Crack formation in the continuous casting of steel

Notch Effects on the Stress Intensity Factor and on the Fatigue Crack Path for Eccentric Circular Internal Cracks in Elliptically Notched Round Bars under Tensile Loading

In this paper, stress intensity factor (SIF) solutions are numerically obtained for notched bars subjected to tensile loading containing an eccentric circular inner crack located in the cross-section corresponding to the notch root. The finite element method and the J-integral have been used to obtain the SIF and to analyze the effect on it of three elliptical notch geometries (of equal radial depth). The results show how the SIF is greater in the notched bars than in the smooth bar and within the former when the axial semi-axis of the notch rises, its effect being greater as the diameter and eccentricity of the inner crack increase. In addition, the fatigue growth of an eccentric crack induces an increase in such eccentricity, greater as the notch axial semi-axis increases. The cause of these phenomena can be attributed to the constraint loss caused by the notch, which also facilitates bending of the specimen due to the asymmetry generated by the crack eccentricity.

Effect of Rare Earth Cerium Content on Manganese Sulfide in U75V Heavy Rail Steel

To study the effect of Ce on the morphology of manganese sulfide, we added different contents of Ce into U75V heavy rail steel. The composition and morphology of sulfide in steel were analyzed. The inclusions’ number, size, and aspect ratio were analyzed by automatic scanning electron microscope ASPEX. The results show that the inclusions in heavy rail steel without Ce are elongated MnS and irregular Al-Si-Ca-O inclusions. With the increase of Ce from 52 ppm to 340 ppm, the composition of main inclusions changes along the route of Ce2O2S-MnS → Ce2O2S-MnS-Ce2S3 → Ce2O2S-Ce3S4-Ce2S3 → Ce2O2S-Ce3S4-CeS. Ce has a noticeable spheroidization effect on MnS, which can make inclusions finely dispersed. When Ce content is 139 ppm, the average size of inclusions is the smallest. The mechanism of Ce-modified MnS was discussed by combining experimental results with thermodynamic calculations. Finally, the effect of Ce treatment on inhibiting MnS deformation was verified by simulated rolling.

Effect of Austenitization Temperature on Hot Ductility of C-Mn-Al HSLA Steel

The article aims to investigate the effect of different austenitization temperatures on the hot ductility of C-Mn-Al High-Strength Low-Alloy (HSLA) steel. The thermo-mechanical simulator of physical processes Gleeble 1500D was used for steel hot ductility study. Hot ductility was estimated by measuring the reduction of area after static tensile testing carried out at temperatures in the range 600 °C to 1200 °C with the step of 50 °C. Evaluation of fracture surfaces after austenitization at 1250 °C and 1350 °C with a holding time of the 30 s showed significant differences in the character of the fracture as well as in the ductility. The fracture surfaces and the microstructure near the fracture surfaces of samples at a test temperature of 1000 °C for both austenitization temperatures were analyzed by Scanning Electron Microscopy (SEM), Light Optical Microscopy (LOM), and AZtec Feature analysis (particle analysis of SEM). AlN and AlN-MnS precipitates at grain boundaries detected by the detailed metallographic analysis were identified as the main causes of plasticity trough in the evaluated steel. Moreover, using Thermo-Calc software, it was found that AlN particles precipitate from solid solution below the temperature of 1425 °C.

The Three-Dimensional Morphology and Distribution of CaS Inclusions in Continuous Casting Slab of Ni20Mn6 Steel

Calcium sulfide (CaS) inclusion with large and irregular shape is detrimental to the properties of steel. Understanding the shape and distribution of CaS inclusions in a continuous casting (CC) slab is of significance for improving the rolling properties. In this study, CaS inclusions were extracted from CC slab of Ni20Mn6 steel using the electrolytic extraction and investigated by scanning electron microscopy (SEM)-energy dispersive X-ray spectroscopy (EDX). The CaS inclusions morphologies vary with their locations in the CC slab and, thus, are classified into five categories. The thermodynamics calculated results showed that CaS inclusions precipitated at the end of solidification due to the microsegregation of sulfur and calcium in the interdendrite liquid and finally precipitated along the austenite grain boundary. The macrosegregation degree of solutes in different regions is one of the reasons that affect the size of CaS inclusion. The morphologies of CaS inclusion are affected by the solidification structure of slab and austenite grain boundary.

Study on Surface Longitudinal Crack Formation of Typical Hypoeutectoid Steel Produced on a Caster with Billet and Slab

This paper investigates the formation mechanism of typical hypoeutectoid steel with longitudinal cracks produced on a caster with billet and slab. It was found that the microstructure of the proeutectoid ferrite is the most critical factor affecting the longitudinal crack. The formation conditions of the proeutectoid ferrite and the reasonable control direction were determined through experiments and calculations. High-temperature tensile experiments revealed that enhanced cooling did not cause additional cracks. Therefore, the final plan was to reduce the formation of proeutectoid ferrite by strengthening the cooling process. As a result, the optimized surface temperature quickly passed the phase transition region of the proeutectoid ferrite and no cracks were found in the optimized billet.

Root Cause Analysis of Surface Cracks in Heavy Steel Plates during the Hot Rolling Process

This paper investigates the root cause of the formation of surface cracks on hot-rolled C–Mn constructional steel heavy plates. Cracks are rather evenly distributed over the surface in the form of colonies of cracks. Samples were cut from the heavy plate. The microstructure of samples in the as-cast and hot-rolled states were studied using optical and electron microscopes as well as energy dispersive X-ray spectroscopy (EDS). Results show that cracks are heavily oxidized. De-carburized areas are also seen alongside cracks. The crack tip is in the form of a deer-horn, indicating that crack branching has taken place during deformation. The crack initiation sites are V-shaped grooves on the surface of as-cast slabs. Correlations between microstructures, processing parameters, and crack formation are discussed.

Dendrite fragmentation induced by massive-like δ-γ transformation in Fe-C alloys

Dendrite arm fragmentation is considered in solidification structure tailoring. Time-resolved and in situ imaging using synchrotron radiation X-rays allows the observation of dendrite arm fragmentation in Fe-C alloys. Here we report a dendrite arm fragmentation mechanism. A massive-like transformation from ferrite to austenite rather than the peritectic reaction occurs during or after ferrite solidification. The transformation produces refined austenite grains and ferrite-austenite boundaries in dendrite arms. The austenite grains are fragmented by the liquid phase that is produced at the grain boundary. In unidirectional solidification, a slight increase in temperature moves the ferrite-austenite interface backwards and promotes detachment of the primary and secondary arms at the δ-γ interface via a reverse peritectic reaction. The results show a massive-like transformation inducing the dendrite arm fragmentation has a role in formation of the solidification structure and the austenite grain structures in the Fe-C alloys.

A Prediction Model for Internal Cracks during Slab Continuous Casting

Slab continuous casting internal cracking is a common quality defect in the production process. The ability to predict the quality of each continuous casting product and assess whether it is suitable for hot delivery or needs to be cleaned down will greatly increase the rolled product rate and reduce the scrap rate and production management cost. According to the quality defects of internal cracks during slab continuous casting and based on the solidification and heat transfer simulations, stress and strain calculations and theoretical analysis of metallurgical processes related to continuous casting combined with an abnormal casting event expert system, the internal crack generation index of the slice unit is used to predict the crack occurrence rating of each sized slab. Moreover, the internal crack prediction model for the slab is successfully developed and applied in a domestic steel mill. The accuracy of the model prediction reached 86.85%. This method achieved the organic combination of theoretical analysis and an expert system and provides an important theoretical tool for the prediction of crack quality defects in slab continuous casting; the method can be applied in slab continuous casting production.

Comparison of Transverse Uniform and Non-Uniform Secondary Cooling Strategies on Heat Transfer and Solidification Structure of Continuous-Casting Billet

Water flux distribution largely influences the heat transfer and solidification of continuously-cast steel billets. In this paper, a secondary cooling strategy of transverse non-uniform water flux (i.e., higher flux density on billet center), was established and compared with the uniform cooling strategy using mathematical modeling. Specifically, a heat transfer model and a cellular automaton finite element coupling model were established to simulate the continuous casting of C80D steel billet. The water flux was measured using different nozzle configurations to assist the modeling. The mathematical results were validated by comparing the surface temperature and the solidification structure. It is shown that the non-uniform cooling strategy enables the increase of corner temperature and reduction in surface temperature difference, while a higher reheating rate is found on the surface center of the billet. Moreover, the non-uniform cooling strategy can enhance the cooling effect and refine the solidification structure. Accordingly, the liquid pool length is shortened, and the equiaxed crystal density is increased along with the decreased equiaxed crystal ratio. The uniform cooling strategy contributes to reducing internal cracks of billet, and the non-uniform one is beneficial for surface quality and central segregation. For C80D steel, the non-uniform cooling strategy outperforms the uniform one.

Cracking and segregation in high-alloy steel 0.4C1.5Mn2Cr0.35Mo1.5Ni produced by thick continuous casting

Based on our innovative application of using thick continuous casting slab 0.4C1.5Mn2Cr0.35Mo1.5Ni (high alloy) for the production of high-quality mould steel, the present study investigated the high cracking susceptibility of high-alloy steel and segregation in continuous casting slab. The thermal expansion and the continuous cooling transformation (CCT) curve measurement, together with a high temperature in situ observation, confirmed the martensite phase transition happening at approximately 583 K that would result in an increase in the hardenability and cracking susceptibility. The cracking susceptibility zone was determined by high-temperature mechanical properties measurement. The high-alloy mould steel has no II brittle zone, and III brittle zone is 973–1148 K. As a conclusion, the straightening temperature should be above 1148 K to avoid the cracking during the continuous casting. Moreover, the elemental segregation of carbon, sulfur, chromium, and molybdenum along the cracking was examined by electron probe microanalysis (EPMA) quantitative analysis that might be another reason for the steel crack formation. It shows that Martensite phase transition happened at approximately 583 K that would result in an increase in the hardenability and cracking susceptibility.

Structure of Solidified Films of CaO-SiO2-Na2O Based Low-Fluorine Mold Flux

As an essential synthetic material used in the continuous casting of steels, mold fluxes improve the surface quality of steel slabs. In this study, a CaO-SiO2-Na2O-based low-fluorine mold flux was solidified by an improved water-cooled copper probe with different temperatures of molten flux and different probe immersion times. The heat flux through solid films and the film structures were calculated and inspected, respectively. Internal cracks (formed in the glassy layer of films during solidification) were observed. The formation and evolution of those cracks contributed to the unstable heat flux density. The roughness of the surface in contact with the water-cooled copper probe formed as films were still glassy and the roughness had no causal relationship with crystallization or devitrification. Combeite with columnar and faceted dendritic shapes were the main crystal in the film.