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On the surface quality of continuously cast steels and phosphor bronzes
KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Casting of Metals. (Casting of Metals)ORCID iD: 0000-0001-9437-3550
2016 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

This thesis work concerns about the importance of the cast surfaces, surface phenomenon such as the formation of the oscillation marks and exudation and related defects including cracks and segregation that happened during the continuous casting. All of the investigated materials were collected during the plant trials while an in-depth analysis on these materials was performed at the laboratory scale with certain explanations supported by the schematic and theoretical models. The work consists on different material classes such as steels and phosphor bronzes with a focus on the surface defects and their improvements. In order to facilitate the theoretical analysis which could be capable of explaining the suggested phenomenon in the thesis, a reduced model is developed which required lesser computational resources with lesser convergence problems.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2016. , 80 p.
Keyword [en]
Continuous Casting, Steels, Ni-based alloy, Peritectic, Phosphor Bronzes, Simulation and Modeling
National Category
Metallurgy and Metallic Materials
Research subject
Materials Science and Engineering; Industrial Engineering and Management; Metallurgical process science
Identifiers
URN: urn:nbn:se:kth:diva-187718ISBN: 978-91-7729-019-3 (print)OAI: oai:DiVA.org:kth-187718DiVA: diva2:931358
Public defence
2016-06-09, Kollegiesalen, Brinellvägen 8, SE-10044, KTH-Campus, Stockholm, 14:00 (English)
Opponent
Supervisors
Projects
Oscilation mark formation during continous casting of steel
Funder
Swedish Energy AgencyVINNOVAHelge Ax:son Johnsons stiftelse
Note

QC 20160527

Available from: 2016-05-30 Created: 2016-05-27 Last updated: 2016-05-30Bibliographically approved
List of papers
1. A Study of the Oscillation Marks’ Characteristics of Continuously Cast Incoloy Alloy 825 Blooms
Open this publication in new window or tab >>A Study of the Oscillation Marks’ Characteristics of Continuously Cast Incoloy Alloy 825 Blooms
2016 (English)In: Metallurgical and Materials Transactions. A, ISSN 1073-5623, E-ISSN 1543-1940, Vol. 47, no 8, 4068-4079 p.Article in journal (Refereed) Published
Abstract [en]

A comprehensive experimental study of oscillation mark (OM) formation and its characteristics during the solidification of Incoloy alloy 825 in the continuous casting of blooms is investigated by plant trials and metallographic study. The experiments involved two heats with the same casting and mold conditions and sampling at different locations across the strand. The metallographic study combined macro/micro-examinations of OMs and segregation analysis of Cr, Mn, Mo, Ni, and Si by microprobe analysis. The results show that OMs have widely different characteristics, such as mark type, depth, segregation, and accompanying microstructure. Furthermore, the mark pitch can vary considerably even for the similar casting conditions, leading to different conditions for the marks’ formation in relation to the mold’s cyclic movement. Finally, a mechanism for the OM formation is discussed and proposed. Possible solutions for minimizing the observed defects by optimizing the mold conditions are suggested.

Place, publisher, year, edition, pages
Springer Publishing Company, 2016
Keyword
Incoloy alloy 825, continuous casting, bloom, oscillations marks, microstructure, microsegregation, cracks, statistical analysis
National Category
Other Materials Engineering
Research subject
Materials Science and Engineering
Identifiers
urn:nbn:se:kth:diva-187818 (URN)10.1007/s11661-016-3582-8 (DOI)000379494700027 ()2-s2.0-84978160768 (Scopus ID)
Projects
Reduction of oscillation marks formation
Funder
Swedish Energy Agency
Note

QC 20160530

Available from: 2016-05-30 Created: 2016-05-30 Last updated: 2017-11-30Bibliographically approved
2. The influence of peritectic reaction/transformation on crack susceptibility in the continuous casting of steels
Open this publication in new window or tab >>The influence of peritectic reaction/transformation on crack susceptibility in the continuous casting of steels
(English)In: Metallurgical and Materials Transactions B, ISSN 1073-5615Article in journal (Other academic) Submitted
Place, publisher, year, edition, pages
Springer
Keyword
Continuous casting, steel, cracks, peritectic reaction/transformation, segregation, simulation and modeling
National Category
Metallurgy and Metallic Materials
Research subject
Materials Science and Engineering
Identifiers
urn:nbn:se:kth:diva-187867 (URN)
Projects
Reduction of oscillation mark formation during continuous casting
Funder
Swedish Energy Agency
Note

QCR 20160531

Available from: 2016-05-30 Created: 2016-05-30 Last updated: 2016-05-31Bibliographically approved
3. Effect of casting parameters on the formation of oscillation marks during continuous casting
Open this publication in new window or tab >>Effect of casting parameters on the formation of oscillation marks during continuous casting
(English)Manuscript (preprint) (Other academic)
Abstract [en]

In the present investigation, oscillations marks formed at the surfaces of two different steel grades are studied; this includes metallographic investigation. The characteristics of the marks are examined rigorously, and the analysis is performed serially. The statistical data is compared withanalytical relations and possible reasons for the deviations from the average values are discussed.From the ongoing analysis, it can be seen that the formation of the primary shell is an important parameter which can affect the depth of the depression. Moreover, the results show that theformation of the oscillation marks is a complex phenomenon and that there could be more than one explanation for their formation.

National Category
Metallurgy and Metallic Materials
Research subject
Materials Science and Engineering
Identifiers
urn:nbn:se:kth:diva-187870 (URN)
Funder
Swedish Energy Agency
Note

QC 20160608

Available from: 2016-05-30 Created: 2016-05-30 Last updated: 2016-06-08Bibliographically approved
4. Formation of the tin rich layer and inverse-segregation in phosphor bronzes during continuous casting
Open this publication in new window or tab >>Formation of the tin rich layer and inverse-segregation in phosphor bronzes during continuous casting
2015 (English)In: Advances in the Science and Engineering of Casting Solidification: An MPMD Symposium Honoring Doru Michael Stefanescu, The Minerals, Metals, and Materials Society, 2015, 15-22 p.Conference paper, Published paper (Refereed)
Abstract [en]

Continuous casting of the phosphor bronzes has been investigated experimentally and analyzed with the help of a thermo-mechanical model. The microscopic investigation shows the spread of the tin rich liquid at the chill surface cause by the formation of flow channels underneath the chill surface. Precipitation of the secondary phases has also been observed under some casting conditions. The macro segregation profile along the solidification thickness predicts a strong casting parameter sensitive inverse segregation. The simulation results show high compressive stresses at the surface of the cast during solidification. The flow channels depth and thermal stress coupled with microsegregation calculations shows the possibility of the pressure driven flow of tin rich liquid towards the chill surface during solidification. The experimental observation and calculated results show that the inverse segregation can be homogenized and decreased by controlling the casting parameter that defines the liquid pool depth into the mould.

Place, publisher, year, edition, pages
The Minerals, Metals, and Materials Society, 2015
Keyword
Continuous casting, Exudation, Inverse segregation, Thermal stress
National Category
Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:kth:diva-170499 (URN)10.1002/9781119093367.ch3 (DOI)2-s2.0-84931297752 (Scopus ID)9781119082385 (ISBN)
Conference
Advances in the Science and Engineering of Casting Solidification: An MPMD Symposium Honoring Doru Michael Stefanescu - TMS 2015 144th Annual Meeting and Exhibition, 15 March 2015 through 19 March 2015, Walt Disney World Orlando, United States
Note

QC 20150702

Available from: 2015-07-02 Created: 2015-07-01 Last updated: 2016-05-30Bibliographically approved
5. Development of an asymptotics-based numerical model for the formation and evolution of air gaps in the vertical continuous casting of alloys
Open this publication in new window or tab >>Development of an asymptotics-based numerical model for the formation and evolution of air gaps in the vertical continuous casting of alloys
2014 (English)In: TMS2014 143rd Annual Meeting & Exhibition: Annual Meeting Supplemental Proceedings, 2014, 339-346 p.Conference paper, Published paper (Refereed)
Abstract [en]

The formation of an air gap at the mould-metal interface in vertical continuous easting has long been known to have a detrimental effect on the efficiency of the process, and has therefore! attracted many attempts at mathematical modelling and multi-dimensional numerical simulation. However, a recent approach has used asymptotic techniques to derive a quasi-analytical thermomechanical model that captures the essential coupling characteristics: that the formation of the air gap affects the heat transfer, whilst the heat transfer affects the stresses that lead to the formation and evolution of the air gap. In this contribution, we report on preliminary attempts to develop that model, which was for the casting of pure metals, to describe the casting of alloys.

Keyword
Air-gap formation, Alloys, Vertical continuous casting
National Category
Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:kth:diva-146706 (URN)000354941300042 ()2-s2.0-84899707680 (Scopus ID)978-111888972-5 (ISBN)
Conference
143rd Annual Meeting and Exhibition, TMS 2014; San Diego, CA; United States; 16 February 2014 through 20 February 2014
Note

QC 20140613

Available from: 2014-06-13 Created: 2014-06-13 Last updated: 2016-05-30Bibliographically approved
6. On the resolution of thermal gradients in a model for the continuous casting of binary alloys
Open this publication in new window or tab >>On the resolution of thermal gradients in a model for the continuous casting of binary alloys
(English)In: Applied Mathematics and Computation, ISSN 0096-3003Article in journal (Other academic) Submitted
Place, publisher, year, edition, pages
Elsevier
Keyword
continuous casting, alloys, boundary immobilization
National Category
Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:kth:diva-187871 (URN)
Note

QCR 20160531

Available from: 2016-05-30 Created: 2016-05-30 Last updated: 2016-05-31Bibliographically approved
7. Towards an asymptotic framework for solidification shrinkage-induced macrosegregation in the continuous casting of binary alloys
Open this publication in new window or tab >>Towards an asymptotic framework for solidification shrinkage-induced macrosegregation in the continuous casting of binary alloys
(English)Manuscript (preprint) (Other academic)
Abstract [en]

The modelling of macrosegregation in the continuous casting of alloysnormally requires resource-intensive computational fluid dynamics(CFD). By contrast, here we develop an asymptotic framework for thecase when macrosegregation is driven by solidification shrinkage; as a firststep, a binary alloy is considered. Systematic asymptotic analysis of thesteady-state two-dimensional mass, momentum, heat and solute conservationequations in terms of the shrinkage parameter indicates that theoverall problem can be reduced to a hierarchy of decoupled problems: aleading-order problem that is non-linear, and a sequence of linear problems,with the actual macrosegregation of the solute then being determinedby means of one-dimensional quadrature.

National Category
Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:kth:diva-187872 (URN)
Note

QC 20160608

Available from: 2016-05-30 Created: 2016-05-30 Last updated: 2016-06-08Bibliographically approved

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Doctoral Thesis(7069 kB)304 downloads
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