Advanced numerical simulation models for continuous casting of steel were developed in Finland by Casim Consulting and Aalto University in cooperation with the University of Oulu and the steel industry. The aim was to develop models that are scientifically rigorous, but also computationally fast enough to be used in online applications. The models developed are a transient three-dimensional heat transfer model, CastManager, and a solidification and microstructure model, IDS. The computing time of these models are short, and they are integrated together in one online concept. This concept is installed in the automation systems of four slab casters in Finland. Testing and validation work is in progress. The system simulates the important heat transfer, solidification and microstructural phenomena in continuous casting online. The future aim is that this information will be used for online quality control and for optimizing the process conditions to avoid formation of defects. Many quality indices have already been developed. A steady state version of the CastManager tool has also been developed, called Tempsimu.
A ferrochrome converter (CRC) is used for removal of silicon and carbon from ferrochrome in stainless steel production. The raw materials are molten ferrochrome and stainless steel scrap, and the process produces a raw material for argon-oxygen-decarburization (AOD). The zinc content prevents the utilization of CRC dust (CRCD). The objective of this work is characterization and sulfuric acid leaching of CRCD and evaluation of formation mechanisms and the effects of mineralogy and microstructure on the hydrometallurgical treatment. CRCD contains critical (Cr, fluorite) and economically important (Fe, Zn) materials. The mineralogy and microstructure of CRCD are complex. The dust has been formed by many mechanisms. Lime and ferrosilicon prove that take-off of solid particles during charging is important. Also, ejection of liquid droplets is considerable because ferrochrome and slag spheres are common. The highest Zn dissolution is 93-94% and at the same time 5-15% of Cr is leached. The existence of zincite explains the high dissolution of zinc. The encapsulation, e.g., magnesiochromite enclosed into glass, explains the low chromium dissolution. The best selectivity for Zn extraction over iron, chromium, and nickel is achieved with 0.5 M, at 30 and 60 8C
In this study the precipitation of silicon in Type 441 steel (18%Cr-0.4%Nb-0.5%Si) was investigated and its influence on strength properties were determined. To simulate high-temperature service conditions, heat treatments with various ageing times up to 120 hours and temperatures up to 800 °C were performed. Following the aging treatments, micro-and macro-hardness and tensile properties were measured. Microstructure and precipitation were analyzed using scanning electron microscopy and energy-dispersive spectroscopy. Predictions for equilibrium pericipitation were calculated using the Factsage software. According to observations, coarse titanium nitrides (TiN) and niobium carbides (NbC, Fe3Nb3C) were present in all specimens including non-aged ones. These precipitates did not coarsen during ageing, which implies that their growth already occurred in the sheet production process. However, silicon started to precipitate in the course of prolonged annealing. Si contributed to the formation of a secondary phase resembling the Laves-phase (FeNbSi) on grain boundaries. Hardness and yield strength were found to decrease with prolonged ageing at high temperatures. Factors affecting the silicon precipitation are discussed.
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