Efects of low frequency electromagnetic ield on surface quality, microstructure and hot-tearing tendency of semi-continuous casting ZK60 magnesium alloy billets

The low frequency electromagnetic field was applied during direct chill(DC) semi-continuous casting of the ZK60 magnesium alloy billets. Effects of low frequency electromagnetic field on surface quality, microstructure and hot-tearing tendency of Φ500 mm ZK60 magnesium alloy billets were investigated. The results showed that with the application of the low frequency electromagnetic field, the surface quality of the ZK60 magnesium alloy billets is markedly improved and the depth of cold fold is decreased. The microstructure of the billets is also significantly refined. Besides, the distribution of the grain size is relatively uniform from the billet surface towards its center, where the average grain size is 42 μm at surface and 50 μm at center. It also shows that the hot-tearing tendency of DC semi-continuous casting ZK60 magnesium alloy billets is significantly reduced under low frequency electromagnetic field.

Analysis of inhomogeneity of solidified microstructure of continuous casting copper tubular billet based on factor analysis

The horizontal continuous casting process,the initial step in TP2 copper tubular processing,directly determines the microstructure and properties of copper tubular.However,the process parameters of the continuous casting characterize time variation,multiple disturbances and strong coupling.As a consequence,their influence on a casting billet is difficult to be determined.Due to the above issues,the common factor and special factor analysis of the factor analysis model were used in this study,and the casting experiment and billet metallographic experiment were carried out to diagnose and analyze the reason of the microstructure inhomogeneity.The multiple process parameters were studied and classified using common factor analysis,2 the cast billets with abnormal microstructures were identified by GT^(2) statistics,and the most important factors affecting the microstructural homogeneity were found by special factor analysis.The calculated and experimental results show that the principal parameters influencing the inhomogeneity of solidified microstructure are the primary inlet water pressure and the primary outlet water temperature.According to the consequence of the above investigation,the inhomogeneity of the copper billet microstructure can be effectively improved when the process parameters are controlled and adjusted.

基于YOLOv7-TSCR的连铸坯表面缺陷检测

为解决连铸生产过程中铸坯表面缺陷检测准确率低、检测速度慢、模型参数量大难以部署等问题,提出一种融合重参数化和注意力机制的轻量化铸坯表面缺陷检测算法YOLOv7-TSCR。首先,利用Mish和SiLU激活函数、SimAM注意力机制,构建了改进的高效层聚合模块ELAN-S,以有效增强对多尺度缺陷特征的提取;其次,设计了C2f_RG模块改进特征融合网络,减少参数量的同时获得更丰富的梯度流信息,增强特征融合能力;最后,根据采集实际生产中的缺陷图像,构建铸坯缺陷数据集并进行验证。结果表明:YOLOv7-TSCR相较其他网络模型检测效果显著提升,在模型参数量减小的情况下,精确率达93.5%,平均精度均值提高了2.8%,检测速度可达120 FPS;在NEU-DET公开数据集上进行的泛化性对比实验证明了算法具有较强的泛化性。改进算法在保证较高检测精度的基础上,具有较快的检测速度和较小的参数量,为铸坯表面缺陷的高效检测提供了技术参考。

Analysis of High-Cr Cast Iron/Low Carbon Steel Wear-resistant Laminated Composite Plate Prepared by Hot-rolled Symmetrical Billet

This study developed a new technology for preparing high-chromium cast iron(HCCI)/low-carbon steel(LCS)wear-resistant composite plates by hot rolling at a 1050°C and a rolling speed of 0.2 m/s.The effects of different rolling reductions(30%,45%,and 60%)on the microstructure(interface and HCCI layer)and mechanical properties(bonding strength,hardness,and wear resistance)of the composite plate were studied.SEM images showed that when the reduction was increased,no impurities and interlayers were found between the microscopic interfaces after hot rolling,and the bonding interface exhibited a wave-like shape.EDS analysis showed that the Cr element diffusion between two metals after hot rolling was promoted when the reduction was increased,thereby improving the bonding quality under the same rolling temperature and rolling speed.Experiments showed that due to the stress release effect of the LCS of the cladded layer,the macro-slab shape after hot rolling performed well,and the brittle HCCI layer underwent thermoplastic deformation without cracking.Moreover,the increase of rolling reduction improved the bonding quality.As the rolling reduction was increased,the volume fraction of Cr-carbides in the HCCI layer also increased,resulting in an increase of hardness and wear-resistance.

High-strength aluminum alloys hollow billet prepared by two-phase zone continuous casting

The two-phase zone continuous casting(TZCC)technique was used to continuously cast high-strength aluminum alloy hollow billets,and a verified 3D model of TZCC was used to simulate the flow and temperature fields at casting speeds of 2-6 mm·min^(-1).Hollow billets under the same conditions were prepared,and their macro/microstructures were analyzed by an optical microscope and a scanning electron microscope.During the TZCC process,a circular fluid flow appears in front of the mushy zone,and the induction heated stepped mold and convective heat transfer result in a curved solidification front with depressed region near the inner wall and a vertical temperature gradient.The deflection of the solidification front decreases and the average cooling rate in the mushy zone increases with increasing casting speed.Experimental results for a 2D12 alloy show that hot tearing periodically appears in the hollow billet accompanied by macrosegregation near the inner wall at casting speeds of 2 and 4 mm·min^(-1),while macroscopic defects of hot tearing and macrosegregation weaken and the average size of columnar crystals in the hollow billets decreases with further increasing casting speed.2D12 aluminum alloy hollow billets with no macroscopic defects,the finest columnar crystals,and excellent mechanical properties were prepared by TZCC at a casting speed of 6 mm·min^(-1),which is beneficial for the further plastic forming process.

低温Hi-B钢全流程组织和织构演变规律研究

采用金相显微镜和X射线衍射仪(XRD)观察低温Hi-B钢连铸坯和经热轧、常化、冷轧、脱碳退火、高温退火工序后钢板的金相组织和织构,分析全流程组织和织构的演变规律。结果表明,连铸坯低倍组织以柱状晶为主,中心等轴晶区比例为7%~12%;热轧板组织由铁素体和珠光体交替的带状组织组成;常化酸洗板组织由细晶带和再结晶组织组成。热轧板和常化板厚度1/8处织构以Goss织构和黄铜织构为主,钢板经过高温退火发生二次再结晶形成强Goss织构。

18CrNiMo7-6锻件机加工面“花纹”研究

采用连铸坯生产18CrNiMo7-6齿轮锻件经正火后,机加工面出现了局部“花纹”。为了明确“花纹”形成机理,采用多种分析方法进行研究,结果表明:“花纹”区和正常区均遗传了原连铸坯凝固枝晶偏析特征,但“花纹”区的枝晶间偏析聚集度更高、颜色更深。枝晶间偏析区碳化物多,显微硬度高,使加工面粗糙度增加,是导致机加工“花纹”的直接原因。

Secondary cooling technology for high-efficiency continuous billet-casting

The mathematical model of high-efficiency continuous billet casting was developed, incorporating the effective spraying water coefficient and the effective specific spraying water flowrate of secondary cooling. To realize uniform cooling in secondary cooling zones, the spraying cooling structure and the arrangement of nozzles were redesigned and optimized, and an additional spraying cooling zone was used. A new secondary cooling model of spraying water was built. It was found that the required spraying water flowrate of a cooling zone was related with the casting speed, the casting temperature, the compositions of liquid steel and the cooling water temperature of secondary cooling. The operation of the reformed caster proved that the spraying cooling structure and the new secondary cooling model were suitable, and the casting speed was greatly enhanced. The highest casting speed was （3.8 to 4.0） m/min for billet with a section of 150× 150 mm^2. The quality And the outout of the billet were imoroved, andthe economical benefit was heightened.

Horizontal continuous casting process under electromagnetic field for preparing AA3003/AA4045 clad composite hollow billets

A modified horizontal continuous casting process under the electromagnetic field was proposed for preparing AA3003/ AA4045 clad composite hollow billets. To investigate the effect of electromagnetic field on this process, a comprehensive three-dimensional model was developed. Two cases with and without electromagnetic field were compared using the simulations. When rotating electromagnetic stirring is applied, the flow pattern of fluid melt is greatly modified; the mushy zone becomes much wider, the temperature profile becomes more uniform, and the solid fraction decreases for both the external and internal alloy melt layers. These modifications are beneficial for the formation of a bimetal interface and fine and uniform grain structure of the clad composite hollow billet. Experiments conducted using the same electrical and casting parameters as the simulations verify that under the electromagnetic field the microstructure of the clad composite hollow billet becomes fine and the diffusion of the elements at the interface is promoted.

Microstructure and properties of Al-0.70Fe-0.24Cu alloy conductor prepared by horizontal continuous casting and subsequent continuous extrusion forming

A novel process for manufacturing A1-0.70Fe-0.24Cu alloy conductor was proposed, which includes horizontal continuous casting and subsequent continuous extrusion forming （Conform）. The mechanical properties, electrical conductivity and the compressed creep behaviour of the alloy were studied. The results indicate that the Conform process induces obvious grain refinement, strain-induced precipitation of AI7CuzFe phase and the transformation of crystal orientation distribution. The processed alloy has good comprehensive mechanical properties and electrical conductivity. Moreover, a better creep resistance under the conditions of 90 ~C and 76 MPa is shown compared with pure A1 and annealed copper, and the relationship between primary creep strain and time may comply with the logarithmic law. The enhanced properties are attributed to the grain refinement as well as the fine and homogeneously distributed thermally stable A1Fe and A17Cu2Fe precipitation phases.

Optimization of flow control devices in a tenstrand billet caster tundish

The physical model of a ten-strand billet caster tundish was established to study the effects of various flow control devices on the melt flow. Before and after the optimization of the melt flow, the inclusion removal in the tundish was evaluated by plant trials. The physical modeling results show that when combined with a baffle, the turbulence inhibitor, instead of the impact pad, can significantly improve the melt flow. A turbulence inhibitor with a longer length of inner cavity and without an extending lip at the top of the sidewall seems to be efficient in the improvement of the melt flow. Various types and designs of baffles all influence the flow characteristics significantly. The "V" type baffles are better than the straight baffles for flow control. The "V" type baffle with four inclined holes at the sidewall away from the stopper rods is better in melt flow control than the one with one inclined hole at each sidewall. The combination of a well-designed turbulence inhibitor and an appropriate baffle shows high efficiency on improving the melt flow and an optimal proposal was presented. Plant trials indicate that, compared with the original tundish configuration in prototype, the inclusions reduce by 42% and the inclusion distribution of individual strands is more similar with the optimal one. The optimal tundish configuration effectively improves the melt flow in the ten-strand billet caster tundish.

Extensive Analysis of Multi Strand Billet Caster Tundish Using Numerical Technique

Continuous casting of steel involving different grades in the same casting sequence remains a challenge to billet caster operators. The intermixed composition obtained during the grade change does not meet the specification of either grade and must be downgraded. Incorrect identification of this intermixed region may result in non-conforming products reaching the customer. In this study, a numerical model based on CFD (computational fluid dynamics approach) has been developed which predicts the start and end of the intermixed composition and the tonnage to be downgraded under different casting conditions. This model was validated and the results were in good agreement with the actual plant data for a 6-strand billet caster at LD-1 of TATA Steel, India. This model is used to calculate transition tonnage for different scenarios, e.g. when one of the outermost strands is not functional or some combinations are not functional and varying casting speed during operation. Furthermore, impact of different design of baffles on performance of Tundish has been evaluated to find a way to reduce transition or intermixed composition.

Rheologic behaviors of A356 aluminum alloy billet produced by semisolid continuous casting process

The experiments for rheologic behaviors of semisolid continuous casting billets of A356 alloy in semisolid state had been carried out with a multifunctional rheometer. The results show that the deformation rate increases with loading time, the maximum strain reaches to 120％ (which is one time larger than that of traditional mold casting billet) and the strain can be rapidly eliminated to 10％ after unloading. Moreover, there is a critic stress for billet deformation even in semisolid state, which is named as critic shear stress. This stress increases with the decreasing of heating time. The theologic behaviors can be expressed by five elements mechanical model (H_2- [N_1|H_2]-[N_2|S]) and can be modified with the increasing of heating time.

Process for improving the ladle free- opening rate for high aluminum steel in continuous casting

Steel 20Mn23AlV is a type of high aluminum steel with a very low ladle free-opening rate. The aluminum composition of 20Mn23AlV ranges from 1.6% to 2.45% ,which is significantly higher than other types of steel. According to the real condition of 40 t ladle in steel-making plant of Baosteel Special Steel Company, previous works show that the key factors affecting the ladle free-opening rate of high aluminum steel in continuous casting are：sand material, accessories baking, ladle nozzle cleaning, the process and amount of adding sand, and the rate of argon stirring during refining. Therefore, improving the ladle filler sand quality, baking all of the raw materials, controlling the addition of ladle filler sand, cleaning the ladle nozzle, and optimizing argon stirring during the refining process can resolve the problem of a low ladle free-opening rate of high aluminum steel caused by the long ladle time of liquid steel.

The EVA plastic film for V-process and steel castings by V-process in China

EVA plastic film is the key material for V-process. Through decades of research, special EVA film for V-process has been produced. The film has adequate elongation; its maximum is about 800% in longitudinal direction and 750% in transversal direction. The single width of the film is 2.8 m and the double width is 5.6 m, which is the widest sheet film for V-process in China. Sheets with different thickness ranging from the thickest 0.35 mm to the thinnest 0.08 mm can meet different demands in China. The film can be used not only for V-process of iron castings, but also for the manganese steel railway frog, steel rocking support and side frame castings for train and the steel bridge box for engine truck.

Fabrication and Studying the Mechanical Properties of A356 Alloy Reinforced with Al₂O₃-10% Vol. ZrO₂Nano-particles through Stir Casting

Al2O3-ZrO2 with a high level of hardness and toughness is known as ceramic steel. Due to its unique properties it can be used as a reinforcement in fabrication of metal matrix composites. In this study, nanoparticles of Al2O3-10% ZrO2 with an average size of 80 nm were used to fabricate Al matrix composites containing 0.5, 1, 1.5 and 2 wt.% of the reinforcement. The fabrication route was stir casting at 850?C. There is no report about usage of this reinforcement in fabrication of composites in the literature. The microstructures of the as-cast composites were studied by scanning electron microscope (SEM). Density measurement, hardness and tensile properties were carried out to identify the mechanical properties of the composites. The results revealed that with increasing the reinforcement content, density decreased while yield, ultimate tensile strength and compressive strength increased. Also, hardness increased by increasing the reinforcement content up to 1 wt.% Al2O3-10% ZrO2 but it decreased in the samples containing higher amounts of reinforcement.

使用连铸圆坯生产破碎锤钎杆用YNS-3钢的生产实践

针对江阴兴澄特种钢铁有限公司使用Φ700 mm连铸圆坯成功开发Φ200~Φ250 mm规格的破碎锤钎杆用YNS-3钢的生产实践,介绍其生产流程、技术指标及过程控制。经检验,生产的YNS-3钢的各项指标均符合钎杆用钢的技术要求。

Al-5Ti-1B对超宽幅超薄铝箔铸轧坯料组织晶粒细化效果的研究与应用

研究Al-5Ti-1B对直接采用电解铝液生产超宽幅超薄铝箔铸轧坯料组织的影响,从Al-5Ti-1B质量、添加量、添加温度、变质时间、添加位置等几个方面进行了分析,结果表明:影响铸轧板坯组织晶粒细化效果最关键的是细化剂中,TiAl_(3)呈细小圆块状、尺寸均匀、弥散分布,TiB_(2)为细小颗粒状、弥散分布;合理的添加量、添加温度、变质时间、添加位置是确保铸轧板坯组织获得最佳细化效果的重要手段。

鞍钢8m弧半径小方坯连铸机提速实践

针对8 m弧半径小方坯铸机拉速低不能满足生产要求的问题,分析了影响铸机提速的主要原因,采取了增加结晶器长度,更新结晶器供水泵,更新二冷水嘴,增大二冷管径以及优化系统温度等措施,铸机拉速由2.8 m/min提高到3.5 m/min,铸坯质量合格率达到99.95%,实现了小方坯铸机高速稳定生产。

超大规格风电用连铸圆坯的氢含量控制

针对直径大于等于800 mm的超大规格风电用连铸圆坯因氢含量高出现探伤不合缺陷的问题,通过检测原辅料水分、利用Hydris定氢仪探究全工序钢水氢含量的变化规律。结果表明,铸坯氢含量的主要来源是原辅料水分、炉气气氛潮湿、耐火材料不完全分解。为降低铸坯氢含量,提出了工艺改进措施:转炉吹炼8 min后应不加或加入水分含量较低的原辅料;LF精炼工序投入较少的原辅料;入VD工序前小渣量控制,破空后低速喂线,控制喂线数量及种类在较小范围;小火烘烤连铸中间包60 min,定期清理中间包透气孔。工艺优化后,VD到站钢水w(H)≤3.6×10^(-6),VD离站钢水w(H)≤0.77×10^(-6),连铸中间包首炉钢水w(H)≤2.0×10^(-6),第2炉w(H)≤1.6×10^(-6),连浇炉次w(H)≤1.1×10^(-6),成功降低了超大规格风电用连铸圆坯的氢含量,保证了成品锻件的质量。