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عدد المساهمات : 19001 التقييم : 35505 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
| موضوع: كتاب Continuous Casting of Steel السبت 26 فبراير 2022, 12:49 am | |
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أخواني في الله أحضرت لكم كتاب Continuous Casting of Steel W. R. Irving FInstP, MIM, CEng
و المحتوى كما يلي :
CONTENTS SUMMARY 1 INTRODUCTION 1.1 Historical background 1.2 Description of the Continuous Casting Process and the Evolution of Machine Design 1.2.1 Brief Description and Basic Principles of the Continuous Casting Process 1.2.2 Evolution of Machine Design 1.3 Advantages of Continuous Casting over Ingot Casting 1.3.1 Improved Yield 1.3.2 Reduced Energy Consumption 2 LIQUID STEEL SUPPLY 2.1 General details 2.2 Compositional Control 2.2.1 Carbon Removal for Low Carbon Strip Grades 2.2.2 Hydrogen Removal 2.2.3 Sulphur Removal and Control 2.2.4 Nitrogen Removal and pickup 2.2.5 Oxygen Control 2.3 Temperature Control in Ladle and Tundish 2.4 Tundish Technology 2.5 Ladle to Tundish Teeming 2.6 Tundish to Mould Teeming 3 MACHINE COMPONENTS, HEAT TRANSFER AND STRAND SOLIDIFICATION 3.1 Mould Technology 3.1.1 Mould Design Details 3.1.1.1 Mould length 3.1.1.2 Mould Materials 3.1.1.3 Mould Oscillation 3.1.1.4 Variable Width Moulds 3.1.1.5 Moulds for twin and triple casting 3.1.2 Mould Heat Transfer 3.1.2.1 Affect of Cooling Water Flow Rate vii xi 1 1 7 7 13 18 19 20 22 22 22 24 24 24 25 26 28 30 32 33 37 37 37 40 40 40 43 44 44 51viii Continuous Casting of Steel 3.1.2.2 Affect of Mould Lubrication 51 3.1.2.3 Affect of Carbon Content 52 3.1.2.4 Affect of Casting Speed 54 3.1.2.5 Temperature Distribution in Copper Plates 55 3.1.2.6 Heat Transfer Measurements on a Slab Mould 55 3.2 Strand Support Systems and Secondary Cooling 58 3.2.1 Strand Support System Details for Various Machine Types 58 3.2.1.1 Below Mould Support System for Slabs 59 3.2.1.2 Main Strand Support Systems for Slab Casters 60 3.2.2 Secondary Cooling 62 3.2.2.1 Spray Cooling with Water Only 66 3.2.2.2 Spray Cooling with Water and Air (Air Mist) 67 3.2.3 Roller Design and Performance 68 3.3 Strand Straightening and Strand Withdrawal 72 3.3.1 Strand straightening 72 3.3.1.1 Strand Completely Solidified 73 3.3.1.2 Straightening with a liquid core 73 3.3.1.3 Straightener design \74 3.3.2 Strand Bending 76 3.3.3 Withdrawal Units 78 3.4 Computer Simulation Models 79 3.4.1 The Strand Solidification Model 80 3.4.2 Strand Deformation Model 82 3.4.2.1 Critical Strain Levels 87 3.4.3 Roller Temperature and Deflection Models 87 4 PRODUCT REQUIREMENTS AND FACTORS AFFECTING AS-CAST QUALITY 93 4.1 Categorisation of Final Products and the As-cast Quality Requirements 93 4.2 Affect of Chemical, Process and Engineering Parameters on Surface Defects 95 4.2.1 Categorisation of Surface Defects 95 4.2.2 Compositional Factors 96 4.2.2.1 Peritectic Grades 96 4.2.2.2 Grain Refined Steels 98Contents ix 4.2.2.3 Affect of Residuals such as sulphur and phosphorus 100 4.2.3 Mould Parameters 103 4.2.3.1 Mould Level Control 105 4.2.3.2 Mould Lubrication 106 4.2.3.3 Mould Oscillation 112 4.2.4 Secondary Cooling 118 4.2.4.1 Below Mould Cooling 118 4.2.4.2 Hard and Soft Cooling for Production of Grain Refined Steels 119 4.2.5 Machine Geometry 120 4.2.5.1 Machine Alignment 120 4.2.5.2 Strand Straightening 120 4.3 Effect of Chemical, Process and Engineering Parameters on Internal Quality 120 4.3.1 Categorisation of Internal Defects 120 4.3.2 Casting Temperature 122 4.3.2.1 Effect on Steel Cleanness 122 4.3.2.2 Effect on Internal Structures 122 4.3.3 Electromagnetic Stirring (EMS) 129 4.3.3.1 EMS on Billet sand Blooms 130 4.3.3.2 EMS on Slabs 135 4.3.4 Compositional Factors 138 4.3.5 Machine Geometry 140 4.3.5.1 Affect on Inter Columnar Segregation 141 4.3.5.2 Affect on Centreline Segregation 143 4.3.6 Secondary Cooling 147 4.3.7 Casting Speed 149 4.4 Geometrical Defects 150 5 SPECIAL PROCESSES AND EMERGING TECHNOLOGIES 156 5.1 Horizontal Casting 158 5.2 Beam Blank Casting 162 5.3 Thin Slab Casting 165 5.4 Strip Casting 173 6 PROCESS CONTROL AND ANCILLARY EQUIPMENT 177 6.1 Automatic On-line Process Control Systems 179 6.1.1 Tundish Level Control 179 6.1.2 Automatic Mould Level Control 179 6.1.3 Secondary Cooling Water Control 182x Continuous Casting of Steel 6.1.4 Automatic Start of Casting 185 6.1.5 Automatic Mould Powder Feeding 186 6.2 On-Line Monitoring Systems 186 6.2.1 Detection of Slag from the Ladle 186 6.2.2 Continuous Tundish Temperature Measurement 187 6.2.3 Mould Thermal Monitoring (MTM) and Sticker Breakout Prediction 188 6.2.4 Mould Oscillation Monitoring 195 6.2.5 Spray Water Monitoring 196 6.3 Off-Line Measuring Systems 196 6.3.1 Mould Geometry Measurements 196 6.3.2 Strand Condition and Spray Water Distribution Monitoring 196 6.3.2.1 Measuring head 197 6.3.2.2 Computer Hardware 197 6.3.2.3 Computer Software 197 6.4 Quality Control Systems 197 6.4.1 On-line Hot Surface Inspection 199 6.4.2 On-line Quality Prediction Systems 201 INDEX 2051. INDEX Index Terms Links A Air ingress 33 34 Air gap formation 8 49 50 Air mist cooling 63 66 67 Argon Shrouding 33 48 Argon Stirring 24 26 28 Automation 177 mould metal level 179 182 on-line predictive grading 201 powder feeding 186 secondary cooling 182 start of casting 185 tundish metal level 179 B Basic oxygen steelmaking (BOS) 13 16 24 Beam blanks 156 162 Bending 3 13 15 76 multi point 78 Billet and/or bloom casting 2 10 15 35 38 48 50 59 130 149 Breakout 13 41 114 193 194Index Terms Links Break ring 158 160 Bulging 8 59 68 82 142 144 C Calcium aluminates 28 sulphides 28 treatment 26 27 Carbon 23 24 effect on heat transfer 53 54 97 effect on internal cracks 124 139 effect on longitudinal facial cracks 97 Casting powders 53 95 97 108 affect on heat transfer 53 107 affect on longitudinal facial cracks 95 97 Central porosity 121 127 129 Centreline segregation macrosegregation 126 129 144 semi-macrosegregation (or'V' segregation) 128 129 135 Chemical composition 22 95 96 aluminium 34 98 99 carbon 23 24 52 54 97 102 117 124 131 135 139 193 manganese/sulphur ratio 101 102 119 139 niobium 98 99 phosphorus 23 100 silicon 23Index Terms Links Chemical composition (Cont.) sulphur 23 24 25 34 100 101 102 vanadium 99 Cleanness 23 26 30 Columnar structure 121 124 Cracks centerline 121 144 intercolumnar (or interdendritic) 121 139 142 longitudinal corner 95 151 longitudinal facial 95 97 101 103 104 111 119 150 star 95 transverse corner 95 99 transverse facial 95 99 105 triple point 121 D Definitions beam blanks 162 billet 2 bloom 2 cast strip 169 slab 2 thin slab 165 Dendritic structure (see columnar structure) Deoxidation 24 25 26 33 Diagonal cracks 151Index Terms Links Direct charging (see hot changing) Dual spray system 67 Dummy bar 11 12 197 E Electromagnetic brake (EMBR) 137 138 Electromagnetic stirring (EMS) 129 billets and blooms 130 horizontal casting 161 162 slabs 134 Energy 19 20 44 Equiaxed structure 121 135 136 Evolution of machine design 13 14 15 F Ferrostatic pressure 8 58 69 Foot rolls 58 151 Free cutting steels 24 G Grain refined steels 98 99 119 H Hazelett process 157 166 168 Heal time (negative strip) 3 7 41 44 49 112 113 195 Heat transfer convective 62 mould 7 44Index Terms Links Heat transfer (Cont.) radiative 62 secondary cooling 8 63 support rols 69 70 Horizontal casting 15 156 158 Hot charging 20 167 Hydrogen 24 32 Hydrogen-induced cracking (HIe) 137 I Ingot casting 1 18 19 20 In-line rolling 167 Inclusions 26 27 28 48 95 96 103 121 129 136 137 138 Internal cracks 121 139 151 L Ladle 9 10 28 32 car 9 10 changing 10 furnace 23 24 28 29 turret 9 10 Liquid core length 17 81 Liquidus temperature 81 122 136 Longitudinal facial cracks 96 97 101 103 104 119 Longitudinal corner cracks 95 151Index Terms Links M Mini-ingot formation 127 Mould construction 38 cooling 8 copper 8 40 41 design 37 38 friction 13 78 160 geometry 196 heat transfer 7 37 44 length 40 lives 39 maintenance 39 materials 40 41 160 metal level control 35 105 multi stage 58 oscillation 40 41 42 48 112 oscillation monitoring 195 powders 48 53 91 95 97 107 plating 40 thermal monitoring 188 taper 43 44 49 tubular 38 twin/triple 17 44 variable width 16 43 44 Multi-nozzle system 66 Multi-roll drive 77 78Index Terms Links N Negative strip (or heal time) 3 7 41 44 112 113 195 Nitrogen 23 25 35 98 99 Nitrogen pick-up 25 33 Nozzle clogging 28 34 Nozzles metering 33 35 48 182 spray 8 60 63 submerged entry 11 22 31 34 44 47 48 O Oscillation 40 41 42 48 112 Oscillation marks 114 Ovality 150 Oxygen 26 P Partition coefficients 140 Pinch roll unit 77 Pinholes 104 105 107 134 Plate mould 38 40 Pouring stream shrouding 9 10 32 Process control computer system 178 Production rate 16 17 44Index Terms Links R Rape seed oil 7 107 109 Reduction in area 98 99 Refractory materials 21 24 27 32 34 Reoxidation 27 28 33 34 103 Rhomboidity 150 Roll alignment 85 86 141 cooling 69 70 designs 68 69 88 89 friction 78 gap measuring device 142 197 198 material 71 measurements 197 Permanent bending 69 90 Rotation transducers 197 split (or divided) 61 wear 72 S Secondary cooling air mist 63 67 design 65 heat flux 65 impact density 64 multi-nozzle 66 148 single nozzle 66 148 spray nozzles 8 63Index Terms Links Secondary cooling (Cont.) twin nozzle 66 148 water only 63 66 Segregation centerline macrosegregation 129 140 144 intercolumnar (or interdendritic) macrosegregation 140 142 143 microsegregation 129 negative segregation (or white bands) 132 133 V segregation (or spot segregation) 128 135 140 144 Sequence casting 10 22 Shape defect 150 151 Sheet 135 Shrinkage cavity 121 127 129 Shrouding 9 10 11 32 tube 9 32 33 gas 11 35 Slag detection 186 187 Slag spots 104 105 106 Sliding gates 9 32 33 Slitting 17 Soft reduction 127 129 137 144 147 Solidification 11 columnar (or dendritic) structure 121 125 127 128 equiaxed structure 121 135 136 solidification constant 16 solidification model 16 18 80 184 solidification rate 16 80 81Index Terms Links Spray Cooling (see secondary cooling) Star cracks 96 Starting chain (see dummy bar) Stirring systems (see electromagnetic stirring) Stopper rod 10 Strand friction 78 guide section 58 59 machine cooling water 63 maintenance 61 secondary cooling 8 62 straightening 11 13 14 72 support grids, plates 59 support, slab strands 59 60 61 taper 127 129 137 144 145 walking beam supports 59 with air mist 63 67 withdrawal force 79 withdrawal 77 Straightening 11 13 14 72 continuous 75 multi point 13 75 76 single point 13 75 76 strains/strain rates 73 Strains bulging 82 misalignment 82 straightening 73 87Index Terms Links Strip casting 156 169 Stroke length 112 113 Submerged entry nozzle (SEN) 11 22 31 33 34 44 47 48 Sulphur 23 24 25 34 100 101 103 Superheat 121 122 125 133 136 Support rolls 8 58 68 87 Surface defects 95 T Taper mould 43 44 49 196 strand 127 129 137 144 145 Temperature control ladle 28 surface 100 120 182 tundish 28 Thin slabs 156 165 Torch cutting 11 18 Transverse cracks 98 99 105 119 Tubular moulds 38 Tundish 10 30 bath level 35 179 changing on-the-fly 10 flow control 33 34 179 180 flow patterns in tundish 31 influence on cleanness 30 31Index Terms Links Tundish (Cont.) metering nozzles 35 182 refractory lining 32 size 30 sliding gates 33 35 stopper rods 10 31 33 34 35 weirs and dams 30 Twin and Triple casting 17 44 V Vacuum degassing 23 24 25 26 28 V-segregation (or spot segregation) 128 135 144 Variable width mould 16 43 44 W Walking beams 59 Water cooling channels 37 38 50 51 impact density 64 machine 63 mould cooling 37 50 52 roll cooling 63 68 88 secondary cooling 62 sprays nozzles 8 62 148 velocity 37 38 water quality 37 Wide flange beams 162Index Terms Links Withdrawal rolls 9 11 77 78 Withdrawal forces 79 Y Yield 19 44
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