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2012年 19卷 8期
刊出日期：2012-08-15
材料
工艺
工艺
1
ZHU De-qing,CHUN Tie-jun,PAN Jian,HE Zhen
Recovery of Iron From High-Iron Red Mud by Reduction Roasting With Adding Sodium Salt
Red mud is the waste generated during aluminum production from bauxite, containing lots of iron and other valuable metals. In order to recover iron from red mud, the technology of adding sodium carbonate—reduction roasting—magnetic separation to treat high-iron red mud was developed. The effects of sodium carbonate dosage, reduction temperature and reduction time on the qualities of final product and the phase transformations in reduction process were discussed in detail. The results showed that the final product (mass percent), assaying Fe of 90.87% and Al2O3 of 0.95% and metallization degree of 94.28% was obtained at an overall iron recovery of 95.76% under the following conditions of adding 8% sodium carbonate, reduction roasting at 1050 ℃ for 80 min and finally magnetic separation of the reduced pellets by grinding up to 90% passing 0.074 mm at magnetic field intensity of 0.08 T. The XRD (X-ray diffraction) results indicated that the iron oxides were transformed into metallic iron. Most of aluminum mineral and silica mineral reacted with sodium carbonate during the reduction roasting and formed nonmagnetic materials.
2012 Vol. 19 (8): 1-5 [
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WANG Yong-qin,LI Li,YAN Xing-chun,LUO Yuan-xin,WU Liang
Modeling of Stress Distribution During Strip Coiling Process
Many strip materials are coiled after rolling process. The stresses are imposed on the material wound on the automatically controlled collapse mandrel under the coiling tension. The coiling process can be described by three typical cases: winding without automatic adjustment, winding with automatic adjustment and after mandrel removal. A new model of equations for predicting the stresses during the strip coiling process is built by consideration of the three cases respectively. By solving the equations of different typical cases, the radial stresses and tangential stress of the layers of coil can be calculated. Also, the coiling parameters, such as strip thickness, coiling tension and necking critical pressure, affecting the coil performance are investigated. It is believed that the present model can be used for design and control of the automatically controlled collapse mandrel.
2012 Vol. 19 (8): 6-11 [
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12
LIU Jun,MA Jiao-cheng,YANG Feng,XIAO Hui,RAO Li-min
New Solution to Surface Temperature of Casting Slab Measurement Based on Preceded Reflector and Multi-Wavelength
The surface temperature of casting slab is an important parameter in the metallurgy field. Because the surface emissivity is uncertain and also unknown, it is difficult to measure the slab surface temperature accurately. A method based on preceded reflector and multi-wavelength was put forward to deal with the difficulty in surface temperature measurement of casting slab. On the premise of preceded reflector and non-preceded reflector, the method establishes the radiation energy equations and works out the emissivity and temperature in the equations. Also, the multilayer modeling of casting slab surface and multiple reflection-absorption process modeling were built by Monte Carlo method. The temperature measuring method had been applied in the continuous casting field. In order to verify the measured result, the thermal imaging method was adopted when the slab surface emissivity was set by repeated tests. Finally, the measured and verified temperature curves keep a same tendency and the error of the values is lower than 5℃. The comparison result shows that the method can measure temperature accurately.
2012 Vol. 19 (8): 12-16 [
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17
Mróz Sebastian
Influence of Non-Uniform Temperature Distribution on Metallic Charge Length on Energy and Force Parameters During Groove-Rolling
Change in the temperature of band over its length, associated with the stock being non-uniformly heated in the furnace, influences the variations in the magnitudes of energy-force parameters. Using the FEM (Finite Element Model) programs for the computation of the values of the energy-force parameters can take into account the distribution of temperature over the band length. The mathematical model of the computer program Forge2008 was used to theoretically examine the energy-force parameters and plastic metal flow in the roughing stands of the continuous rolling mill. The results of experimental investigation of influence of the non-uniform temperature distribution were presented on the metallic charge length on the energy and force parameters and dimensions of the band during round bars rolling. Thermovision monitoring energy and force parameters monitoring were carried out in continuous rolling mill D350 in one of the Polish industrial plants. On the basis of obtained results, it could be stated that non-uniform distribution of temperatures along the charge length causes local increase of energy and force parameters values and also such distribution affects the local increase of the width of rolled band. The rolling process of charge with non-uniform distribution of temperature could lead to exceeding required dimensional tolerances of the final products.
2012 Vol. 19 (8): 17-24 [
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25
QI Xiang-dong,WANG Tao,XIAO Hong
Optimization of Pass Schedule in Hot Strip Rolling
Rolling schedule not only determines the rolling process to be going smoothly, but also affects the shape accuracy and structure properties of finished strip. In order to gain good strip crown and flatness, the calculation formulas of the most suitable rolling force and bending force are deduced. By taking relatively equal load of rolling power and good shape as objective functions, the optimization mathematical models of finish rolling schedule are established. By contrast, the rolling schedules after optimization can improve the rolling mill working status and ensure the strip crown and flatness to be good. At the same time, the setting value of bending force is improved and this leaves more space for on-line shape control.
2012 Vol. 19 (8): 25-28 [
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29
JIANG Hai-tao,DING Wei,,TANG Di,HUANG Wei
Mechanical Property and Microstructural Characterization of C-Mn-Al-Si Hot Dip Galvanizing TRIP Steel
Mechanical properties and microstructure in high strength hot dip galvanizing TRIP steel were investigated by optical microscope (OM), transmission electron microscope (TEM), X-ray diffraction (XRD), dilatometry and mechanical testing. On the heat treatment process of different intercritical annealing (IA) temperatures, isothermal bainitic transformation (IBT) temperatures and IBT time, this steel shows excellent mechanical properties with tensile strength over 780 MPa and elongation more than 22%. IBT time is a crucial factor in determining the mechanical properties as it confirms the bainite transformation process, as well as the microstructure of the steel. The microstructure of the hot dip galvanizing TRIP steel consisted of ferrite, bainite, retained austenite and martensite during the short IBT time. The contents of ferrite, bainite, retained austenite and martensite with different IBT time were calculated. The results showed that when IBT time increased from 20 to 60 s, the volume of bainite increased from 14.31% to 16.95% and the volume of retained austenite increased from 13.64% to 16.28%; meanwhile, the volume of martensite decreased from 7.18% to 1.89%. Both the transformation induced plasticity of retained austenite and the hardening of martensite are effective, especially, the latter plays a dominant role in the steel containing 7.18% martensite which shows similar strength characteristics as dual-phase steel, but a better elongation. When martensite volume decreases to 1.89%, the steel shows typical mechanical properties of TRIP, as so small amount of martensite has no obvious effect on the mechanical properties.
2012 Vol. 19 (8): 29-36 [
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37
SUI Feng-li,CHEN Qi-wei,ZHU Guo-hui,LIU Bao-dong
Deformation Uniformity of Cold-Rolled Q235 Steel Rebar by FEM in Bending and Rolling Processes
An analytic model based on ANSYS/LS-DYNA has been developed on the cold rolling process for Q235 steel rebar with 12 mm in diameter. The elastic-plastic finite element method (FEM) and the cold deformation resistance model of Q235 steel were adopted in this model. Deformation uniformity of the final product has been analyzed using this model. The results indicate that the uniformity of the final product is obtained only as the centerline of the bending rolls is vertical to the centerline of the driven roll and parallel to the centerline of the drive roll in the whole rolling process. Besides, the number of the bending rolls must even realize the continuous bending and reverse bending process. Also, the number of the bending rolls must match the deformation degree of the workpiece in the cold rolling process. The validity of this finite element model was verified by the size and distribution of grains from the billet to the rebar in a practical cold rolling process.
2012 Vol. 19 (8): 37-42 [
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LI Hua-bing,JIANG Zhou-hua,FENG Hao,MA Qi-feng, ZHAN Dong-ping
Aging Precipitation Behavior of 18Cr-16Mn-2Mo-1.1N High Nitrogen Austenitic Stainless Steel and Its Influences on Mechanical Properties
The solution-treated (ST) condition and aging precipitation behavior of 18Cr-16Mn-2Mo-1.1N high nitrogen austenitic stainless steel (HNS) were investigated by optical microscope (OM), scanning electron microscope (SEM), and transmission electron microscope (TEM). The results show that the ST condition of 18Cr-16Mn-2Mo-1.1N HNS with wN above 1% is identified as 1100 ℃ for 90 min, followed by water quenching to make sure the secondary phases completely dissolve into austenitic matrix and prevent the grains coarsening too much. Initial time-temperature-precipitation (TTP) curve of aged 18Cr-16Mn-2Mo-1.1N HNS which starts with precipitation of 0.05% in volume fraction is defined and the “nose” temperature of precipitation is found to be 850 ℃ with an incubation period of 1 min. Hexagonal intergranular and cellular Cr2N with a=0.478 nm and c=0.444 nm precipitates gradually increase in the isothermal aging treatment. The matrix nitrogen depletion due to the intergranular and a few cellular Cr2N precipitates induces the decay of Vickers hardness, and the increment of cellular Cr2N causes the increase in the values. Impact toughness presents a monotonic decrease and SEM morphologies show the leading brittle intergranular fracture. The ultimate tensile strength (UTS), yield strength (YS) and elongation (El) deteriorate obviously. Stress concentration occurs when the matrix dislocations pile up at the interfaces of precipitation and matrix, and the interfacial dislocations may become precursors to the misfit dislocations, which can form small cleavage facets and accelerate the formation of cracks.
2012 Vol. 19 (8): 43-51 [
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52
Marcin Górny
Fluidity and Temperature Profile of Ductile Iron in Thin Sections
It has been shown that it is possible to produce thin wall ductile iron (TWDI) castings of considerable length using an Archimedes spirals with a wall of 1, 2 or 3 mm in thickness. The fluidities for different moulding materials ［(classical mould, chemically bonded silica sand and chemically bonded low-density alumina-silicate ceramic sand (LDASC)］, chemical composition, and pouring temperature were estimated. There is a significant temperature drop in thin sections (contrary to typical sections) during the mould filling. A profile of real temperature drop is presented along with theoretical predictions. The high temperature drop of liquid iron results in an increased cooling rate (before the eutectic equilibrium solidification temperature), which in turn affects the solidification and microstructure of TWDI castings. Microstructures were characterized quantitatively using an image analyser. Structure parameters for different wall thicknesses and moulding materials (graphite nodule count, ferrite and cementite fraction) are plotted, which is versus distance from the entrance to the mould cavity. It has been shown that the thin wall castings have a gradient structure. Moreover, a strong influence of LDASC sand (material with low ability to absorb the heat) on the structure parameters of TWDI castings is presented.
2012 Vol. 19 (8): 52-59 [
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WU Tao,WANG Ming-zhi,GAO Yu-wei,LI Xiao-pu,ZHAO Yu-cheng,ZOU Qin
Effects of Plastic Warm Deformation on Cementite Spheroidization of a Eutectoid Steel
The warm compression tests were performed on the eutectoid steel to investigate the evolution of cementite morphology. Several processing parameters, such as temperature, strain rate and reduction, were changed to analyze the effect of each parameter on spheroidization of cementite. The results showed that the warm compression promoted the fragmentize and the spheroidization of lamellar cementites. When the specimen was compressed with reduction of 50% at 700 ℃ and in the strain rate of 0.01 s-1, the excellent spheroidized cementite was obtained. The mechanism of fragmentation and spheroidization of lamellar cementites during compression was discussed by using transmission electron microscope. The formation of spheroidized cementite was related to the time of compression process. The fragmentize of lamellar cementites was due to the extension of sub-grain boundary in the cementite. The spheroidization of cementite depended on the diffusion of carbon atoms at the tip of bended and breakup cementite.
2012 Vol. 19 (8): 60-66 [
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ZHANG Zuo-tai,ZHANG Ying-yi
Simultaneous Recrystallization and Oxidation Behavior of Mn-Containing IF Steel
The recrystallization and oxidation of a Mn-containing interstitial free (IF) steel were investigated simultaneously using confocal scanning laser microscope (CSLM) under controlled atmosphere of Ar 95% and H2 5% (in volume percent) at different temperatures. It was found that the grain boundary played a significant role in controlling recrystallization and oxidation in overall oxidation kinetics of the steel. The surface morphology was composed of two networks along the original and new grain boundaries respectively, which did not coexist. The grain boundary moved in different directions with different velocities during annealing process. The recrystallization processes were studied by CSLM motion video through observing the moving grain boundary to estimate the time for 50% recrystallization, and the activation energy for recrystallization was therefore calculated. The oxidation mechanism was discussed through comparison of the fluxes among mass transfer of water vapor, dissociation of water vapor and outward diffusion alloying elements. The results indicated that the oxidation was controlled by the mass transfer from the bulk gas to the surface, or dissociation rate, or outward diffusion of manganese, which depended on the temperature to form a grain boundary ridge or groove.
2012 Vol. 19 (8): 67-74 [
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ZHAO Xin,YANG Xiao-ling,JING Tian-fu
Effect of Initial Microstructure on Warm Deformation Behavior of 45 Steel
In order to investigate the effect of initial microstructure on warm deformation behavior, some specimens of 45 steel were annealed and some quenched. Then the specimens were isothermally compressed on a Gleeble 3500 machine. The deformation temperature range was 550 to 700 ℃ and the strain rate range was 0.001 to 0.1 s-1. An optical microscope (OM) and a transmission electron microscope (TEM) were used to study the microstructures. The results show that the microstructure of annealed specimens is ferrite and pearlite and that of quenched specimens is martensite. The flow stress of quenched specimens is higher than that of annealed ones at 550 ℃ when strain rates are greater than 0.001 s-1. However, at 600 to 700 ℃ and strain rate of 0.001 s-1, the whole flow curves of quenched specimens are below that of annealed ones. Under the rest conditions, the flow stress of quenched specimens is higher at the beginning of compression and then the opposite is true after the strain is greater than a critical value. The microstructure examination proves that the tempering and dynamic recrystallization easily occur in the specimens with martensite during warm compression, which results in the above phenomena.
2012 Vol. 19 (8): 75-78 [
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