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2015年 22卷 6期
刊出日期：2015-06-15
Material
Metallurgy and Metal Working
Metallurgy and Metal Working
457
Yan-dong LI,Cheng-jun LIU,Chun-long LI,Mao-fa JIANG
A Coupled Thermodynamic Model for Prediction of Inclusions Precipitation during Solidification of Heat-resistant Steel Containing Cerium
A coupled thermodynamic model of inclusions precipitation both in liquid and solid phase and microsegregation of solute elements during solidification of heat-resistant steel containing cerium was established. Then the model was validated by the SEM analysis of the industrial products. The type and amount of inclusions in solidification structure of 253MA heat-resistant steel were predicted by the model, and the valuable results for the inclusions controlling in 253MA steel were obtained. When the cerium addition increases, the types of inclusions transform from SiO2 and MnS to Ce2O3 and Ce2O2S in 253MA steel and the precipitation temperature of SiO2 and MnS decreases. The inclusions CeS and CeN convert to Ce2O3 and Ce2O2S as the oxygen content increases and Ce2O3 and CeN convert to Ce2O2S, Ce3S4, and MnS as the sulfur content increases. The formation temperature of SiO2 increases when the oxygen content increases and the MnS precipitation temperature increases when the sulfur content increases. There is only a small quantity of inclusions containing cerium in 253MA steel with high cleanliness, i. e. , low oxygen and sulfur contents. By contrast, a mass of SiO2, MnS and Ce2O2S are formed in steel when the oxygen and sulfur contents are high enough. The condition that MnS precipitates in 253MA steel is 1. 2w［O］+w［S］＞0. 01% and SiO2 precipitates when 2w［O］+w［S］＞0. 017% (w［S］＜0. 005%) and w［O］＞0. 006% (w［S］＞0. 005%).
2015 Vol. 22 (6): 457-463 [
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464
Lei GUO,Jin-tao YU,Jing-kun TANG,Yin-he LIN,Zhan-cheng GUO,Hui-qing TANG
Influence of Coating MgO on Sticking and Functional Mechanism during Fluidized Bed Reduction of Vanadium Titano-magnetite
The vanadium titano-magnetite (VTM) iron ore fines of 110-150 μm in diameter were reduced in a transparent quartz fluidized bed by 70%CO-30%H2 (volume fraction) mixtures. MgO powders served as coating agent to solve sticking problem. Two coating methods were introduced in this experiment: high temperature injection method and briquetting→oxidizing roast→crushing method. According to the experimental results, the minimum effective coating amount of MgO was 0. 1 mass%. The metallization ratio (MR) of the product rose from around 58% to above 90% with the above treatments. To investigate the sticking mechanism of fine ore, the morphology evolution was investigated. Instead of iron whiskers, an interlaced fibrous porous surface formed. The ulvospinel (2FeO·TiO2) in VTM is more difficult to be reduced than FeO according to thermodynamic calculation. XRD results showed that MgO diffused into Fe2O3 lattice before forming pleonaste (MgO·Fe2O3) during oxidizing roast at 1273 K. The melting point of the pleonaste is 1986 K and that made contribution to prevent the sticking problem.
2015 Vol. 22 (6): 464-472 [
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473
Zong-ping LI,,Xiao-hui FAN,Gui-ming YANG,Jin-chao WEI,Ying SUN,Min WANG
Life Cycle Assessment of Iron Ore Sintering Process
Iron ore sintering is an energy-intensive process associated with emission of pollutants in iron and steel industry. In order to comprehensively evaluate the environmental impacts of sintering, a detailed life cycle assessment of a sintering plant was conducted. Life cycle inventory showed that, in the production of 1 t sinter ore, 241. 53 kg CO2, 22. 68 kg CO, 0. 294 kg SO2, 0. 63 kg NOx, 1. 18 μg dioxin and 0. 48 kg dust were discharged. Global warming potentials, acidification potentials, photochemical ozone creation potentials and human toxicity potentials were selected as four impact categories, and the evaluation index for the sintering plant was calculated as 3. 45×10-12. Finally, based on the environmental impact analysis, several measures of reducing environmental loadings of the sintering plant were provided, which included the utilization of denitrification equipment, recirculation of the hot waste gas and process improvement to reduce fuel consumption.
2015 Vol. 22 (6): 473-477 [
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478
Xin-yu LI,Bu-xin SU,Lei-ge XIA,Jian-liang ZHANG,Hong-wei GUO
Effect of Nickel on Formation Mechanisms of Silico-ferrite of Calcium and Aluminum (SFCA)
Under the pressures of both the decrease of high-grade high-quality iron ore resources and the increase of raw material costs, the iron and steel enterprises in China turn to adopt iron ores which contain special elements such as nickel, manganese, etc. in the sintering blend. Analytical reagents were used for sintering experiments, and the sinters were analyzed with X-ray diffraction, scanning electron microscopy and mineralogical microscopy to study the effect of nickel on the silico-ferrite of calcium and aluminum (SFCA) bonding phase formation during sintering. The results indicated that SFCA was divided into nickel-containing and nickel-free areas due to the presence of nickel. The increasing content of nickel would greatly reduce the content of SFCA and promote the formation of calcium aluminum silicate. A great deal of Fe2O3 participated in the crystal transition to Fe3O4, reducing the amount of Fe2O3 involved in the formation of calcium ferrite. When the blending ratio of NiO, which is used to provide the nickel in the sintering process, is less than 3%, the calcium ferrite is in substantially interleaving corrosion with hematite and magnetite. Both the porosity and silicate glass phase content are low, which contributes to the sintering production.
2015 Vol. 22 (6): 478-486 [
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487
Meng YUAN,Ping ZHOU,Ming-liang LI,Rui-feng LI,Hong WANG,,Tian-you CHAI
Intelligent Multivariable Modeling of Blast Furnace Molten Iron Quality Based on Dynamic AGA-ANN and PCA
Blast furnace (BF) ironmaking process has complex and nonlinear dynamic characteristics. The molten iron temperature (MIT) as well as Si, P and S contents of molten iron is difficult to be directly measured online, and large-time delay exists in offline analysis through laboratory sampling. A nonlinear multivariate intelligent modeling method was proposed for molten iron quality (MIQ) based on principal component analysis (PCA) and dynamic genetic neural network. The modeling method used the practical data processed by PCA dimension reduction as inputs of the dynamic artificial neural network (ANN). A dynamic feedback link was introduced to produce a dynamic neural network on the basis of traditional back propagation ANN. The proposed model improved the dynamic adaptability of networks and solved the strong fluctuation and resistance problem in a nonlinear dynamic system. Moreover, a new hybrid training method was presented where adaptive genetic algorithms (AGA) and ANN were integrated, which could improve network convergence speed and avoid network into local minima. The proposed method made it easier for operators to understand the inside status of blast furnace and offered real-time and reliable feedback information for realizing close-loop control for MIQ. Industrial experiments were made through the proposed model based on data collected from a practical steel company. The accuracy could meet the requirements of actual operation.
2015 Vol. 22 (6): 487-495 [
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Material
496
Yan-lei ZHOU,Xiang-jun ZHANG,Tao JIA,Zhen-yu LIU
Corrosion Behavior of High Performance Offshore Platform Steel with Chromium and Nickel Addition in the Environment Containing Chloride Ions
The characterization of corrosion products formed on a high performance offshore platform steel in the environment containing chloride ions has been investigated by scanning electron microscopy (SEM), X-ray diffraction (XRD), electron probe microanalysis (EPMA) and electrochemical impedance spectroscopy (EIS). The results reveal that the corrosion process can be divided into the initial stage and the later stage. The main constituents of rust layers are α-FeOOH, β-FeOOH, γ-FeOOH, Fe3O4 and large amounts of amorphous compounds. With increasing corrosion time, the mass fraction of α-FeOOH and Fe3O4 increased, while that of γ-FeOOH and β-FeOOH changed slightly. The enrichment of Cr and Ni at the inner/outer interface, especially the side of inner rust, can be observed in the later corrosion stage of Cr-Ni steel, which can promote the formation of compact inner rust layer, impeding the transmission of corrosion mediums and slowing down the electrochemical reaction process.
2015 Vol. 22 (6): 496-505 [
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506
Xin-cun ZHUANG,Hua XIANG,Tao WANG,Zhen ZHAO,Tan LI
Determination of Flow Curve and Plastic Anisotropy of Medium-thick Metal Plate: Experiments and Inverse Analysis
Sheet bulk metal forming is widely used for medium-thick metal plate due to its convenience in the manufacture of accurately finished 3D functional components. To obtain precise anisotropy and flow curve of metal plate is a prerequisite for correct simulation of sheet bulk metal forming processes. Inverse analysis of compression test was introduced here to evaluate the sensitivity of different flow curve models and geometric influence of compression test specimen. Besides, a methodology was proposed to compute plastic anisotropic coefficients of Hill quadratic yield criterion, which is based on the ratios of flow curves obtained by inverse analysis of compression tests using specimens cut in six directions on the medium-thick metal plate. The obtained flow curves and anisotropic coefficients were compared with those calculated from tensile tests. Flow curves based on inverse analysis of compression tests cover the curves of the tensile tests well, while the anisotropic coefficients are different, especially for the coefficient related to the RT45 direction. To estimate the effectiveness of the proposed method, the calculated material properties and those based on the traditional tensile tests were applied in a rim-hole process simulation. The simulation results based on the material properties from inverse analysis of compression tests accorded with the tested properties better.
2015 Vol. 22 (6): 506-512 [
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513
Jie JIN,,Feng-bin LIU,Yun-bo CHEN,Ke-wei GAO
Surface Carbon Chemical States of Ion Implanted AISI 440C Martensitic Stainless Steel
Carbon atoms segregate in the surface region for polished AISI 440C stainless steel. After ion implantation, the surface carbon atoms exist in different forms. To elucidate their existence, surface structures and carbon chemical states of unimplanted, N+ implanted, Ti+ implanted and N+/Ti+ co-implanted samples were analyzed by X-ray diffraction (XRD), transmission electron microscopy (TEM) and X-ray photoelectron spectroscopy (XPS). The results indicated that various phases form in the surface or subsurface region after ion implantation, while the surface topography of the samples remains intact. For polished unimplanted sample, besides some Fe3C phase and C-C phase, CrxCy phase dominates its surface region. Little change of carbon chemical states occurs after N+ ion implantation. For Ti+ implanted sample, besides some metal oxycarbide phases, most carbon amorphous phases form in surface region. Concerning N+/Ti+ co-implantation, CrxCy compound as well as Fe3C phase dominates the surface region while no C-C phase is found. In addition, compared with single-ion implantation, N+/Ti+ co-implantation would increase the ion implantation depth significantly. The formed phases of the carbon atoms play an important role in affecting the surface properties of AISI 440C stainless steel.
2015 Vol. 22 (6): 513-518 [
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519
Ming-dong HUANG,Bao-yu WANG,Jing ZHOU
Hot Stamping Parameters Optimization of Boron Steel Using a Response Surface Methodology Based on Central Composite Design
The effect of hot stamping parameters on the mechanical properties of 22MnB5 steel sheet with thickness of 1. 1 mm is studied. The considered parameters are austenization temperature (800-1000 ℃), austenitizing soaking time (60-540 s), initial deformation temperature (560-800 ℃) and tool temperature (20-220 ℃). In order to obtain hot stamped parts with optimal mechanical properties, response surface methodology based on the central composite design has been employed to design the experiment matrix. Tensile strength of hot stamped parts is determined as the relation in the mathematical model. The optimal condition and objective effects of parameters are determined via this relation. The statistical analysis showed that all four factors significantly affect the tensile strength of the hot stamped parts. The optimum austenization temperature is found to be 918. 89 ℃ with the austenitizing soaking time, initial deformation temperature and tool temperature of 279. 45 s, 684. 69 ℃ and 21. 85 ℃, respectively. These optimal hot stamping parameters prove to have high tensile strength (1631. 84 MPa) where deviation between predicted and actual response falls within 2%.
2015 Vol. 22 (6): 519-526 [
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527
Shuai YANG,,Yun PENG,Xiao-mu ZHANG,Zhi-ling TIAN
Phase Transformation and Its Effect on Mechanical Properties of C300 Weld Metal after Aging Treatment at Different Temperatures
The influence of aging temperature on phase transformation and mechanical properties of weld metal of maraging steel (grade C300) was studied. Microstructure was analyzed by means of optical microscopy, transmission electron microscopy, scanning electron microscopy and energy dispersive spectrum analysis. Gibbs free energy of Ni3Ti and Fe2Mo at different temperature was calculated by Thermal-calc software. The microstructure of weld metal in as-welded state is martensite. The yield strength of weld metal after 430 ℃ aging process may increase to 1561 MPa from 890 MPa in as-welded state, which is ascribed to the formation of spinodal constitute and GP zones. After 480 ℃ aging process, there are great deal of Ni3Ti precipitates in the martensite matrix and 10% reverted austenite phase in the cellular grain boundary, and the yield strength increases to 1801 MPa. After aging process at 580 ℃, there are many Fe2Mo precipitates in the martensite matrix and 30% reverted austenite phase in the cellular grain boundary, and the yield strength is 1329 MPa, which is the lowest among the three cases. The phase transformation may also influence the toughness. It is found that precipitates make the toughness decrease and reverted austenite increases it. The mechanism of phase transformation on strength and toughness is discussed.
2015 Vol. 22 (6): 527-533 [
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534
Zhen ZHANG,Zheng-fei HU,Li-kun FAN,Bin WANG
Low Cycle Fatigue Behavior and Cyclic Softening of P92 Ferritic-martensitic Steel
The low cycle fatigue (LCF) behavior of P92 martensitic steel was investigated under different controlled strain amplitudes at room and high temperatures (873 K). The cyclic stress responses at all temperatures and strain amplitudes exhibited obviously rapid softening behavior at the early stage of fatigue life, and there was no saturated stage at high temperature. The fracture surfaces of the fatigue samples were observed by scanning electron microscopy (SEM) and optical microscopy. It was shown that crack initiation and propagation occurred transgranularly at both testing temperatures. A typical character was the high density crack branches or secondary cracks along fatigue striations at high temperature, which initiated from the oxidized inclusions and grain boundaries. Further investigation by transmission electron microscopy (TEM) showed that the softening behavior was attributed to the microstructure evolution during fatigue life, such as annihilation of dislocations and migration of martensite laths as well as carbide coarsening, especially for samples tested at high temperature.
2015 Vol. 22 (6): 534-542 [
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543
Ting LUO,Jian-hua LIU,Hong-bo LIU,Jian LIU
Effects of Particle Size on Nitridation Kinetics of Manganese Powder
Isothermal thermo-gravimetric analysis was applied to investigate the nitridation kinetics of manganese powder with different particle sizes at 800, 900 and 1000 ℃. The apparent activation energy and nitridation kinetics equations of manganese powder with different particle sizes were obtained from unreacted shrinking core model and Arrhenius formula. It was found that the nitridation mechanism was controlled by interfacial chemical reaction. The apparent activation energy and the apparent rate constant of nitridation reaction were affected by particle sizes. With the decrease of particle size, the apparent activation energy decreased whilst the apparent rate constant increased. It was suggested that the refinement of the manganese powder contributed to the increase of molar surface energy, which accounted for the lower apparent activation energy.
2015 Vol. 22 (6): 543-550 [
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551
He-yong QIN,Gang CHEN,Qiang ZHU,Chuan-jie WANG,Peng ZHANG
High Temperature Low Cycle Fatigue Behavior of GH4742 Alloy
High temperature low cycle fatigue tests on GH4742 superalloy were studied under the total strain-controlled conditions at 650 ℃. Combined with fatigue test data, fatigue properties of the alloy were analyzed. Fracture morphology and dislocation structure were observed by scanning electron microscopy and transmission electron microscopy. The results showed that fatigue life and fatigue resistance of GH4742 alloy decreased significantly with increasing total strain amplitude. The cyclic hardening, cyclic softening and cyclic stability phenomena of the alloy occurred during the low cycle fatigue process. The increasing total strain amplitude is conducive to the formation of γ′ phase. Fatigue crack propagation is controlled jointly by ductile and brittle fracture. Inhomogeneous deformation and deformation restricted in slip bands are the main reasons for the reduction of fatigue life of GH4742 alloy.
2015 Vol. 22 (6): 551-556 [
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