Eetu-Pekka Heikkinen

Precipitation of Si and its Influence on Mechanical Properties of Type 441 Stainless Steel

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.

Determination of Alloying Elements Ti, Nb, Mn, Ni, and Cr in Double-Stabilized Ferritic Stainless Steel Process Sample Using an Electrolytic Extraction Method and Separate Analysis of Inclusions

Chromium, nickel, and manganese are common alloying elements in stainless steels. Additionally, titanium and niobium are added as microalloying elements to certain stainless steel grades. A double-stabilized stainless steel sample was dissolved in electrolyte using an electrolytic extraction method. Inclusions were separated from the electrolyte with vacuum filtration and put through a separate elemental analysis. Steel-soluble alloying elements were determined from the electrolyte after the extraction, and the elemental analysis of inclusions was performed. The results were compared to the ones obtained from the surface analysis commonly used in the steel industry. It was concluded that the alloying elements were distributed between inclusions and the steel matrix. Therefore, optical emission analysis from a solid steel sample can be misleading. The results might not accurately depict the composition of the steel matrix. Electrolytic extraction methods combined with elemental analysis provide accurate information about the real matrix composition of microalloying elements in steel. The method is also a tool for the simultaneous analysis of inclusions in 3D and soluble alloying elements.

Dielectric properties and carbothermic reduction of zinc oxide and zinc ferrite by microwave heating

This paper aims to study the dielectric properties and carbothermic reduction of zinc oxide (zincite, ZnO) and zinc ferrite (franklinite, ZnFe2O4) by microwave heating. To achieve this aim, the dielectric properties were measured with an open-ended coaxial method to understand the behaviour of the samples under microwave irradiation. The effects of microwave power, duration time and sample mass on the heating rate, and the effects of the stoichiometric amount of graphite on the reduction of ZnO and decomposition of ZnFe2O4 were investigated. The results show that ZnFe2O4 has significantly higher dielectric properties compared to ZnO. Generally, for both samples, the dielectric values at room temperature were quite low, indicating that both ZnO and ZnFe2O4 are poor microwave absorbers. It was found that the temperatures have a more significant effect on the imaginary permittivities than on the real permittivities. The heating rate showed that the sample temperature increased with increase in microwave power and sample mass. Using 700 W of microwave power and two times the stoichiometric amount of graphite, almost complete reduction of ZnO was achieved in 12 min, while ZnFe2O4 completely decomposed to zincite and wustite in 3 min.

A Mathematical Model for Reactions During Top-Blowing in the AOD Process: Derivation of the Model

In an earlier work, a fundamental mathematical model was proposed for side-blowing operation in the argon–oxygen decarburization (AOD) process. The purpose of this work is to present a new model, which focuses on the reactions during top-blowing in the AOD process. The model considers chemical reaction rate phenomena between the gas jet and the metal bath as well as between the gas jet and metal droplets. The rate expressions were formulated according to a law of mass action-based method, which accounts for the mass-transfer resistances in the liquid metal, gas, and slag phases. The generation rate of the metal droplets was related to the blowing number theory. This paper presents the description of the model, while validation and preliminary results are presented in the second part of this work.

Advanced Methods in Modelling of Metallurgical Unit Operations

This paper summarizes and discusses our recent work on modelling of several steelmaking processes. The work started by developing a detailed sub-model for a single gas bubble reacting in liquid steel. The key feature in this model was an approach based on LOMA, Law of Mass Action, which was employed for defining the chemical rate of a reaction in a robust way. The bubble reaction model was then coupled with a new simulator concept for the AOD process, Argon-Oxygen Decarburization. After a successful validation, the same approach was used to model chemical reactions and chemical heating of liquid steel in the CAS-OB process, Composition Adjustment by Sealed Argon Bubbling Oxygen Blowing, using a supersonic lance. Finally, a new model was developed and implemented into the existing AOD process model for slag reduction with slag droplets. The purpose of this paper is to present a generalised framework for applying and validating the LOMA approach into modelling of metallurgical unit operations. In addition, the use of Computational Fluid Dynamics (CFD) in the validation and verification work is discussed.

Modelling of the Refining Processes in the Production of Ferrochrome and Stainless Steel

In stainless steel production as in almost any kind of industrial activity it is important to know what kind of influence different factors such as process variables and conditions have on the process outcome. In order to productionally, economically and ecologically optimize the refining processes used in the production of stainless steels, one has to know these connections between the process outcomes and the process variables. In an effort to obtain this knowledge, process modelling and simulation as well as experimental procedures and analyses can be used as valuable tools (Heikkinen et al., 2010a).

Pedagogical basis of DAS formalism in engineering education

The paper presents a new approach for a bachelor-level curriculum structure in engineering. The approach is called DAS formalism according to its three phases: description, analysis and synthesis. Although developed specifically for process and environmental engineering, DAS formalism has a generic nature and it could also be used in other engineering fields. The motivation for this new curriculum structure originates from the urge to solve the problems that engineering education has faced during the past decades, e.g. student recruitment problems and dissatisfactory learning outcomes. The focus of this paper is on the structure of the curriculum but the content is also discussed when it has an effect on the structure and its implementation. The presented structure, i.e. DAS formalism, builds upon the ideas of some classical pedagogical theories, which have regularly been applied at course level but seldom used to solve curriculum-level issues.

A Mathematical Model for Reactions During Top-Blowing in the AOD Process: Validation and Results

In earlier work, a fundamental mathematical model was proposed for side-blowing operation in the argon oxygen decarburization (AOD) process. In the preceding part “Derivation of the Model,” a new mathematical model was proposed for reactions during top-blowing in the AOD process. In this model it was assumed that reactions occur simultaneously at the surface of the cavity caused by the gas jet and at the surface of the metal droplets ejected from the metal bath. This paper presents validation and preliminary results with twelve industrial heats. In the studied heats, the last combined-blowing stage was altered so that oxygen was introduced from the top lance only. Four heats were conducted using an oxygen–nitrogen mixture (1:1), while eight heats were conducted with pure oxygen. Simultaneously, nitrogen or argon gas was blown via tuyères in order to provide mixing that is comparable to regular practice. The measured carbon content varied from 0.4 to 0.5 wt pct before the studied stage to 0.1 to 0.2 wt pct after the studied stage. The results suggest that the model is capable of predicting changes in metal bath composition and temperature with a reasonably high degree of accuracy. The calculations indicate that the top slag may supply oxygen for decarburization during top-blowing. Furthermore, it is postulated that the metal droplets generated by the shear stress of top-blowing create a large mass exchange area, which plays an important role in enabling the high decarburization rates observed during top-blowing in the AOD process. The overall rate of decarburization attributable to top-blowing in the last combined-blowing stage was found to be limited by the mass transfer of dissolved carbon.

A triangular approach to integrate research, education and practice in higher engineering education

ABSTRACT Separate approaches in engineering education, research and practice are not very useful when preparing students for working life; instead, integration of education, research and industrial practices is needed. A triangular approach (TA) as a method to accomplish this integration and as a method to provide students with integrated expertise is proposed. The results from the application of TA, both at the course and programme level, indicate that the approach is suitable for developing engineering education. The student pass rate for courses where TA has been used has been higher than for previous approaches, and the student feedback has been very positive. Although TA aims to take both theoretical and practical aspects of engineering as well as research and education into account, the approach concentrates mainly on activities and therefore leaves the goals of these activities as well as the values behind these goals uncovered.

Preparation of Mono-, Di- and Hemicalcium Ferrite Phases via Melt for Reduction Kinetics Investigations

Iron ore concentrates that are used in the iron production are usually agglomerated into sinter or pellets in order to improve their properties in the blast furnace. The main minerals in the magnetite base sinters are hematite, magnetite and Si and Al containing calcium ferrites of which the latter can exist as either monocalcium ferrite, dicalcium ferrite or hemicalcium ferrite depending on the conditions and on the materials iron/calcium-ratio. In order to study the reduction behaviour of the sinter in the iron production, samples of monocalcium ferrite, dicalcium ferrite and hemicalcium ferrite were prepared by melting different proportions of pure calcium and iron oxides. After melting the samples were cast and cooled. Samples of hemicalcium ferrite were also heated at a certain temperature before the actual reduction experiments in order to ensure the wanted phase composition of the samples. The mineral compositions of the samples were verified using scanning electron microscopy (SEM-EDS) as well as X-ray diffraction (XRD). The verification showed that it was possible to produce the samples of calcium ferrites via melting. The conditions needed to reduce the calcium ferrites were estimated with thermodynamic calculations.