电渣连铸技术的开发

在结合电渣重熔和连铸技术优点的基础上。东北大学钢铁冶金研究所采用双极串联、交换电极及在线切割等技术，在国内首次成功地开发了电渣连铸（ESCC）技术；解决了电渣重熔钢锭直径小于300mm时熔速很慢、冶炼费用很高的难题。通过对重熔方坯质量的低倍、高倍、夹杂物检验等分析表明，该技术生产的方坯表面质量和内部质量良好，具有广泛应用前景和经济价值。     

Metallurgical Source of Cryogenic Intergr anular Fracture of Fe-38Mn Austenitic Alloy

SEM and Field emitting TEM-EDAX were used to investigate the fracture surface of series impact specimens and the grain boundary chemistries of VIM (vacuum-induction-melted) Fe-38Mn austenitic alloy before and after ESR (electroslag remelting,). The quantity and the size of inclusions were also examined. The results show that the VIM Fe-38Mn aust enitinic alloy water-quenched from 1 100 ℃ undergoes an obvious ductile-to-brittle transition, and the impact work at ambient temperature is 242 J, the corresponding fracture surface exhibits adimple character. However, the impact work at 77 K of VIM alloy is only 25 J and the fracture mode is IGF (intergranular f racture). After ESR, the impact work at ambient temperature is 320 J and the fra cture surface exhibits a character of "volcano lava" (meaning excellent toughn ess); The impact work at 77 K is up to 300 J and the fracture mode is microvoid coalescence mixed with quasi-cleavage. The segregation of Mn is not found in all specimens, but the segregation of S is observed, and the S segregation is decreased after ESR. The examined results of inclusions show that ESR reduces the quantity and improves the morphology of inclusions. From the above results it can be seen that the cryogenic IGF of VIM Fe-38Mn austenitic alloy is related to the S segregation at grain boundary. After ESR the decrease in the quantity and size of inclusion results in the increase of the impact work at ambient temperature, while the restriction of IGF is related to the decrease in the total level, and hence in the grain boundary segregation of S.     

Ductile Fracture Behaviour of Hot Isostatically Pressed Inconel 690 Superalloy

Herein we assess the differences in Charpy impact behavior between Hot Isostatically Pressed and forged Inconel 690 alloy over the temperature range of 300 °C to ? 196 °C. The impact toughness of forged 690 exhibited a relatively small temperature dependence, with a maximum difference of ca. 40 J measured between 300 °C and ? 196 °C, whereas the HIP’d alloy exhibited a difference of approximately double that of the forged alloy over the same temperature range. We have conducted Charpy impact testing, tensile testing, and metallographic analyses on the as-received materials as well as fractography of the failed Charpy specimens in order to understand the mechanisms that cause the observed differences in material fracture properties. The work supports a recent series of studies which assess differences in fundamental fracture behavior between Hot Isostatically Pressed and forged austenitic stainless steel materials of equivalent grades, and the results obtained in this study are compared to those of the previous stainless steel investigations to paint a more general picture of the comparisons between HIP vs forged material fracture behavior. Inconel 690 was selected in this study since previous studies were unable to completely omit the effects of strain-induced martensitic transformation at the tip of the Chary V-notch from the fracture mechanism; Inconel 690 is unable to undergo strain-induced martensitic transformation due to the alloy’s high nickel content, thereby providing a sister study with the omission of any martensitic transformation effects on ductile fracture behavior.     

Austenite recrystallization and carbonitride precipitation in niobium microalloyed steels

The response of austenite to thermomechanical treatment is investigated in two series of niobium microalloyed steels. Optical and electron metallographic techniques were used to follow the austenite recrystallization and carbonitride precipitation reactions in these steels. The first series of steels contained a constant level of 0.05Nb, with carbon levels varying from 0.008 to 0.25 pct. It was found that a lower carbon concentration results in faster austenite recrystallization, due to a smaller carbonitride supersaturation, which leads to a reduced precipitate nucleation rate. The second series of steels was designed with a constant carbonitride supersaturation, by simultaneously varying the Nb and C concentrations while maintaining a constant solubility product. In these steels, the recrystallization kinetics increase as the volume fraction of Nb(C, N) is reduced and/or as the precipitate coarsening rate is increased. The volume fraction of carbonitrides increases as the Nb: (C+12/14 N) ratio approaches the stoichiometric ratio of approximately 8:1. The precipitate coarsening rate was shown to increase with increasing amounts of niobium remaining in solution in the austenite (i. e., “excess” Nb after precipitation). As expected, recrystallization proceeds more slowly at lower temperatures and after a reduced amount of deformation. An experiment to determine whether Nb atoms dissolved in the austenite could exert a significant solute-drag effect on the recrystallization reaction indicated that 0.20Nb in solution could reduce the rate of recrystallization compared to a Nb-free C-Mn steel. However, this solute effect was smaller than the retarding effect which 0.01Nb can have when it is precipitated in the form of carbonitrides on the austenite substructure after rolling.     

Kinetics of the σ-phase formation in Fe-Cr-Co hard magnetic alloys

Three magnetic hard alloys 22Kh15K, 25Kh15KYuBF and 30Kh5K of the Fe-Cr-Co system are used to study the kinetics of σ phase formation after quenching from 1300–1100°C and tempering in the temperature range 700–800°C by measuring HV ₃₀₀ hardness, X-ray diffraction, and metallographic analysis. The main σ-forming element in these alloys is shown to be cobalt. The rate of formation of σ-phase during tempering is maximal at 750°C.     

HR-2钢电渣工艺及夹杂物去除研讨

HR-2钢对夹杂物要求很严，采用一般电渣重熔工艺难以使夹杂物级别符合技术条件要求。本文对采用不同渣系电渣重熔工艺进行了研究和讨论，认为控制电渣重熔过程的熔化速度和选择对夹杂物吸附强的渣系有利于去除钢中夹杂物。     

Simulation of Cooling of Double-Layered Splat and its Experimental Validation Using Jackson–Hunt Theory

A model of heat transfer and fluid flow during the sequential impingement of two liquid Al-33 wt pct Cu droplets on a 304 stainless steel substrate has been developed on the FLUENT 6.3.16 platform. The model was validated using the Jackson–Hunt theory (K.A. Jackson and J.D. Hunt: Trans. Metall. Soc. AIME, 1966, vol. 236, pp. 1129–42). During the impingement of the second droplet on the first splat, transient air gap formation and remelting of solidified region of the first splat occurred.     

电渣重熔工艺对高氮钢脱硫的影响

对电渣重熔制备高氮钢的脱硫过程进行了研究,分别采用不同渣系和熔炼速率对高氮钢进行制备。对电渣重熔前后夹杂物进行电镜及成分分析,分析结果表明:硫化物夹杂的平均直径和单位面积数量大大减少,夹杂物的主要类型为MnS+Al2O3复合型夹杂物;适度提高渣中CaO含量可提高硫分配比,是提高脱硫效率的有效手段。同时,实验结果表明重熔速率对电渣重熔中的脱硫率具有重要影响。通过脱硫动力学推导,发现重熔速率越低,脱硫效果越明显,但实验发现脱硫率随重熔速率的降低有时呈现先降低后升高的趋势,其原因在于渣池中发生硫化物富集,导致"回硫"现象发生,降低了脱硫率。     

Microstructural development during solidification of stainless steel alloys

The microstructures that develop during the solidification of stainless steel alloys are related to the solidification conditions and the specific alloy composition. The solidification conditions are determined by the processing method,i.e., casting, welding, or rapid solidification, and by parametric variations within each of these techniques. One variable that has been used to characterize the effects of different processing conditions is the cooling rate. This factor and the chemical composition of the alloy both influence (1) the primary mode of solidification, (2) solute redistribution and second-phase formation during solidification, and (3) the nucleation and growth behavior of the ferrite-to-austenite phase transformation during cooling. Consequently, the residual ferrite content and the microstructural morphology depend on the cooling rate and are governed by the solidification process. This paper investigates the influence of cooling rate on the microstructure of stainless steel alloys and describes the conditions that lead to the many microstructural morphologies that develop during solidification. Experiments were performed on a series of seven high-purity Fe-Ni-Cr alloys that spanned the line of twofold saturation along the 59 wt pct Fe isopleth of the ternary alloy system. High-speed electron-beam surface-glazing was used to melt and resolidify these alloys at scan speeds up to 5 m/s. The resulting cooling rates were shown to vary from 7°C/s to 7.5×10⁶°C/s, and the resolidified melts were analyzed by optical metallographic methods. Five primary modes of solidification and 12 microstructural morphologies were characterized in the resolidified alloys, and these features appear to be a complete “set” of the possible microstructures for 300-series stainless steel alloys. The results of this study were used to create electron-beam scan speedvs composition diagrams, which can be used to predict the primary mode of solidification and the microstructural morphology for different processing conditions. Furthermore, changes in the primary solidification mode were observed in alloys that lie on the chromium-rich side of the line of twofold saturation when they are cooled at high rates. These changes were explained by the presence of metastable austenite, which grows epitaxially and can dominate the solidification microstructure throughout the resolidified zone at high cooling rates. J. W. ELMER, formerly Graduate Student at the Massachusetts Institute of Technology     

Q235B中厚板延伸率不合格原因分析及改进

分析了Q235B中厚板延伸率合格与不合格试样拉伸断口的形貌,用金相显微镜对试样中的夹杂物种类、级别及金相组织进行了定性分析和评级,用扫描电镜对夹杂物进行了定量分析,认为Q235B中厚板延伸率不合格的主要原因是钢中含有较多的夹杂物和带状组织。改进炼钢和轧钢工艺后,2011年Q235B中厚板的延伸不合格率由原来的9%降至1%,可创效益120万元。     

Effect of Slag on Inclusions During Electroslag Remelting Process of Die Steel

Many factors influence the non-metallic inclusions in electroslag steel including furnace atmosphere and inclusions’ content in the consumable electrode, slag amount and its composition, power input, melting rate, filling ratio, and so on. Fluoride containing slag, which influences the non-metallic inclusions to a great extent, has been widely used for the electroslag remelting process. The current paper focuses on the effect of fluoride containing slag on the inclusions in electroslag ingots based on the interaction of the slag-metal interface and electroslag remelting process. In this work, die steel of CR-5A and several slags have been employed for investigating the effect of slag on inclusions in an electrical resistance furnace under argon atmosphere in order to eliminate the effect of ambient oxygen. Specimens were taken at different times for analyzing the content, dimensions, and type of non-metallic inclusions. Results of quantitative metallographic analysis indicate that a multi-component slag has better capacity for controlling the amount of inclusions; especially protective gas atmosphere has also been adopted. The findings of inclusions in electroslag steel by SEM–EDS analysis reveal that most non-metallic inclusions in electroslag steel are MgO-Al₂O₃ inclusions for multi-component slags, but it is Al₂O₃ inclusions when remelting using conventional 70 wt pct CaF₂-30 wt pct Al₂O₃ slag. The maximal inclusions’ size using multi-component slags is less than that using conventional binary slag. Small filling ratio as well as protective gas atmosphere is favorable for controlling the non-metallic inclusions in electroslag steel. All the results obtained will be compared to the original state inclusions in steel, which contribute to choice of slag for electroslag remelting.     

Macro- and Microstructure Evolution of 5CrNiMo Steel Ingots during Electroslag Remelting Process

A comprehensive mathematical model was established and used to simulate the macro and microstructure evolution during the production process of 5CrNiMo steel ingot by electroslag remelting （ESR） method. Along the ingot height, the macrostructure distribution characteristics changed from vertical, fine columnar grains to tilted, coarse columnar grains, and this transformation process occurred at the very beginning of ESR. In the cross section of the ingot, there were three grain morphology regions and two grain type transition regions from the outside to the center of the ingot. These regions were the fine columnar grain region, columnar competitive growth transition re gion, coarse columnar grain region, columnar to equiaxed grain transition （CET） region, and coarse equiaxed grain region. The influence of the remelting rate on the macrostructure and mlcrostructure was investigated using a series of experiments and simulations. The results showed that a low remelting rate could produce a small grain growth angle （GGA） ; the average secondary dendrite arm spacing （SDAS） firstly decreased and then increased as the remelting rate increased. An excessively high or low remelting rate can increase the GGA and average SDAS in ingots. Thus, the remelting rate should be controlled within a suitable range to reduce composition microsegregation and microshrinkage in the ingot to produce an ESR ingot with satisfactory hot forging performance.     

Modeling of the peritectic reaction and macro-segregation in casting of low carbon steel

Macro-microscopic models have been developed to describe the macrosegregation behavior associated with the peritectic reaction of low carbon steel. The macrosegregation model has been established on the basis of previously published work and experimental data. A microscopic model of a three-phase reaction L+δ→γ has been modeled by using Fredriksson’s approach. Four horizontal and unidirectional solidified experimental groups simulating continuous casting have been performed with a low carbon steel containing 0.13 wt pct carbon. The extent of macrosegregation of carbon was determined by wet chemical analysis of millings. It is confirmed, by comparing calculated results with experimental results, that this model successfully predicts the occurrence of macrosegregation. The results indicate that a peritectic reaction which is associated with a high cooling rate generates high thermal contraction and a high tensile strain rate at the peritectic temperature. Therefore, the macrosegregation, particularly at the ingot surface, is very sensitive to the cooling rate, where extremely high positive segregation was observed in the case of a high cooling rate. However, in the case of slow cooling rate, negative segregation was noted. The mechanism of macrosegregation with peritectic reaction is discussed in detail.     

Enhancement of Inclusion Removal in Electroslag Remelted M2 High-Speed Steel Assisted by Axial Static Magnetic Field

The effect of axial static magnetic field (ASMF) on inclusion removal during the magnetically controlled electroslag remelting M2 high-speed-steel was investigated. The results showed that the application of ASMF can significantly increase the inclusion removal efficiency, especially for the inclusions larger than 20 μm. The reason for the accelerated removal of inclusions was attributed to the alternating Lorentz force and the magnetically controlled spin-vibration induced in the liquid melt film after the application of ASMF.

     

Characterization of the peritectic reaction in medium-alloy steel through microsegregation and heat-of-transformation studies

In the present work, the phenomenon of the peritectic reaction was characterized in a medium-alloy steel. Several directional solidifcation and thermal-analysis experiments were done to investigate the reaction process. Directional solidification experiments carried out did not tend to show any direct evidence of a peritectic reaction. Microsegregation studies on the directionally solidified samples and those solidified under isothermal conditions bring out some interesting features. It has been documented that if the segregation ratio for Ni is higher than that for Cr, there is a correlation that the peritectic reaction had occurred in that region. On the other hand, a higher Cr segregation ratio as compared to Ni showed the possibility that the liquid had directly transformed to γ-austenite without undergoing a peritectic reaction. Measurement of energies of transformations and the analysis of their values in different segments of the cooling-curve differential thermal analysis (DTA) experiments have helped in understanding the peritectic reaction. It is revealed that the transformation is more like diffusionless transformation, where γ-austenite directly precipitates from δ-ferrite. Indeed, this proposition is also supported by the segregation patterns for Cr and Ni obtained in the solidified samples of this steel during directional solidifcation and DTA experiments and also by calculations to show the presence of enough lattice defects or vacancies to aid the aforementioned transformation.     

TIG重熔对6005A-T6铝合金焊接接头组织及性能的影响

针对铝合金焊接接头缺陷TIG重熔修复,采用6005A-T6铝合金作为母材,先采用MIG焊对母材进行焊接,焊后采用无脉冲TIG焊对焊趾处进行重熔,有无脉冲TIG焊对焊缝处进行重熔,对重熔前后的焊接试验件进行金相显微组织形貌及性能对比分析.结果表明,重熔后热影响区宽度明显大于重熔前,组织晶粒更加粗大,弥散相分布更加均匀;硬...     

RH去除Al2O3夹杂物的数值模拟及工艺分析

 RH已经成为炉外精炼的重要组成部分,以180 t RH设备参数为基础建立三维模型,通过工艺试验和数值模拟的方法分析夹杂物分布及去除情况。试验结果表明,RH净循环时间为300 s夹杂物去除效率最高,但是夹杂物去除净循环时间不超过850 s。数值模拟比较夹杂物直径60、40、20 μm去除行为影响因素情况,通过数值模拟与金相试验的方法相比较,两者质量分数相差15.8%,因此说明数值模拟的方法可以应用到RH炉外精炼工艺过程中指导生产实践的预测。     

Microstructural evolution of predeformed SiC<Subscript><Emphasis Type="Italic">p</Emphasis></Subscript>/ZA27 composites during partial remelting

The microstructural evolution process in SiC particle (SiC _p )-reinforced ZA27 composites, previously compressed by different lengths at 270 °C, was investigated during partial remelting. The results indicated that, after being compressed, the microstructure of SiC _p /ZA27 composites changed gradually from developed primary α dendrites, to coarsened short dendrites, and then to a structure consisting of texture cells with different orientations with increasing compression. During subsequent partial remelting, the microstructure evolution exhibited four stages: initial rapid coarsening, structural separation, spheroidization, and final coarsening. The change of the primary α particle size with the heating time obeyed the law developed by Lifshitz and Slyosov and Wagner (LSW) after the semi-solid system was up to the dynamic solid-liquid equilibrium state. High compression, high remelting temperature, and large size and proper content of SiC _p s were beneficial to achieving a desirable structure for semisolid forming (SSF). The primary α particle size distribution was significantly affected by coalescence. These phenomena were extensively discussed metallographically and theoretically.     

The Estimation and Control of the Electroslag Remelting Melt Rate by Mechanism-Based Modeling

The process control of industrial electroslag remelting production is addressed in this work. This article proposes a mechanism-based model using electrode displacement to estimate the melt rate, designs the remelting process control system, and uses practical application data to verify the validity of the model. The soft measurement of the melt rate based on mechanism modeling is proved to be an economical and reliable solution to the online melt rate estimation and control for large industrial electroslag remelting furnaces.