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Open AccessArticle

Crystallization of Slag Films of CaO-Al₂O₃-BaO-CaF₂-Li₂O-Based Mold Fluxes for High-Aluminum Steels’ Continuous Casting

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Materials 2023, 16(5), 1903; https://doi.org/10.3390/ma16051903 - 25 Feb 2023

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Abstract

In this study, solidified films of CaO-Al₂O₃-BaO-CaF₂-Li₂O-based mold fluxes with different contents of Al₂O₃ addition were acquired by immersing an improved water-cooled copper probe in bulk molten slags. This probe can obtain [...] Read more.

In this study, solidified films of CaO-Al₂O₃-BaO-CaF₂-Li₂O-based mold fluxes with different contents of Al₂O₃ addition were acquired by immersing an improved water-cooled copper probe in bulk molten slags. This probe can obtain films with representative structures. Different slag temperatures and probe immersion times were employed to investigate the crystallization process. The crystals in the solidified films were identified using X-ray diffraction, the morphologies of the crystals were observed using optical microscopy and scanning electron microscopy, and the kinetic conditions, especially the activation energy of devitrified crystallization in glassy slags, were calculated and discussed based on the differential scanning calorimetry. The results indicated that after adding extra Al₂O₃, the growing speed and thickness of the solidified films increased, and more time was required for the film thickness to reach a steady state. In addition, fine spinel (MgAl₂O₄) precipitated in the films at the early stage of solidification after adding 10 wt% of extra Al₂O₃. Together with LiAlO₂, spinel (MgAl₂O₄) acted as nuclei for the precipitation of BaAl₂O₄. The apparent activation energy of initial devitrified crystallization decreased from 314.16 KJ/mol (original slag) to 297.32 KJ/mol (5 wt% Al₂O₃ added) and 269.46 KJ/mol (10 wt% Al₂O₃ added). The crystallization ratio of the films also increased after adding extra Al₂O₃. Full article

(This article belongs to the Special Issue Metallurgical Process Simulation and Optimization - 2nd Volume)

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Open AccessArticle

Fluid Flow in Continuous Casting Mold for Ultra-Wide Slab

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Materials 2023, 16(3), 1135; https://doi.org/10.3390/ma16031135 - 28 Jan 2023

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Abstract

Ultra-wide slabs have a good application market and prospect, but there is still a lack of research on the flow field. To explore the characteristics of its flow field, this study built a 0.5-scale physical model of mold using Perspex. The effect of [...] Read more.

Ultra-wide slabs have a good application market and prospect, but there is still a lack of research on the flow field. To explore the characteristics of its flow field, this study built a 0.5-scale physical model of mold using Perspex. The effect of casting speed on flow field and surface flow speed was investigated by using an ink tracer experiment and contact measurement. There were various flow patterns in the ultra-wide slab mold, and they continue to transform each other. The jet momentum from the nozzle ports was diffused by colliding with the wide face, which lowered its kinetic energy and affected its subsequent diffusion. Compared with the conventional mold, the upper flow intensity of the ultra-wide slab mold was weaker, which made its liquid surface inactive and caused it to produce a flux rim or slag strip. At different casting speeds, the average flow speed distribution of the ultra-wide slab was C-shaped. When it increased from 0.9 to 1.4 m/s, the corresponding maximum average flow speed increased from 0.08 to 0.2 m/s. At the same time, the proportion of the low-flow speed zone at the most active part of the surface also gradually decreased from more than 90% to about 49%. Full article

(This article belongs to the Special Issue Metallurgical Process Simulation and Optimization - 2nd Volume)

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Open AccessArticle

Design Improvement of Four-Strand Continuous-Casting Tundish Using Physical and Numerical Simulation

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Materials 2023, 16(2), 849; https://doi.org/10.3390/ma16020849 - 15 Jan 2023

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Abstract

The flow pattern is vital for the metallurgical performance of continuous casting tundishes. The purpose of this study was to design and optimize the flow characteristics inside a four-strand tundish. Numerical simulations and water model experiments were validated and utilized to investigate the [...] Read more.

The flow pattern is vital for the metallurgical performance of continuous casting tundishes. The purpose of this study was to design and optimize the flow characteristics inside a four-strand tundish. Numerical simulations and water model experiments were validated and utilized to investigate the flow behavior. The effect of different flow rates in the original tundish was evaluated; two modified retaining walls and a new ladle shroud were designed for optimization. The molten steel inside the original tundish tends to be more active as the flow rate increases from 3.8 L/min to 6.2 L/min, which results in a reduction in dead volume from 36.47% to 17.59% and better consistency between different outlets. The dead volume and outlet consistency inside the tundish are improved significantly when the modified walls are applied. The proper design of the diversion hole further enhances the plug volume from 6.39% to 13.44% of the tundish by forming an upstream circular flow in the casting zone. In addition, the new trumpet ladle shroud demonstrates an advantage in increasing the response time from 152.5 s to 167.5 s and alleviating the turbulence in the pouring zone, which is beneficial for clean steel production. Full article

(This article belongs to the Special Issue Metallurgical Process Simulation and Optimization - 2nd Volume)

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Open AccessArticle

The Thermodynamics and Kinetics of a Nitrogen Reaction in an Electric Arc Furnace Smelting Process

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Materials 2023, 16(1), 33; https://doi.org/10.3390/ma16010033 - 21 Dec 2022

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Abstract

The nitrogen content of electric arc furnace (EAF) steel is much higher than that of basic oxygen furnace (BOF) steel, which cannot meet the requirements of high-grade steel. Most denitrification processes only considered a single smelting condition, which leads to poor denitrification effect. [...] Read more.

The nitrogen content of electric arc furnace (EAF) steel is much higher than that of basic oxygen furnace (BOF) steel, which cannot meet the requirements of high-grade steel. Most denitrification processes only considered a single smelting condition, which leads to poor denitrification effect. In this study, a hot state experiment was conducted to simulate the melting process of EAF steelmaking and to explore the thermodynamic and kinetic constraints of the molten steel nitrogen reaction in the scrap melting, oxygen blowing decarburization, and rapid temperature rise stages. The experimental results showed that the nitrogen reaction in the molten pool during the scrap melting stage was a first-order nitrogen absorption reaction, and the reaction-limiting link was the diffusion of nitrogen atoms in the molten steel. When the carbon content increases to 4.5%, the bath temperature decreases to 1550 °C, and the nitrogen partial pressure decreases to 0.2 P^Θ, the nitrogen saturation solubility decreased to 0.0198%, 0.0318%, and 0.0178%, respectively. At the same time, the rate constants decreased to 0.132 m/min, 0.127 m/min, and 0.141 m/min, respectively. The nitrogen reaction in the oxygen blowing decarburization stage was a secondary denitrification reaction, and the reaction-limiting link was the gas–liquid interface chemical reaction. Argon had better degassing effect. When the argon flow rate increased from 100 mL/min to 300 mL/min, the reaction constant increased by about four times. When the oxygen content of molten steel was 0.0260%, the denitrification rate constant decreased by about 2.5 times. The nitrogen content of liquid steel was higher than 0.045%, and the reaction was a secondary reaction. As the nitrogen content decreased, the reaction rate decreased, and the reaction-limiting link changed from the gas–liquid interface chemical reaction to the joint control of mass transfer and chemical reaction. The oxygen content in the molten steel can not only hinder the chemical reaction of nitrogen at the gas–liquid interface, but also reduce the mass transfer rate of nitrogen atoms in the molten steel. The results provided a theoretical basis for the optimization of nitrogen removal process and further reduction of nitrogen content in liquid steel. Full article

(This article belongs to the Special Issue Metallurgical Process Simulation and Optimization - 2nd Volume)

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Open AccessArticle

Behavior of Mold Electromagnetic Stirring for Round Bloom Castings and Its Eccentric Stirring Problem

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Materials 2022, 15(24), 8814; https://doi.org/10.3390/ma15248814 - 09 Dec 2022

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Abstract

In this paper, a mold electromagnetic stirring (M-EMS) model was established to investigate the behavior of M-EMS for round bloom castings under different conditions, and an electromagnetic-flow-heat transfer-solidification coupling model was established to explore the problem of eccentric stirring for various formats of [...] Read more.

In this paper, a mold electromagnetic stirring (M-EMS) model was established to investigate the behavior of M-EMS for round bloom castings under different conditions, and an electromagnetic-flow-heat transfer-solidification coupling model was established to explore the problem of eccentric stirring for various formats of round blooms. The results show that the magnetic flux density decreased with the increase in the current frequency, but the electromagnetic torque increases first and then decreases with it, and the same structure of M-EMS for round blooms has the same optimal current frequency at any current intensity. The electromagnetic torque and electromagnetic force both increase as a quadratic function of the current intensity, and the electromagnetic torque, which drives the steel flow, can directly characterize the real M-EMS performance. The mold copper tube has a significant magnetic shielding effect on M-EMS, the stirring intensity decreases rapidly as the tube thickness increases, and the optimal stirring frequency decreases as well. In fact, the deviation between the stirrer center and the geometric center of the strand can result in the eccentric stirring phenomenon. When blooms with a section size of Φ350 mm are produced by Φ650 mm SMS-Concast casting machine, the upper region of the inner arc side and the lower region of the outer arc side are subject to a stronger washing effect, which makes the temperature of the inner and outer arcs show alternating differences. The jet flow from the five-port nozzle can suppress the difference in initial solidification symmetry between the inner and outer arcs of round blooms caused by eccentric stirring. This paper reveals the magnetic shielding effect of the mold copper tube and the magnetic field loss of the air between the stirrer and the inner and outer arcs of the copper, which lead to the stirring intensity and the eccentric stirring phenomenon. Full article

(This article belongs to the Special Issue Metallurgical Process Simulation and Optimization - 2nd Volume)

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Open AccessArticle

Effects of Different RH Degasser Nozzle Layouts on the Circulating Flow Rate

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Materials 2022, 15(23), 8476; https://doi.org/10.3390/ma15238476 - 28 Nov 2022

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The effects of gas flow rate and 22 kinds of nozzle layouts on the circulation flow rate were researched during the RH refining process using a water model and a mathematical model. Numerical simulations agreed with the water model experiment well. The results [...] Read more.

The effects of gas flow rate and 22 kinds of nozzle layouts on the circulation flow rate were researched during the RH refining process using a water model and a mathematical model. Numerical simulations agreed with the water model experiment well. The results showed that the circulating flow rate increased with an increase of the gas flow rate. The critical value of the gas flow rate was 2.4 m³/h. Out of the 22 kinds of layouts, the 127-87 symmetrical layout was the optimal layout, for which the circulating flow rate reached 29.8 m³/h, the area of blind zone was the smallest and the mixing effect of the molten steel was the best. The working stroke and carrying capacity of the bubbles were important factors that affected the circulating flow rate. Among the four types of layouts, when the nozzles were in the one-side layout and the one-row layout, the main factor for improving the circulating flow rate was the working stroke of the bubbles. When nozzles were in the staggered layout and the symmetrical layout, the carrying capacity of the bubbles was the main factor for improving the circulating flow rate. For the same conditions, the carrying capacity of the bubbles had a greater effect on improving the circulating flow rate than the bubble stroke. Full article

(This article belongs to the Special Issue Metallurgical Process Simulation and Optimization - 2nd Volume)

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Open AccessArticle

Effect of Swirling Flow Nozzle on Fluid Flow and Solidification in a Round Bloom Continuous Casting Mold

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Materials 2022, 15(23), 8474; https://doi.org/10.3390/ma15238474 - 28 Nov 2022

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Abstract

The nozzle structure has an important effect on the fluid flow in the mold, which can significantly improve the solidified shell and product quality of alloy steel round bloom. The transient fluid flow, heat transfer, and solidification behavior under different nozzle structures and [...] Read more.

The nozzle structure has an important effect on the fluid flow in the mold, which can significantly improve the solidified shell and product quality of alloy steel round bloom. The transient fluid flow, heat transfer, and solidification behavior under different nozzle structures and mold electromagnetic stirring (M-EMS) are investigated using a 3D transient mathematical model. The results show that a third small recirculation zone appears near the meniscus after the application of the swirling flow nozzle (SFN). The impact depth of SFN is shallower than that of the original submerged entry nozzle (SEN) impact, and the lower circulation zone is shifted upward. The horizontal swirling flow generated by SFN can significantly weaken the washing of the initial shell by high-temperature steel and improve the uneven growth phenomenon of the inner and outer curved solidified shell caused by mold curvature. The swirling flow produced by M-EMS in the mold can also improve the washing of the initial shell by the high-temperature jet and the uneven growth of the inner and outer curved shell. M-EMS can expand the high-temperature zone in the upper part of the mold, promote the superheat dissipation of the molten steel, and promote the growth of the solidified shell. In addition, after the application of M-EMS, the tangential velocity of –15° SFN in the meniscus is smaller, and the resulting liquid level fluctuation is lower at 5.07 mm, which is less likely to produce slag entrapment and is conducive to improving the quality of round bloom. Full article

(This article belongs to the Special Issue Metallurgical Process Simulation and Optimization - 2nd Volume)

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Open AccessArticle

Attempt to Optimize the Corrosion Resistance of HRB400 Steel Rebar with Cr and RE

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Materials 2022, 15(22), 8269; https://doi.org/10.3390/ma15228269 - 21 Nov 2022

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Abstract

The corrosion resistance of the HRB400 steel rebar alloyed with Cr and rare earths (RE) was systematically studied from two aspects, including the properties of the passive film and the protectiveness of the rust layer. The results presented that Cr increased the corrosion [...] Read more.

The corrosion resistance of the HRB400 steel rebar alloyed with Cr and rare earths (RE) was systematically studied from two aspects, including the properties of the passive film and the protectiveness of the rust layer. The results presented that Cr increased the corrosion resistance of the steel rebar through stabilizing the passive film and was not involved in the formation of corrosion pits, while the pitting corrosion was initiated by the dissolution of (RE)₂O₂S inclusion, resulting in the local acidification at the bottom of the corrosion pits, which decreased the stability of the passive film. As for the long-term corrosion process, both Cr and RE decreased the corrosion rate of the steel rebar, which was related to the promotion effect on the formation of α-FeOOH in the rust layer from Cr and RE. Full article

(This article belongs to the Special Issue Metallurgical Process Simulation and Optimization - 2nd Volume)

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Review

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Open AccessReview

Channel-Type Induction Heating Tundish Technology for Continuous Casting: A Review

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Materials 2023, 16(2), 493; https://doi.org/10.3390/ma16020493 - 04 Jan 2023

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Abstract

With the increasing demand for special steel, the quality of steel has become critical during the continuous casting tundish process. In recent years, tundish heating technology has played a key role in low superheat casting. Toward this, researchers have reported on the metallurgical [...] Read more.

With the increasing demand for special steel, the quality of steel has become critical during the continuous casting tundish process. In recent years, tundish heating technology has played a key role in low superheat casting. Toward this, researchers have reported on the metallurgical effects of induction heating tundish (IHT). From 1984 to date, the channel-type IHT has been investigated in the production of continuous casting of special steel. In this article, the principle of this channel-type IHT technology and equipment composition were illustrated. A brief summary and comments were undertaken on the channel-type IHT, including physical modeling and numerical modeling. The application development trend of tundish induction heating equipment is summarized combined with industrial application data, which provide a reference for a better understanding of the induction heating process of tundish. Full article

(This article belongs to the Special Issue Metallurgical Process Simulation and Optimization - 2nd Volume)

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