钢铁研究学报(英文版)
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2018年 25卷 5期
刊出日期：2018-05-15
477
Lei Cui? Chao Zhang Yong-chang Liu, Xiu-guo Liu, ? Dong-po Wang Hui-jun Li
Recent progress in friction stir welding tools used for steels
Friction stir welding (FSW) technology is being increasingly attractive in welding steels on account of the high-quality weld formation and excellent weld properties. The feasibility of FSW of steels has been convinced for nearly 20 years. However, the application progress for FSW of steels is slower than that of aluminum alloys owing to the high cost and poor usability of tools. The FSW tools are called as the heart of FSW process which is critical for welding quality control and the weld microstructure and properties. The recent progresses in research and development of FSW tools for welding steels have been reviewed. Material selections, geometry parameters, wear behavior and use life of the tools are summarized from the available literatures.
2018 Vol. 25 (5): 477-486 [
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487
Yang Li Hai-yang Yu Hua-mei Yang Feng Zheng Xiong Zhang Bei-bei Xiong Qiang Zhen Hong-wei Ni
Separation and comprehensive utilization of valuable elements in Ti-bearing electric arc furnace molten slag
A novel route to comprehensive utilization of valuable elements such as Ti, Al, Si and Mg in Ti-bearing electric arc furnace molten slag (Ti-bearing EAF slag) was proposed. The route can be expressed as a three-step process including alkali fusion, water leaching and acidolysis. Following these processes under the optimum conditions, the recovery ratios of TiO2, Al2O3, SiO2 and MgO were about 97.5, 93.5, 27.9 and 53.5%, respectively. Meanwhile, nanostructured TiO2, NaA zeolite and Mg(OH)2 fire retardant were synthesized simultaneously by using Ti-bearing EAF slag as raw materials. In addition, the photocatalytic activity of prepared nanostructured TiO2 and the adsorption property of obtained NaA zeolite were investigated. The results showed that the photodegradation efficiency of as-prepared TiO2 was 80% for rhodamine B and the adsorption efficiency of NaA zeolite was 61% for Cu2+ under the optimum conditions.
2018 Vol. 25 (5): 487-496 [
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497
Ran Wang, Zheng-gen Liu Man-sheng Chu Hong-tao Wang Wei Zhao Li-hua Gao
Modeling assessment of recovering iron from red mud by direct reduction: magnetic separation based on response surface methodology
Red mud, the waste generated during alumina production, contains iron and other valuable metals. To recover the iron efficiently from red mud, a three-factor five-level central composite design in response surface methodology was used to study the effects of process parameters, such as FC/O (the molar ratio of fixed carbon in coal to reducible oxygen of iron oxide in red mud), reduction temperature, reduction time, and their interaction on the iron recovery rate and total iron content in magnetic product obtained from the process of direct reduction–magnetic separation. The relevant assessment model was established. The model could predict the changing rules of iron recovery rate and total iron content in the magnetic product affected by the process parameters. The results show that the iron recovery rate is significantly influenced by three factors and reduction temperature plays the most important role. The iron recovery rate and total iron content in magnetic product could be up to 98.37 and 82.52%, respectively, under the numerically optimal process parameters condition of reduction temperature of 1400 °C, FC/O of 0.80 and reduction time of 100 min obtained by the assessment model. The predicted values are in good agreement with the experimental values.
2018 Vol. 25 (5): 497-505 [
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506
De-qing Zhu Zheng-qi Guo ? Jian Pan Zhao-yuan Wang
Insights on pretreatment of Indian hematite fines in grate–kiln pelletizing process: the choice of grinding processes
Indian hematite fines are normally characterized by high iron grade and minor impurities, which are usually used for sinter fines. With macroscale operations technology of blast furnace in Indian, pellets, as a kind of high-quality materials, attract more and more attention. However, the hematite fines possess the coarse size. Hence, they inevitably need to be further finely ground for pelletizing before balling. The grinding behavior of Indian hematite fines was revealed by conducting the ball milling tests and determining the Bond ball mill work index (Wi). The results show that Indian hematite fines have an excellent grindability with Wi of only 7.40–7.73 kWh/t, indicating that ball milling is an economically viable way to pretreat Indian hematite fines. Nonetheless, due to poor sedimentation and filtering properties of wet ground products, the dry ball milling is more appropriate to process Indian hematite fines. In addition, the superior quality green balls can be manufactured with dry ground products under the conditions of 0.5% bentonite dosage, 7.5% moisture and balling for 12 min, which further confirmed that the recommended pellet feed preparation technique is reasonable.
2018 Vol. 25 (5): 506-514 [
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515
Romie D. Laranjo Nathaniel M. Anacleto
Direct smelting process for stainless steel crude alloy recovery from mixed low-grade chromite, nickel laterite and manganese ores
Stainless steel crude alloy recovery from direct smelting of low-grade chromite, nickel laterite and manganese ores was investigated. The mixed low-grade ores were directly smelted in an elevator furnace at smelting temperatures ranging from 1550 to 1600 °C. Smelting experiments were conducted in a laboratory elevator furnace equipped with 8 U-shaped high-quality molybdenum disilicide heating elements. A low-grade coal was used as the reductant. Experimental results showed that the recovery of Fe, Cr, Ni, Mn and Si within the alloy increased from 34.22, 60.27, 57.14, 25.42 and 13.02% to 69.91, 99.26, 86.02, 60.8 and 34.21%, respectively, when the temperature was increased from 1550 to 1600 °C. There was a general increase in the total recoveries of Fe, Cr, and Ni in the alloy with CaO addition increasing from 0.4 g up to 1.2 g. However, the recoveries of Mn and Si vividly decreased as the CaO contents were increased. In general, the recoveries of the metal contents of the crude alloy increase with the increase in the amount of manganese ore. Compared to the recoveries of Fe, Cr, and Ni when CaO was added, the recoveries of Fe, Cr and Ni were lower when manganese ore was used as an additive.
2018 Vol. 25 (5): 515-523 [
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524
Xiao-jun Liu Sheng-ming Liao ? Zheng-hua Rao Gang Liu
An input–output model for energy accounting and analysis of industrial production processes: a case study of an integrated steel plant
To promote sustainability, it has become increasingly vital to properly account material and energy flows in industrial production processes. Therefore, a generic process-level input–output (IO) model was developed to provide an integrated energy (material) accounting and analysis approach for industrial production processes. By extending the existing process level IO models, the production, usage, export and loss of by-products were explicitly considered in the proposed IO model. Moreover, the by-products allocation procedures were incorporated into the proposed IO model to reflect individual contributions of products to energy consumption. Finally, the proposed model enabled calculating embodied energy of main products and total energy consumption under hierarchical accounting scope. Plant managers, energy management consultants, governmental officials and academic researchers could use this input–output model to account material and energy flows, thus calculating energy consumption indicators of a production process with their specific system boundary requirements. The accounting results could be further used for energy labeling, identifying bottlenecks of production activities, evaluating industrial symbiosis effects, improving materials and energy utilization efficiency, etc. The model could also be used as a planning tool to determine the effect that a particular change of technology and supply chains may have on the industrial production processes. The proposed model was tested and applied in a real integrated steel mill, which also provided the reference results for related researches. At last, some concepts, computational issues and limitations of the proposed model were discussed.
2018 Vol. 25 (5): 524-538 [
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539
Qing-bao Yang Jun-ying Min John E. Carsley Yuan-yuan Wen Bernd Kuhlenko¨tter Thomas B. Stoughton Jian-ping Lin
Prediction of plane-strain specimen geometry to efficiently obtain a forming limit diagram by Marciniak test
Plane-strain forming limit strain (also known as FLD0) is an important data point on a forming limit diagram (FLD). The effects of friction coefficients and material parameters on the specimen width associated with the FLD0 (WFLD0) in Marciniak test were studied by finite element simulation. WFLD0 was expressed as a function of the Lankford coefficients, n-value, k-value and sheet thickness and validated with various sheet materials. The determination of WFLD0 is of significance not only to reduce iterative attempts to accurately obtain FLD0, but also to obtain a full valid FLD with the least number of test specimens, which largely increases the efficiency and reduces cost to experimentally measure valid FLDs.
2018 Vol. 25 (5): 539-545 [
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546
Chang-ling Zhuang Jian-hua Liu
Determination of liquidus temperatures in high-alloyed Fe–C–Mn–Si–Al steels using differential thermal analysis
The liquidus temperature of the Fe–C–Mn–Si–Al alloy was investigated by using an improved differential thermal analysis method, which effectively tackles down the manganese evaporation in the course of differential thermal analysis experiments for high-manganese twinning-induced plasticity (TWIP) steels at high temperature. It was found that the liquidus temperature is more strongly dependent on the silicon content than expected. By considering the high manganese content in the Fe–C–Mn–Si–Al TWIP steels, the effect of carbon content on the depression coefficient of manganese should not be ignored, which has considerable impact on the liquidus temperature. An equation was summarized to effectively predict the liquidus temperature for a wide range of high-manganese steels. Meanwhile, the prediction results of the equation are consistent with the experimental results, as well as those results acquired from ThermoCalc.
2018 Vol. 25 (5): 546-553 [
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554
Emna Ben Fredj Hadi Ghasemi Nanesa Mohammad Jahazi Jean-Benoit Morin
Influence of initial microstructure and grain size on transformation of bainite to austenite in large size forgings
The kinetics of austenite formation in the surface and center regions of a 40 t forged ingot of a high-strength medium-carbon low-alloy steel was studied using high-resolution dilatometry. The starting microstructures from the surface or center regions had different proportions of bainite and residual austenite as well as different prior austenite grain sizes. Two heating rates representing the actual heating rates in the surface (5 °C s-1) and center regions (0.5 °C s-1) of large size forged blocks were utilized. Dilatometric curves revealed only one transformation step of austenite formation at both heating rates independent of grain size or proportion of phases. Optical microscopy, field emission gun scanning electron microscopy and X-ray diffraction were used to study microstructure evolution and confirm the results obtained by dilatometry. The kinetic parameters for austenite formation were determined from the dilatometry data by Johnson–Mehl–Avrami–Kolmogorov (JMAK) equation. The JMAK coefficients were determined for each condition of the investigated steels. The calculations indicated that the nucleation and growth of austenite in the surface region were accelerated more than 10,000 times due to a significantly smaller average prior austenite grain size, stability of initial retained austenite, and accumulation of coarse carbides at the surface. The results were discussed in the framework of classical nucleation and growth theories using the kinetic parameters for austenite formation.
2018 Vol. 25 (5): 554-562 [
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563
Jian Liu, Wei-ping Chen Xian-man Zhang Zhi-qiang Fu
Corrosion behavior of a spark plasma sintered Fe–20Mn–11Al–1.8C–5Cr alloy in molten aluminum
The corrosion behavior of an Fe–20Mn–11Al–1.8C–5Cr alloy prepared by spark plasma sintering was investigated via immersion tests in molten aluminum at 750 °C for 1 and 4 h, respectively, and a hot work steel (AISI H13) was included as a reference. The experimental results show that the corrosion rate of Fe–20Mn–11Al–1.8C–5Cr alloy is ~ 24% of that of H13 steel, suggesting that Fe–20Mn–11Al–1.8C–5Cr alloy in molten aluminum possesses better corrosion resistance than H13 steel. Detailed analysis show that j-carbide ((Fe, Mn)3AlCx) and Cr7C3 carbide precipitated in the matrix play a key role in enhancing the corrosion resistance of Fe–20Mn–11Al–1.8C–5Cr alloy in molten aluminum. Both of them show better corrosion resistance than c-Fe matrix and H13 steel, and can also take on the role of roots in grasping the corrosion product and restrain them from spalling into the molten aluminum.
2018 Vol. 25 (5): 563-571 [
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572
Xiao-rong Yang, Li-feng Ma Guang-ming Liu Guang-hui Zhao Zheng-yi Jiang
Hot-rolling influence of hot rolling on microstructure and mechanical characteristics of explosive-welded FSS/CS laminate
The influence of hot rolling on the microstructure and subsequent mechanical characteristics of explosive-welded ferritic stainless steel (FSS)/carbon steel (CS) laminate was investigated. The results indicate that by hot rolling, decarburization layer disappears and a uniform structure is gained in CS side, but ferrite grains and carbides in constituent FSS form an uneven band microstructure which is denser at superficial zone than near the interface. The transmission electron microscopy results indicate that the layers adhering to the interface show typical deformed microstructure features, i.e., stream-like strips and elongated grains in FSS plates, carbide precipitates and bended cementite fragments in CS plates; and high-density dislocations in both plates. With hot rolling, various mechanical strengths and hardness are increased, while the elongation percentage is diminished. Examination of fractographs from tensile tests reveals predominately small dimples for explosive-welded specimens, whereas both big dimples and cleavage fracture for rolled specimens. Stereomicroscopic fractographs taken on shear samples indicate that the surfaces of explosive-welded specimens exhibit uniform deformation, but uneven deformation is displayed for that of rolled specimens. These results indicate that hot rolling is beneficial to improve the strength of explosive-welded FSS/CS laminate but not good for enhancing its plasticity.
2018 Vol. 25 (5): 572-579 [
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580
Hai-sheng Chen Yong-qin Wang, Wei-qi Du Liang Wu Yuan-xin Luo,
Fatigue–creep interaction based on continuum damage mechanics for AISI H13 hot work tool steel at elevated temperatures
AISI H13 (4Cr5MoSiV1) is one of the commonly used materials for extrusion tool, and it suffers from fatigue–creep damage during the hot extrusion process. Stress-controlled fatigue and creep–fatigue interaction tests were carried out at 500 °C to investigate its damage evolution. The accumulated plastic strain was selected to define the damage variable due to its clear physical meaning. A new fatigue–creep interaction damage model was proposed on the basis of continuum damage mechanics. A new equivalent impulse density for fatigue–creep tests was proposed to incorporate the holding time effect by transforming creep impulse density into fatigue impulse density. The experimental results indicated that the damage model is able to describe the damage evolution under these working conditions.
2018 Vol. 25 (5): 580-588 [
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589
Zhao-xuan Hou Min Wan ? Xiang-dong Wu Zheng-yang Cai Xue-li Gong Hao Wang
Biaxial tensile behavior and yield loci of dual-phase steel sheets
The biaxial tensile tests were carried out to investigate the deformation behavior and yield loci of dual-phase (DP) steel sheets under biaxial tensile conditions. The true stress–true strain curves of DP steel sheets for different loading ratios were obtained, and the experimental yield loci were determined based on the equivalent plastic work principle. The experimental yield loci were compared to the theoretical yield loci based on Hill48, Hill90, Hill93, Hosford, Barlat89, Yld2000-2d and Gotoh yield criteria. It is found that Yld2000-2d yield criterion can describe the general trends of experimental yield loci of DP steel sheets with comparably higher accuracy. Hosford criterion has the maximum error for DP590, whereas Hill48 and Barlat89 have the maximum errors for DP780 and DP980.
2018 Vol. 25 (5): 589-597 [
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