This paper expatiates on domestic status of heavy steel casting production, with a special focus on hydraulicturbine castings for Three Gorges Project. In China, there is magnificent demand for heavy castings with the...This paper expatiates on domestic status of heavy steel casting production, with a special focus on hydraulicturbine castings for Three Gorges Project. In China, there is magnificent demand for heavy castings with the rapidgrowth of the national economy in recent years and the expected high growth in the coming 10 to 20 years. Someheavy and large castings such as mill housing and hydraulic turbine runner crown, blade and band for Three GorgesProject have been successfully made. However, the domestic production capability is still far from meeting the giganticrequirements. The domestic capability still lags behind the world class level, and a lot of heavy castings still dependon import. The paper also gives a particular introduction of the key technologies in the manufacturing of heavy steelcastings like metal melting, foundry technology, heat treatment technology and numerical simulation technique, etc.In addition, several case studies on the application of numerical simulation in the production of heavy steel castingsare presented.展开更多
In order to solve the problem of the high surface longitudinal crack ratio of heavy peritectic steel slabs produced by the No. 3 continuous caster at Baosteel,the physical properties of the original mold flux and the ...In order to solve the problem of the high surface longitudinal crack ratio of heavy peritectic steel slabs produced by the No. 3 continuous caster at Baosteel,the physical properties of the original mold flux and the optimized mold flux were compared in a comprehensive way by using analytical measures, such as a slag film heat-flow simulator, a thermowire molten flux crystallization tester and an X-ray diffractometer in the laboratory. The results reveal that one of the major reasons for the cracks is the poor heat transfer ability of the original mold flux. However, the optimized mold flux with a high basicity features a high crystallizing rate,low crystallization temperature and low heat-flow density. Therefore, the optimized mold flux is more suitable for casting peritectic steel by the heavy slab continuous caster. The test results show that the slabs produced by using the optimized mold flux had no surface longitudinal crack in four test casts, while the surface longitudinal crack ratio of the slabs produced by using the original mold flux was 5%. The optimized mold flux can effectively prevent slab surface longitudinal cracks from occurring.展开更多
This paper presents the shear performance analysis of a heavy-duty universal hinged cast steel support with the largest bearing capacity. The effect of 9 parameters ( 52 specimens) ,i. e. height of the upper support,d...This paper presents the shear performance analysis of a heavy-duty universal hinged cast steel support with the largest bearing capacity. The effect of 9 parameters ( 52 specimens) ,i. e. height of the upper support,depth of the ring of the upper support,depth of the top plate of the bottom support,height of the ribs of the bottom support,depth of the ribs of the bottom support,bolt hole diameter,number of the ribs of the bowl,depth of the ribs of the bowl,and yield strength of the material,were analyzed with a 3-dimensional elastic-plastic finite element model in which the nonlinearities of geometry,material and contact were all considered. Analysis shows that height of the upper support,depth of the ring of the upper support and yield strength of the material have a great effect on the mechanical performance of the support. Height of the upper support has the largest effect on performance price ratio of the support,and the maximum effect can be up to 160% . Depth of the top plate of the bottom support,height of the ribs of the bottom support and depth of the ribs of the bottom support have a medium effect on performance price ratio of the support,and the effect is within the limit of 15% 19% .展开更多
1.IntroductionMedium Mn steel was developed be-cause the wear resistance of Hadfield steel(Mn13)is poor under low or medium im-pact and extrusion abrasion[1-4].In theforegoing investigations[2-4]we found thatwith the ...1.IntroductionMedium Mn steel was developed be-cause the wear resistance of Hadfield steel(Mn13)is poor under low or medium im-pact and extrusion abrasion[1-4].In theforegoing investigations[2-4]we found thatwith the increase of C content,theneedle-like and network carbide in mediumMn steel increased(as shown in Fig.1(a)and(c)).Although its wear resistance was largelyimproved,its impact toughness was greatlydecreased.In order to increase toughness,along-term high temperature heat-treatmentwas needed.But the treatment caused cracks展开更多
The SMART/ASTC dynamic soft reduction technology of VAI and its application on the 6-strand bloom continuous caster at Pangang, China are presented. The operation results show that soft reduction technology is effecti...The SMART/ASTC dynamic soft reduction technology of VAI and its application on the 6-strand bloom continuous caster at Pangang, China are presented. The operation results show that soft reduction technology is effective to improve the inner quality of continuously cast blooms. At Pangang, both the central porosity and the central segregation ratings are no more than 1.0, the central shrinkage cavity rating is no more than 0.5, and the central segregation index of carbon is no more than 1.05. Rails made from the blooms have excellent quality and are used for high-speed tracks.展开更多
To replace metal padding by insulation padding for castings can save the melt and reduce cleaning work of castings. The design of insulation padding was investigated. The equation of the modulus extension factor for i...To replace metal padding by insulation padding for castings can save the melt and reduce cleaning work of castings. The design of insulation padding was investigated. The equation of the modulus extension factor for insulation padding and the ratio of its thickness over the modulus of a casting were improved to deter- mine the thickness of insulation padding. The insulation padding was designed for a turbine guide vane casting weighing 3.5 t. A sound casting was obtained with 750 kg steel saved. On the other side, the cast- ing obviously expanded at the interface with the insulation padding, which is perhaps the reason that the use of insulation padding has been suspended for many years. To avoid the expansion of insulation pad- ding, a shielding layer made of a kind of material of good fire resistance was adopted to prevent the insula- tion layer from touching the melt. The shielding layer serves as a cushion of heat and expansion during so- lidification process so as to resist the expansion of castings and guarantee the feeding effect at the same time. Furthermore, insulation padding can be placed by a certain offset into the mold cavity so as to coun- teract the expansion of castings.展开更多
文摘This paper expatiates on domestic status of heavy steel casting production, with a special focus on hydraulicturbine castings for Three Gorges Project. In China, there is magnificent demand for heavy castings with the rapidgrowth of the national economy in recent years and the expected high growth in the coming 10 to 20 years. Someheavy and large castings such as mill housing and hydraulic turbine runner crown, blade and band for Three GorgesProject have been successfully made. However, the domestic production capability is still far from meeting the giganticrequirements. The domestic capability still lags behind the world class level, and a lot of heavy castings still dependon import. The paper also gives a particular introduction of the key technologies in the manufacturing of heavy steelcastings like metal melting, foundry technology, heat treatment technology and numerical simulation technique, etc.In addition, several case studies on the application of numerical simulation in the production of heavy steel castingsare presented.
文摘In order to solve the problem of the high surface longitudinal crack ratio of heavy peritectic steel slabs produced by the No. 3 continuous caster at Baosteel,the physical properties of the original mold flux and the optimized mold flux were compared in a comprehensive way by using analytical measures, such as a slag film heat-flow simulator, a thermowire molten flux crystallization tester and an X-ray diffractometer in the laboratory. The results reveal that one of the major reasons for the cracks is the poor heat transfer ability of the original mold flux. However, the optimized mold flux with a high basicity features a high crystallizing rate,low crystallization temperature and low heat-flow density. Therefore, the optimized mold flux is more suitable for casting peritectic steel by the heavy slab continuous caster. The test results show that the slabs produced by using the optimized mold flux had no surface longitudinal crack in four test casts, while the surface longitudinal crack ratio of the slabs produced by using the original mold flux was 5%. The optimized mold flux can effectively prevent slab surface longitudinal cracks from occurring.
基金Sponsored by the National Natural Science Foundation of China( Grant No. 50878066)the National Key Technology R&D Program during the 11th Five-Year Plan Period of China( Grant No. 2006BAJ01B02)
文摘This paper presents the shear performance analysis of a heavy-duty universal hinged cast steel support with the largest bearing capacity. The effect of 9 parameters ( 52 specimens) ,i. e. height of the upper support,depth of the ring of the upper support,depth of the top plate of the bottom support,height of the ribs of the bottom support,depth of the ribs of the bottom support,bolt hole diameter,number of the ribs of the bowl,depth of the ribs of the bowl,and yield strength of the material,were analyzed with a 3-dimensional elastic-plastic finite element model in which the nonlinearities of geometry,material and contact were all considered. Analysis shows that height of the upper support,depth of the ring of the upper support and yield strength of the material have a great effect on the mechanical performance of the support. Height of the upper support has the largest effect on performance price ratio of the support,and the maximum effect can be up to 160% . Depth of the top plate of the bottom support,height of the ribs of the bottom support and depth of the ribs of the bottom support have a medium effect on performance price ratio of the support,and the effect is within the limit of 15% 19% .
文摘1.IntroductionMedium Mn steel was developed be-cause the wear resistance of Hadfield steel(Mn13)is poor under low or medium im-pact and extrusion abrasion[1-4].In theforegoing investigations[2-4]we found thatwith the increase of C content,theneedle-like and network carbide in mediumMn steel increased(as shown in Fig.1(a)and(c)).Although its wear resistance was largelyimproved,its impact toughness was greatlydecreased.In order to increase toughness,along-term high temperature heat-treatmentwas needed.But the treatment caused cracks
文摘The SMART/ASTC dynamic soft reduction technology of VAI and its application on the 6-strand bloom continuous caster at Pangang, China are presented. The operation results show that soft reduction technology is effective to improve the inner quality of continuously cast blooms. At Pangang, both the central porosity and the central segregation ratings are no more than 1.0, the central shrinkage cavity rating is no more than 0.5, and the central segregation index of carbon is no more than 1.05. Rails made from the blooms have excellent quality and are used for high-speed tracks.
基金funded by National Basic Research Program of China(No.2011CB012900)
文摘To replace metal padding by insulation padding for castings can save the melt and reduce cleaning work of castings. The design of insulation padding was investigated. The equation of the modulus extension factor for insulation padding and the ratio of its thickness over the modulus of a casting were improved to deter- mine the thickness of insulation padding. The insulation padding was designed for a turbine guide vane casting weighing 3.5 t. A sound casting was obtained with 750 kg steel saved. On the other side, the cast- ing obviously expanded at the interface with the insulation padding, which is perhaps the reason that the use of insulation padding has been suspended for many years. To avoid the expansion of insulation pad- ding, a shielding layer made of a kind of material of good fire resistance was adopted to prevent the insula- tion layer from touching the melt. The shielding layer serves as a cushion of heat and expansion during so- lidification process so as to resist the expansion of castings and guarantee the feeding effect at the same time. Furthermore, insulation padding can be placed by a certain offset into the mold cavity so as to coun- teract the expansion of castings.
