Feasibility of using Continuously Cast Round Bloom as a Substitute to Cast Ingot in the Manufacture of Heavy Forgings

Abstract

Continuously cast large round blooms have gained widespread attention due to the improved quality, enhanced economy, higher yields, and lower operating costs obtained through continuous operation. Because the continuous casting (CC) process combines the cleanliness and radial solidification symmetry of the ingot casting process with the higher axial symmetry obtainable through bloom casting, it can deliver a more homogeneous product than conventional ingot casting. Herein, the shop floor manufacturing of a main shaft is discussed to confirm the feasibility of using continuously cast round bloom in the manufacture of heavy forgings. For comparison, the characteristics of a 1000 mm‐diameter continuously cast round bloom are assessed against those of a conventionally cast 20.6 ton ingot. To eliminate cavities at the centerline of the cylindrical bloom, additional studies on void closure efficiency at the center of the billet under various forging die geometries (e.g., flat, V, and round dies) are conducted, and the results reveal that the V‐die geometry is most effective in consolidating centerline voids. A comparison of the respective operational characteristics reveals that the round bloom CC method could be feasibly applied in the manufacture of main shafts.

Characteristics of the Side Surfaces and Edges of Welded Wire Meshes Used in the Construction of Welded Slotted Screens

“…Product design takes into account durability and reliability. A well-designed product is more likely to operate without failures for an extended period, which is crucial in an industry where downtime can be costly [14][15][16][17].…”