Search Results (148)

Hypo-peritectic steels are susceptible to interfacial cracking during thin-slab continuous casting, in which non-metallic inclusions play a critical role. This study systematically investigates the effects of inclusion type and morphology on interface cracking behavior in the steel matrix, with the aim of improving billet shell quality. Hot tensile experiments were conducted using a Gleeble 3800 thermal simulator, and a finite element–based cohesive zone model was developed to simulate inclusion-induced crack nucleation and propagation. The results demonstrate that inclusions markedly influence interfacial stress distribution and damage evolution. The maximum interfacial stresses associated with MnS, Al₂O₃, and composite inclusions are 20.7, 23.4, and 30.5 MPa, respectively. Owing to severe stress concentration at sharp corners, composite inclusions exhibit the earliest crack nucleation at an applied stress of 11.3 MPa and the highest energy dissipation. In all cases, cracks initially nucleate at the location of maximum tensile stress (α = 90°), propagate along the interface, and subsequently penetrate into the matrix, ultimately leading to failure. The strong agreement between numerical simulations and experimental results confirms that angular inclusions accelerate damage by disrupting matrix continuity. These findings provide theoretical guidance for improving hypo-peritectic steel quality through inclusion morphology control during continuous casting. Full article

The utilization of recycled steel is essential for achieving carbon neutrality and sustainable engineering, yet repeated recycling inevitably leads to the accumulation of residual elements that are difficult to remove during conventional refining. Among them, copper (Cu) readily enriches in scrap-based steels and is a primary cause of surface hot shortness during high-temperature processing due to its segregation at the oxide/steel interface. While the compositional effects of Cu have been extensively studied, the influence of thermo-history associated with different industrial processing routes remains poorly understood. In this work, Cu enrichment during high-temperature oxidation was systematically investigated under thermo-histories representative of conventional hot rolling, thin slab continuous casting and rolling (TSCR), and strip casting. Plain carbon steels containing 0.05–0.30 wt.% Cu were oxidized at 1000–1200 °C, and interfacial microstructures were characterized using SEM–EDS. The results show that Cu enrichment is highly sensitive to both temperature and thermal exposure time, with a critical temperature range of 1100–1150 °C promoting the formation of continuous Cu-rich liquid films. Prolonged thermo-history in conventional hot rolling markedly enhances Cu enrichment, TSCR partially suppresses interfacial segregation, whereas strip casting effectively inhibits Cu enrichment even at elevated Cu contents. These findings highlight thermo-history as a dominant factor controlling Cu-induced surface hot shortness and provide guidance for process optimization in recycled steels. Full article

Slag entrainment within the mold is a significant cause of surface defects in continuously cast slabs. As a key component for controlling molten steel flow, the structure of the submerged entry nozzle directly influences the flow field characteristics and slag entrainment behavior within the mold. This paper employs a 1:4-scale water–oil physical model combined with numerical simulation to investigate the effects of elliptical and circular submerged entry nozzles on slag entrainment behavior in a wide slab mold under different casting speeds and immersion depths. High-speed cameras were used to visualize meniscus fluctuations and oil droplet entrainment processes. An alternating control variable method was employed to quantitatively delineate a slag-free “safe zone” and a “slag entrainment zone” where oil droplets fall, determining the critical casting speed and critical immersion depth under different operating conditions. The results show that, given the nozzle immersion depth and slag viscosity, the maximum permissible casting speed range without slag entrainment can be obtained, providing a reference for industrial production parameter control. The root mean square (RMS) of surface fluctuations was introduced to characterize the activity of the meniscus flow. It was found that the RMS value decreases with increasing nozzle immersion depth and increases with increasing casting speed, showing a good correlation with the frequency of slag entrainment. Numerical simulation results show that compared with elliptical nozzles, circular nozzles form a more symmetrical flow field structure in the upper recirculation zone, with a left–right vortex center deviation of less than 5%, resulting in higher flow stability near the meniscus and thus reducing the risk of slag entrainment. Full article

Edge cracks in hot-rolled sheets of industrial grain-oriented electrical steel significantly affect the yield rate and pose substantial challenges to cold rolling fabrication. Eliminating such structural defects through hot rolling requires a thorough understanding of their formation mechanism. This study investigates the formation mechanism of edge cracks in hot-rolled sheets, which are characterized by coarse strip-like grains with typical thicknesses ranging from 20 μm to 100 μm. Coarse, strip-shaped grains have low fracture stress, which is the cause of edge cracks. They originate from abnormally developed columnar grains in continuous casting slabs after reheating, which is unavoidable in industrial large-scale production. Inadequate fragmentation and insufficient recrystallization during rough rolling result in residual coarse grains of intermediate slabs, and their preferential deformation and outward protrusion lead to the formation of grooves. In the subsequent finishing rolling process, deformed coarse grains near the grooves undergo further elongation, developing into distinct strip-like structures. Based on the above mechanistic understanding, the edge microstructure under various rolling parameters was investigated, and targeted improvement measures for edge cracks were proposed. It is concluded that the edge quality can be significantly enhanced through increasing the total width reduction, additional rough rolling passes, and the implementation of edge heating during rough rolling. Quantitative analysis demonstrates that increasing the rolling passes from D to E significantly reduces the fraction of band structure from 64% to 48% and the average width of elongated grains from 43.5 μm to 38.4 μm. Full article

Central segregation, a typical internal defect in continuous casting slabs, significantly deteriorates the mechanical properties of steel products. However, traditional manual defect evaluation methods rely heavily on experience, are highly subjective and inefficient, making it difficult to meet the quality assessment requirements of today’s high-end steel materials. In this study, an approach which combines an unsupervised image enhancement algorithm and Otsu algorithm analysis was proposed to achieve automatic recognition and quantitative features extracting of central segregation in continuous casting slabs. The challenges posed by insufficient brightness and low contrast in central segregation images were addressed using unsupervised image enhancement algorithms. Following this enhancement, batch objective quantification of the segregation images was conducted through Otsu processing. Comparative experimental results showed that the enhanced images yielded an average Dice Similarity Coefficient of 0.965 for segregation recognition, representing a 38% improvement over unprocessed images, with consistent accuracy gains across complex segregation scenarios. This intelligent detection method eliminates the need for manually labeling a training set, substantially improves the consistency of segregation quantification and reduces the time cost significantly. Consequently, multiple parameters can be employed to quantify segregation characteristics, offering a more comprehensive and precise approach than current simplified rating methods. This advancement holds promise for enhancing quality control in steel processing and advancing Artificial Intelligence-driven technological progress within the metallurgical sector. Full article

Mold level fluctuation significantly affects the stability and quality of the slab during the continuous casting process. However, traditional mechanism models are insufficient for providing accurate time-series predictions under complex and multivariable operating conditions. Additionally, the dynamic interdependencies between process variables and transient abnormal fluctuation events have been largely overlooked in existing studies. To address these limitations, we propose an integrated time–frequency characterization and prediction framework that combines multi-domain feature extraction with a long-sequence Informer model. First, the preprocessing pipeline transforms heterogeneous sensor data into standardized time series through normalization and standardization, thereby establishing a robust foundation for subsequent feature extraction and predictive modeling. Second, the time–domain and frequency–domain feature extraction methods are integrated to capture essential patterns in casting signals with improved resolution and interpretability. Third, the fusion features are embedded into a time-series prediction model, which performs robust forecasting of mold level behavior and enhances the identification of root causes behind fluctuation anomalies. Compared with conventional LSTM and Transformer models, the proposed framework achieves over 90% reduction in prediction error and provides interpretable insights into the correlations between casting parameters and mold level variations. Finally, real industrial experimental results demonstrate the performance of the proposed framework in enhancing prediction reliability and providing insight into fluctuations with scalable implementation. Full article

The quality of heavy plates produced from low-carbon steel is directly linked to the structural characteristics inherited from the initial continuously cast thick slabs. This study explores how different casting technologies affect the morphology and distribution of allotriomorphic ferrite along prior austenite grain boundaries (PAGBs) within these slabs. Using quantitative microstructural analysis based on advanced computer vision techniques (OpenCV), the research identifies significant variations in ferrite boundary thickness and volume fraction associated with different casting methods. These microstructural differences strongly correlate with variations in Charpy V-notch impact energy (KVZ20) and susceptibility to microcrack formation during subsequent rolling processes. The results obtained allow us to evaluate the influence of the cast structure on the formation of the initial structural characteristics of the material, especially on the formation of microcracks of the slab microstructure and their propagation during further processing. Full article

In slab continuous casting, achieving uniform cooling in the secondary cooling zone is essential for ensuring both surface integrity and internal quality. To optimize the process for ship plate steel, a solidification heat transfer model was developed, incorporating radiation, water film evaporation, spray impingement, and roll contact. The influence of secondary cooling water flow on slab temperature distribution was systematically investigated from multiple perspectives. The results show that a weak cooling strategy is crucial for maintaining higher surface temperatures and aligning the solidification endpoint with the soft reduction zone. Along the casting direction, a “strong-to-weak” cooling pattern effectively prevents abrupt temperature fluctuations, while reducing the inner-to-outer arc water ratio from 1.0 to 0.74 mitigates transverse thermal gradients. In addition, shutting off selected nozzles in the later stage of secondary cooling at medium and low casting speeds increases the slab corner temperature in the straightening zone by approximately 50 °C, thereby avoiding brittle temperature ranges. Overall, the proposed multi-dimensional uniform cooling strategy reduces temperature fluctuations and significantly improves slab quality, demonstrating strong potential for industrial application. Full article

In steel continuous casting, the secondary cooling zone is usually equipped with air-mist nozzles. Spray nozzle clogging is a common problem that reduces cooling efficiency and affects product quality. This study uses a 3D CFD model to investigate its impact on heat transfer. The model includes the full-size caster geometry and actual nozzle layout to analyze the effect of clogging on the cooling process. The solidification process is modeled using the enthalpy-porosity method. Spray cooling is defined through empirical HTC correlations on the slab surface. The study focuses on how nozzle clogging changes the surface temperature, cooling rate, and metallurgical length (ML). Simulation results show that clogging raises the local surface temperature by about 100 K and increases the ML. More clogged nozzles lead to a longer ML. Clogging near the meniscus has a stronger impact, showing that early-stage cooling plays an important role in solidification. Even a single clogged nozzle can increase the ML by 3.2%, highlighting the significant effect of nozzle clogging on the casting process. Full article

The existing continuous caster layout curves cause plastic deformation of slabs during bending and straightening segments, while no effective deformation occurs in the basic arc segment, which tends to induce defects, such as cracks, and compromise slab quality. High-temperature creep deformation is generally regarded as detrimental to material performance. If the significant and inevitable creep deformation of a slab could be utilized to accomplish bending and straightening deformation during continuous casting, it would turn a potential harm into an advantage, ultimately enhancing both production efficiency and final product quality. Therefore, a new continuous bending and straightening curve based on the high-temperature creep property of a low-alloy steel slab was designed. The new curve cancelled the original basic arc segment and smoothly connected the bending and straightening segments, which not only substantially prolonged the effective bending and straightening deformation time but also extended the creep time. The locations within the slab corresponding to the temperature range of 1100 °C to 1200 °C were obtained from the simulated temperature field results. Comparing the calculated strain rates with the steady-state creep rates revealed that within the temperature range exhibiting favorable hot ductility, the bending and straightening deformation of the slab could be accomplished entirely through creep deformation. Full article

This paper investigates the effects of Ti and Nb addition with varying Mn content on the solidification macrostructure and microstructure in the continuous casting slab of Q355 steel using optical microscopy, scanning electron microscopy, transmission electron microscopy, and electron probe microanalysis. The evolution of central segregation and MnS inclusions during thermal simulation compress deformation has been clearly established using Gleeble-1500 thermal simulation tester. The results indicate that by reducing the Mn content and adding a small amount of Ti and Nb, it is possible to refine the grain and mitigate the center segregation of Q355 steel. Mn steel with 1.25% Mn and without Ti and Nb addition exhibits the most severe center segregation. The TiNb steel with 0.52% Mn and a small amount of Ti and Nb addition showed a marked improvement in the center segregation of the slab. The Nb steel with 0.56% Mn and 0.009% Nb shows the presence of thin film ferrite along prior grain boundaries surrounded by Widmanstätten ferrite, and the central segregation has not shown significant improvement. The thermal simulation samples of the three steel types inherit the characteristics of their respective casting structures. Full article

Rare earth can modify inclusions in non-oriented silicon steel which is harmful to magnetic properties. This study focused on the 3.1% Si non-oriented silicon steel under industrial production conditions. Samples were taken during the stages before and after addition of rare earth ferrosilicon alloy in Ruhrstahl-Heraeus (RH) unit, different pouring time in tundish, and continuous casting slab. This study systematically examined the morphology, composition, and size distribution of inclusions throughout the smelting process of non-oriented silicon steel by scanning electron microscopy with energy-dispersive spectroscopy (SEM/EDS), and thermodynamic analysis at liquid steel temperature and thermodynamic analysis of equilibrium solidification. The research results demonstrated that the rare earth treatment ultimately modifies the original Al₂O₃ inclusions in the non-oriented silicon steel into REAlO₃ and RE₂O₂S inclusions, while also aggregating AlN inclusions to form composite inclusions. After rare earth modification, the average size of the inclusions decreases. In the RH treatment process, the inclusions before the addition of rare earth ferrosilicon alloy are mainly AlN and Al₂O₃. After the addition of rare earth ferrosilicon alloy, the inclusions are mainly RES and REAlO₃. In the tundish and continuous casting, the rare earth content decreased, and the rare earth inclusions transform into RE₂O₂S and REAlO₃. For the size of inclusions, after adding rare earth ferrosilicon alloy, the average size of inclusions rapidly decreased from 16.15 μm to 2.65 μm and reach its minimum size 2.16 μm at the end of RH treatment. When the molten steel entered the tundish, the average size of inclusions increased slightly and gradually decreased with the progress of pouring. The average size of inclusions in the slab is 5.79 μm. Phase stability diagram calculation indicates the most stable rare earth inclusion is Ce₂O₂S in molten steel. Thermodynamic calculations indicated that Al₂O₃, Ce₂O₂S, Ce₂S₃, AlN, and MnS precipitate sequentially during the equilibrium solidification process of molten steel. Full article

Accurate prediction of slab temperature during the continuous casting and rolling process is essential for optimizing reheating furnace scheduling and achieving energy savings and emission reductions in steel production. However, because of the dynamic boundary conditions caused by the complex transport processes, obtaining precise temperature data for slabs remains challenging. These difficulties lead to issues such as low hot charging rates, mixing of hot and cold slabs in reheating furnaces, and excessive heat loss from slabs after cutting. To address these challenges, this study develops a mathematical model to calculate slab temperatures during the continuous casting and rolling process, providing a foundation for production scheduling optimization. The model accounts for the coupled heat transfer effects induced by dynamic slab stacking and the stacking heat transfer effects resulting from slabs with varying cross-sectional dimensions. Validation against experimental data demonstrated the model’s accuracy and reliability. Key findings highlighted that neglecting dynamic stacking effects or simplifying slab dimensions introduces errors. These results enhance slab temperature tracking in complex processes and advance related theoretical understanding. Full article

This study investigates the distribution characteristics of residual ferrite in 304L austenitic stainless steel continuous casting slab and the impact of heat treatment processes on its content. Through optical microscopy (OM), thermodynamic calculation software (Thermo–Calc) and heat treatment experiments, it is found that the residual ferrite content along the thickness direction at the width center of the slab exhibits an “M”-shaped distribution—lowest at the edges (approximately 3%) and highest near the center (approximately 13%). Within the triangular zone of the slab, the residual ferrite content varies between 1.8% and 12.2%, with its average along the thickness direction also showing an “M”-shaped distribution; along the width direction, the average residual ferrite content is lower at the edge positions, while within the internal triangular zone, it ranges between 8% and 10%. The ferrite morphology changes significantly across solidification zones: elongated in the surface fine-grain zone, lath-like and skeletal in the columnar grain zone and network-like in the central equiaxed grain zone. Thermodynamic calculations indicate that the solidification mode of the 304L continuous casting slab follows the FA mode. Heat treatment experiments conducted across the entire slab thickness demonstrate effective reduction in residual ferrite content; the optimal reduction is achieved at 1250 °C with a 48 min hold followed by air cooling while preserving the original “M”-shaped distribution characteristic after treatment. Increasing the heat treatment temperature, prolonging the holding time and reducing the cooling rate all contribute to reducing residual ferrite content. Full article

To address the central cracking problem in continuous casting slabs of 38CrMoAl steel, high-temperature tensile tests were performed using a Gleeble-3800 thermal simulator to characterize the hot ductility of the steel within the temperature range of 600–1200 °C. The phase transformation behavior was computationally analyzed via the Thermo-Calc software, while the microstructure, fracture morphology, and precipitate characteristics were systematically investigated using a metallographic microscope (MM), a field-emission scanning electron microscope (FE-SEM), and transmission electron microscopy (TEM). Additionally, the effects of different holding times and cooling rates on the microstructure and precipitates of 38CrMoAl steel were also studied. The results show that the third brittle temperature region of 38CrMoAl steel is 645–1009 °C, and the fracture mechanisms can be classified into three types: (I) in the α single-phase region, the thickness of intergranular proeutectoid ferrite increases with rising temperature, leading to reduced hot ductility; (II) in the γ single-phase region, the average size of precipitates increases while the number density decreases with increasing temperature, thereby improving hot ductility; and (III) in the α + γ two-phase region, the precipitation of proeutectoid ferrite promotes crack propagation and the dense distribution of precipitates at grain boundaries causes stress concentration, further deteriorating hot ductility. Heat treatment experiments indicate that the microstructures of the specimen transformed under water cooling, air cooling, and furnace cooling conditions as follows: martensite + proeutectoid ferrite → bainite + ferrite → ferrite. The average size of precipitates first decreased, then increased, and finally decreased again with increasing holding time, while the number density exhibited the opposite trend. Therefore, when the holding time was the same, reducing the cooling rate could increase the average size of the precipitates and decrease their number density, thereby improving the hot ductility of 38CrMoAl steel. Full article