This paper first reviews the metallurgical process of continuous steel slab casting in terms of fluid flow, heat and mass transfers in the manufacture production. Finally, this paper reviews the physical and mathematical modelling in physical experiment and mathematical models, which has been used to study in the process.
Keywords: Continuous Casting, Steel, Slab, Physical Modelling, Tundish, Mathematical Modelling, Fluid Flow, Heat Transfer, Mass Transfer, Instruction, Report
1. Introduction
Continuous casting is a casting process that is used in the manufacturing industry to produce molten steel at the temperature of 1,600OC and converted into particular size of slabs. This modern casting process is used in many steel manufactures as it has superior quality of castings, less loss of material, cost reduction and high productivity rate over the cast ingot production [1].
The continuous slab casting is started by adding and mixture the basic raw materials such as steels, silicon, magnesium and other basic materials of steelmaking in the furnace. The steel has low carbon contained, which is below 2% of carbon in the steel. The process of continuous slab casting process begins with melting and mixing the raw materials in the furnace. The molten steel in the ladle is tapped out from the bottom of the ladle into the intermediate container called as tundish by gravitational force, which helps the filling the mold along the continuous steel casting. Additionally, the continuous slab casting process is required a large space for the casting operation due to the tundish alone is located approximately 250m above the ground level and it can hold several tones of steel. The roles of the tundish are to supply a certain constant amount of the ...
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...he principle numbers of Froude, Reynolds and Weber. Mathematical model predicts the heat and mass transfer in numerical framework for both transports phenomena of relevance to the industry continuous casting tundish system. Additionally, it has an excellent agreement outlet temperature respond the step input temperatures in the inlet stream of water in the tundish model. The simulations of 8x8 grid and 16x16 grid are applied to obtain significant difference between the TAV maps in which both grids are computed by software represent the specific flow of the fluid in the model and the steel caster as the actual size system. Therefore, the physical and mathematical modeling is used as a guidance to build a model before the prototype is constructed in terms of calculation, measurement and determination of specific fluid flow, heat and mass transfer in the water model.
The heat input rate is one of the most important variables in fusion welding, since it governs heating rates, cooling rates and weld pool size. In the welding of steel, this is important relationship since increased cooling rates increase the risk of hydrogen-induced cracking. The other metallurgical feature that is directly affected by the heat input rate is grain size in the heat affected zone (HAZ) and in the weld metal. In steel welding it is necessary to seek a heat input rate that gives the optimum combination of grain size and cooling rate [11]. Before the actual welding is done, all the earlier steps such as layout, plate edge preparation, fit up and alignment should be well planned with regard to achieving...
-Developed and implemented strip casting overseas to eliminate a step in the steel making process
The first step in the heat treatment of AISI D2 tool steel was hardening. The purpose of hardening was to harden steel to increase the wear resistance, cutting ability. Hardening of AISI D2 tool steel was done at a temperature of 1020°C [6] for 1 Hour. Harden AISI D2 tool steel followed air cooling which provides great benefit of minimizing distortion and dimensional changes [6]
To make the steel stronger and reduce the ductile – brittleness transition temperature composition of the steel should Reduce the amount of sag ( a by-product of smelting) by 2-3%
Borehole mining (BHM) is a process that incorporates a high pressure waterjet cutting system and a down-hole slurry pumping system through a single borehole drilled from the surface into the mineralized rock. The waterjet cuts the material resulting the slurry flows into an eductor pump near the base of the tool and pumped out to the surface. A cavity will be created as a consequence of this excavation process [2]. Understanding the relationship between the cavity stability and the operational parameters is critical in designing any borehole mining system.
The major environmental benefits of increased scrap usage comes from the very fact that production of one ton of steel through the EAF route consumes only 9–12.5 GJ/tcs, whereas the BOF steel consumes 28–31 GJ/tcs and consequently enormous reduction in CO2 emissions. In addition, a discussion on various alloying elements in steel and their presence in residual concentrations in the scrap on steel properties also presented. Finally, this paper presents a discussion on policy issues that could enhance the use of scrap in steel making also presented (Yellishetty, 2011).
In this report, we will introduce and illustrate on precast concrete, pre-stressed concrete, ready-mix concrete, reinforced concrete, terrazzo and Urbanite in details.
The basis for the understanding of the heat treatment of steels is the Fe-C phase diagram. Because it is well explained in earlier volumes of Metals Handbook and in many elementary textbooks, the stable iron-graphite diagram and the metastable Fe-Fe3 C diagram. The stable condition usually takes a very long time to develop, especially in the low-temperature and low-carbon range, and therefore the metastable diagram is of more interest. The Fe-C diagram shows which phases are to be expected at equilibrium for different combinations of carbon concentration and temperature. We distinguish at the low-carbon and ferrite, which can at most dissolve 0.028 wt% C at 727 oC and austenite which can dissolve 2.11 wt% C at 1148 oC. At the carbon-rich side we find cementite. Of less interest, except for highly alloyed steels, is the d-ferrite existing at the highest temperatures. Between the single-phase fields are found regions with mixtures of two phases, such as ferrite + cementite, austenite + cementite, and ferrite + austenite. At the highest temperatures, the liquid phase field can be found and below this are the two phase fields liquid + austenite, liquid + cementite, and liquid + d-ferrite. In heat treating of steels the liquid phase is always avoided. Some important boundaries at single-phase fields have been given special names. These include: the carbon content at which the minimum austenite temperature is attained is called the eutectoid carbon content. The ferrite-cementite phase mixture of this composition formed during cooling has a characteristic appearance and is called pearlite and can be treated as a microstructural entity or microconstituent. It is an aggregate of alternating ferrite and cementite particles dispersed with a ferrite matrix after extended holding close to A1. The Fe-C diagram is of experimental origin. The knowledge of the thermodynamic principles and modern thermodynamic data now permits very accurate calculations of this diagram.
It is a complex metallurgical process in which liquid steel is cooled and shaped into semi-manufactures of desired dimensions. To achieve proper quality of cast steel, it is essential to control the metal flow and heat transfer during the casting process. In the continuous casting process, molten steel flows from a ladle, through a Tundish into the mould. It should be protected from exposure to air by a slag cover over each vessel and by ceramic nozzles between vessels. Once in the mould, the molten steel freezes against the water-cooled copper mould walls to form a solid shell. Drive rolls, lower in the machine continuously; withdraw the shell from the mould at a rate or “casting speed” that matches the flow of incoming metal, so the process ideally runs in steady state. Below mould exit, the solidifying steel shell acts as a container to support the remaining liquid. Rolls support the steel to minimize bulging due to the Ferro-static pressure. Water and air mist sprays cool the surface of the strand between rolls to maintain its surface temperature until the molten core is
The study of flow pipes is extremely important as application of pipe system have been used in variety field in real life. For example, transportation of consumed water, waste water, oil and gas are seemed to be easier after application of pipe system.
The metals are then taken to their own respective furnaces due to each one of these having different melting points and they are melted down. Afterwards the metals undergo a purification process known as the electrolysis process. This process will remove impurities in the metal to improve its overall quality. After the metals are melted and purified they are casted, typically into bars and ingots for steel and into sheet metal for aluminum. Afterwards, these ingots and sheets are then distributed to places that will make use of them for example a car factory that will use these metals for the manufacture of
Concrete has been cast in rigid formwork since it was invented. The traditional rigid formworks are constructed using flat, straight sheets with uniform section built with 90-degree joints [1]. The resulting forms are simple, uniform cross-section shapes. However, uniform section or prismatic shapes are not always the most desirable. Unlike the rigid formwork, fabric formworks
Forging, one of many manufacturing process, is where metal is pressed, pounded or squeezed under great pressure into high strength parts known as forgings. The process begins with starting stock which is heated to its plastic deformation temperature, then upset between dies to the desired shape and size. It is important to note that the forging process is entirely different from the casting (or foundry) process, as metal used to make forged parts is never melted and poured (as in the casting process). During this hot forging process, coarse grain structure is broken up and replaced by finer grains. Mechanical properties are therefore improved through reduction of cast structure, voids and segregation. Forging also provides means for aligning
This paper reports the results of a study conducted on the effects of applied pressure during solidification on the morphology of graphite flakes and casting density of a hyper-eutectic grey cast
Annealing and tempering are not the same types of heat treatment. Annealing can be defined as heating the steel to aus...