Masahito Hanao

High-Temperature Mechanical Behavior and Fracture Analysis of a Low-Carbon Steel Related to Cracking

Cracking in continuously cast steel slabs has been one of the main problems in casting for decades. In recent years, the use of computational models has led to a significant improvement in caster performance and product quality. However, these models require accurate thermomechanical properties as input data, which are either unreliable or nonexistent for many alloys of commercial interest. A major reason for this lack of reliable data is that high-temperature mechanical properties are difficult to measure. Several methods have been developed to assess the material strength during solidification, especially for light alloys. The tensile strength during solidification of a low carbon aluminum-killed (LCAK; obtained from Tata Steel Mainland Europe cast at the DSP plant in IJmuiden, the Netherlands) has been studied by a technique for high-temperature tensile testing, which was developed at Sumitomo Metal Industries in Japan. The experimental technique enables a sample to melt and solidify without a crucible, making possible the accurate measurement of load over a small solidification temperature range. In the current study, the tensile test results are analyzed and the characteristic zero-ductility and zero-strength temperatures are determined for this particular LCAK steel grade. The fracture surfaces are investigated following tensile testing, which provides an invaluable insight into the fracture mechanism and a better understanding with respect to the behavior of the steel during solidification. The role of minor alloying elements, like sulfur, in hot cracking susceptibility is also discussed.

Development of Mould Flux for High Speed Thin Slab Casting

Mould powders impact the stability of the continuous casting process for steel at all casting speeds. The main functions of mould powder are to provide sufficient lubrication and to control the mould heat transfer between the solidifying steel shell and the copper mould. At higher casting speeds associated with thin slab casting, the role of the mould powder is even more important. Actual casting speeds for the thin slab caster at Corus IJmuiden are between 5.4 and 6 m/min; the production level is around 1.3 Mt/year (coils). It has been decided to increase the production of this caster to a level of 1.8 Mt/year (coils). In order to meet this demand, the steel in mould time has to be increased to approximately 85% and the maximum casting speed will be increased to 8 m/min. A collaborative project between Sumitomo Metal Industries (SMI) and Corus IJmuiden was initiated to develop mould powders which facilitate casting speeds up to 8 m/min at the thin slab caster. Main subjects of this project are: mould powder design, characterisation of mould powder and mould slag, trials at the pilot caster of Sumitomo and finally plant trials at the thin slab caster of Corus. A special point of attention is the condition to use mould powder as a granulated material at the thin slab caster. As a consequence, the characterisation work focussed on the choice of raw materials and on the corresponding phase relations at elevated temperatures. Typical of the developed mould powders are so-called mild cooling properties which will result in a controlled mould heat transfer during casting. In this paper, several aspects of this joint project between Sumitomo and Corus will be described.

Influence of Basicity of Mold Flux on its Crystallization Rate

Crystallization of mold flux was observed with confocal laser microscope. Crystallization temperature, CCT curve and crystallization rate were evaluated from the observed images. The evaluated results were compared between two kinds of mold flux, and influence of basicity on crystallization rate was discussed. Crystallization temperature increased with basicity. Crystallization rate also increased with basicity, but its dependency on cooling rate was differed by basicity. The difference could be explained by the viscosity of mold flux at crystallization temperature. Crystallization rate has clear relation to the viscosity at crystallization temperature, and the rate increased with decrease of the viscosity. Two kinds of mold flux were unified in this relationship. Crystallization is controlled with basicity in terms of not only equilibrium but also kinetics through viscosity.