composition and to promote the flotation of alumina inclusions into the slag. The chemistry of steel and slag, different temperatures and the amounts of fluxes and argon injected are monitored in the LF stage.The solidification of steel in the form of billets occurs in the CC unit. Liquid steel is poured from the ladle into the tundish, a small distributer that controls the flow rates and feeds the mold. Billets are usually 75 to 200 millimeters square. Chemical compositions and temperatures make up the parameters recorded at this stage.Rods are obtained from billets through HR. The steel is passed through several pairs of rolls to reduce the thickness (the final cross-section is typically between 8 and 12 mm in diameter). The temperature of steel during forming is above the recrystallization temperature, because of its low resistance to plastic deformation at this temperature. Rods are coiled after HR.