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...
This new form was called hydraulic die-forming. Hydraulic stems from the Greek word hydro meaning water and aulos meaning tube (McCreight, 2004). In today’s society, hydraulic pressing and stamping of dies are used for everything from making small pots and pans to the more extravagant automobile body models. Another use that has recently developed is the more artistic use of, producing form in silver and gold. In order to achieve this smaller, cheaper scale of die-forming experiment were conducted by Richard Thomas and Ruth Girard, which eventually led to the development of the pourable epoxy steel...
For over half a century the Pittsburgh region was the largest concentration of steel making in the world. Its collapse was spectacular. The mill towns strung along the Monongahela Valley have now suffered forty years of decline. Much of their shabby infrastructure and buildings (at best homely even in their prime) has decayed, most of their population has fled to the metropolitan suburbs or left the region, and those that remain, for the most part poor, struggle or live off memories. Regeneration is a continuing problem for public policy makers as the mill towns struggle on life-support systems — public welfare for individual households; funding from federal, state and local agencies for public services, projects and a plethora of `initiatives´. Re-born they are not.
-Developed and implemented strip casting overseas to eliminate a step in the steel making process
Metalcraft, an automotive part supplier has an order from a car company for rubber vent hose to be used in a new luxury sedan. To complete this order Metalcraft will need to work with a third party supplier to create the needed hoses. The company came up with a ranking system that’s meant to give information about all of the suppliers and judge them on quality, timing and delivery. This scorecard system is put in place so Metalcraft could improve product quality, and could base decisions on this information. The member of the program management team has come together to make the final decision of where they should supply from. Of the 4 managers, they had amassed 3 different suppliers that they all wanted for different reasons. Giving the contract to the wrong company could cause more defects, which could in return shift Metalcraft’s ranking down on the automotive company’s scorecards. At the same time, it’s the company’s job to source a product that conforms to the standard put forward by Metalcraft will reducing the overall cost.
One main category of welding is arc welding. Arc welding uses a current sent from an electrode, through the base metal, and back into the ground clamp on your welder. This arc creates a tiny spot of immense heat that melts the metal around it, thus creating a weld puddle, or the puddle of molten metal. Within arc welding there are MIG, TIG, and stick welding.
In the early part of this century was a time when industry was booming with growth around the installation of major railroads. With this growth came the transatlantic cable, the telegraph, and a whole lot of steel. Steel would be needed in the construction of these new transportation systems and communications were now possible between businesses and industries. (Wren, 2005)
This chart shows the relationship between the fanning friction factor and the Reynolds number over a wide range of flow rates, from which the roughness parameter (e/D) for the piping system can be estimated.
The author derived the single-phase and two-phase isothermal steady state flow equations based on isothermal flow assumption.
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.
Cooling allows the plastic to solidify and become dimensionally stable before ejection. Heat that has been transferred to the mould by the molten plastic is carried away by a coolant that circulates through cored passages in the mould. Coolant temperature and flow rate determines the efficiency of heat removal. Cooling the moulded components uniformly may mean either, cooling the mould with different flow rates of cooling medium in different areas or, using the same flow rate throughout the mould but with different temperatures of cooling medium. The objective is to cool the components as quickly and as uniformly as possible, while ensuring that defects such as poor surface finish and changes in physical properties are not
For my first example, I am using motorcycle engines. The first motorcycle engines were steam powered but soon changed to internal combustion engines sourced from ditch-pumps and early aircraft engines all of which were produced in a similar manner. The casting and machining of the casings and cylinders was very primitive but effective. The cavity in the sand is formed by using a pattern (an approximate duplicate of the real part), which are typically made out of wood, sometimes metal. The cavity is contained in an aggregate housed in a box called the flask. Core is a sand shape inserted into the mould to produce the internal features of the part such as holes or internal passages. Cores are placed in the cavity to form holes of the desired shapes. Core print is the region added to the pattern, core, or mould that is used to locate and support the core within the mould. A riser is an extra void created in the mould to contain excessive molten material. The purpose of this is feed the molten metal to the mould cavity as the molten metal solidifies and shrinks, and thereby prevents voids in the main casting. In a two-part mould, which is typical of sand castings, the upper half, including the top half of the pattern, flask, and core is called cope and the lower half is called drag. The parting line or the parting surface is line or surface that separates the cope and drag. The drag is first filled partially with sand, and the core print, the cores, and the gating system are placed near the parting line. The cope is then assembled to the drag, and the sand is poured on the cope half, covering the pattern, core and the gating system. The sand is compacted by vibration and mechanical means. Next, the cope...
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
In this paper we will explore on the brief manufacturing process of steel containers and some vital issues relating to the production process.
Annealing and tempering are not the same types of heat treatment. Annealing can be defined as heating the steel to aus...