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2022年 29卷 08期
刊出日期：2022-08-25
论著
论著
1153
Zheng Wang, Yue-hui Guan, Hai-wen Luo
Progress on statistical models of evaluating inclusions in clean steels
Hot!
Non-metallic inclusions are critical for the fatigue failure of clean steels in service; especially, the large and hard inclusions are detrimental. Since it is not possible to measure all the inclusions in the large-volume clean steels, statistical models have been developed to evaluate inclusions, aiming at predicting the maximum inclusion size in the large volume from the data of inclusions, which are derived from the limited observations on small-volume specimens. Different statistical models were reviewed together with their supporting theories. In particular, the block maxima and the threshold types of models were discussed through a thorough comparison as they are both widely used and based on the extreme value theory. The predicted results not only are used to distinguish the different cleanliness levels of steels, but also help to estimate fatigue strength. Finally, future research is proposed to focus on tackling the present difficulties encountered by statistical models, including the sufficient credibility of obtained results and the robustness of models for applications.
2022 Vol. 29 (08): 1153-1163 [
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1164
Hong-yu Tian, Zheng-qi Guo, Ruo-ning Zhan, Jian Pan, De-qing Zhu, Cong-cong Yang, Liao-ting Pan, Xue-zhong Huang
Upgrade of nickel and iron from low-grade nickel laterite by improving direct reduction-magnetic separation process
Hot!
Low-grade saprolite nickel laterite, characterized by complicated minerals composition and fine-grained and complex dissemination, was commonly treated with a low recovery efficiency of Ni and Fe by conventional methods. Hence, an improved direct reduction and magnetic separation process was proposed. Meanwhile, the mechanisms on the enhanced growth of the Ni–Fe particles and the phase transformation in the nickel laterite pellets were explored. The low-nickel concentrates as a nucleating agent can obviously decrease the activation energy for growth of Ni–Fe alloy particles during the improved direct reduction process from 197.10 to 154.81 kJ/mol when the low-nickel concentrates were added from 0 to 20%. Hence, it is able to decrease nucleation barrier, induce the growth of Fe–Ni alloy particles and increase their average size. As a result, the size of Ni–Fe particles in the pellets from less than 10 lm grew to more than 20 lm, which is beneficial for the full liberation and recovery of Ni and Fe in subsequent magnetic separation process. Therefore, the preferable Ni–Fe alloy concentrates with 6.44% Ni and 82.48% Fe can be prepared with corresponding recovery rates of 96.90% and 95.92%, respectively, when adding 20% low-nickel concentrates.
2022 Vol. 29 (08): 1164-1175 [
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1176
Hong-ming Long, Yu-dong Zhang, Tao Yang, Li-xin Qian, Zheng-wei Yu
A promising method to recover spent V2O5–WO3/TiO2 catalyst: treatment by vanadium–titanium magnetite sintering process
Hot!
A large number of spent selective catalytic reduction (SCR) denitration catalysts are produced after the ultra-low emission transformation of coal-fired power plants in China. According to the China’s ‘‘Directory of National Hazardous Wastes (Version 2021)’’, these spent vanadium–tungsten–titanium catalysts are classified as ‘‘HW50’’ hazardous waste, and their disposal and utilization processes have been strictly controlled. Thus, an effective and low-cost technique was developed to treat and utilize these spent SCR catalysts by the vanadium–titanium magnetite sintering process. Effects of adding spent SCR catalysts on the sintering production process and product quality indexes of sinter were studied. The results showed that adding spent SCR catalysts can improve the sintering granulation and green feed permeability, thereby increasing the productivity and flame front speed. When the addition proportion of spent SCR catalysts is less than 1 wt.%, the performance indexes of the finished sinter are basically equal to those of the finished sinter without adding spent SCR catalysts. Further increasing the proportion of spent SCR catalysts to 2.0 wt.% results in a decrease in product quality indexes, which could be attributed to the increase in perovskite content in the finished sinter.
2022 Vol. 29 (08): 1176-1184 [
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1185
Kai-kai Bai, Hai-bin Zuo, Wen-guo Liu, Jing-song Wang, Jian-sheng Chen, Qing-guo Xue
Effect of quaternary basicity on softening–melting behavior of primary slag based on magnesium flux pellet
Hot!
It is generally accepted that the softening–melting properties of ferrous burden play a vital role in optimizing the shape and position of cohesive zone. The effect of quaternary basicity and atmosphere on softening, melting and permeation temperatures of primary slag based on magnesium flux pellet was investigated by visualization method. The mechanisms were analyzed utilizing thermodynamic calculation, X-ray diffraction analysis and electron probe microanalysis. The results indicated that the softening and melting temperatures of oxide samples increased by approximately 120 ℃ with increasing quaternary basicity from 0.3 to 1.2 owing to the formation of slag phases with high melting point and solid Fe. Meanwhile, the difference between softening and melting temperatures decreased from 21 to 11 ℃. The permeation temperature was not affected by the quaternary basicity and fluctuated around a level of 1250 C, given that the permeation temperature depends on the wettability between slag and coke bed. On the other hand, as the ratios of CO/CO2 varied from 3/7 to 7/3, there were no significant differences in either the softening or melting temperatures, whereas the permeation temperature was increased from 1239 to 1271 ℃ since the reduction of FeO-bearing phases to solid Fe could decrease the wettability between slag and coke bed.
2022 Vol. 29 (08): 1185-1193 [
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1194
Xun Xu, Li-jun Wu, Zhao-kuo Yuan
Thermal test and numerical simulation of cooling stave with internal ribbed tube
Hot!
A new type of cooling stave with internal ribbed tube was proposed, and the heat transfer performance of the stave was studied by means of thermal test and numerical simulation. The temperature of cooling stave was monitored in the conditions of furnace gas temperature of 200–700 C and cooling water velocity of 0.2–1.0 m/s. The thermal test results show that the internal rib structure can form swirl in the water pipe and improve the cooling capacity of the cooling stave. The higher the furnace temperature or the lower the cooling water flow rate, the more obvious the advantage of the cooling stave with internal ribbed tube. The mathematical model of the cooling stave with internal ribbed tube was established by FLUENT software, and the influence of the internal rib structure parameters on the heat transfer performance of the cooling stave was discussed. It is suggested that the parameters of the internal ribbed tube should be 4 ribs, 1 mm in height, 5–7 mm in width, and 20–30 mm in lead. In the same common working conditions of the cooling stave, the maximum temperature of the newly designed cooling stave with internal ribbed tube is reduced by 5.6% compared with that of common cooling stave with round tube. The water flow rate in the internal ribbed tube only needs 0.9 m/s to reach the cooling effect of 2 m/s in the common tube cooling stave, which can save 55% of water. In case of water shortage accident of cooling stave, the maximum temperature of the cooling stave with internal ribbed tube is decreased by 22.4% compared with that of common round tube, which can effectively reduce the harm of water shortage and protect the cooling stave.
2022 Vol. 29 (08): 1194-1204 [
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1205
Zong-xin Chen, Hui Liu, Long Qi
Feature selection of BOF steelmaking process data by using an improved grey wolf optimizer
Hot!
Basic oxygen furnace (BOF) steelmaking end-point control using soft measurement models has essential value for economy and environment. However, the high-dimensional and redundant data of the BOF collected by the sensors will hinder the performance of models. The traditional feature selection results based on meta-heuristic algorithms cannot meet the stability of actual industrial applications. In order to eliminate the negative impact of feature selection application in the BOF steelmaking, an improved grey wolf optimizer (IGWO) for feature selection was proposed, and it was applied to the BOF data set. Firstly, the proposed algorithm preset the size of the feature subset based on the new encoding scheme, rather than the traditional uncertain number strategy. Then, opposition-based learning was used to initialize the grey wolf population so that the initial population was closer to the potential optimal solution. In addition, a novel population update method retained the features closely related to the best three grey wolves and probabilistically updated irrelevant features through measurement or random methods. These methods were used to search feature subsets to maximize search capability and stability of algorithm on BOF steelmaking data. Finally, the proposed algorithm was compared with other feature selection algorithms on the BOF data sets. The results show that the proposed IGWO can stably select the feature subsets that are conductive to the end-point regression accuracy control of BOF temperature and carbon content, which can improve the performance of the BOF steelmaking.
2022 Vol. 29 (08): 1205-1223 [
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1224
Xiang Lu, Xiao-li Huang, Ru-fei Wei, Wen Chen, Da-qiang Cang, Fei-hua Yang, Chun-lei Pu
Novel method for improving iron recovery from electric arc furnace slag: on-site hot modification
Hot!
The iron element in electric arc furnace (EAF) slag is extremely difficult to recycle due to the low specific magnetic susceptibility of the RO phase (a solid solution of FeO, MgO, CaO, and MnO). Landfilling EAF slag is strictly forbidden for environmental consideration because of poisonous Cr6? leaching. The original RO phase could be transformed to a spinel structure, whose specific magnetic susceptibility is much higher than that of other minerals, through hot modification, resulting in significantly increased iron recovery by magnetic separation. Precipitation of spinel crystals encloses chromium, such that iron and chromium could be recovered simultaneously. The chromium in obtained iron concentrates is considerably useful for stainless steel making rather than polluting the environment. As a result, recovering iron and chromium is truly beneficial for cleaner production. Hot modification of EAF slag should be conducted at 1500–1600 ºC for at least 60 min to guarantee homogeneous liquid slag. The liquid slag was poured onto an iron mold to obtain modified slag (MS) through air quenching. MS was characterized by thermodynamic analysis, X-ray diffraction, and scanning electron microscopy combined with energy-dispersive spectroscopy to correlate the relationship between mineral structures and iron recovery. The iron recovery rate of MS first increased and then decreased with increasing modifier. It was less than 10% when the modifier addition amount was below 12 wt.%, but it increased rapidly as the modifier addition amount increased from 16 to 24 wt.%, mainly due to spinel formation. The highest iron recovery rate was 81.9% when the modifier amount reached 20 wt.%. Meanwhile, Cr6? was enriched in the spinel phase but was not observed in other minerals. Industrial tests were performed on-site with the modifier ranging from 12 to 18 wt.% because additional heat was not provided during the tests. Results showed that MS with 18 wt.% modifier addition exhibited an iron recovery rate of 61.0%, much higher than that (34.6%) of the original slag.
2022 Vol. 29 (08): 1224-1235 [
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1236
Ya-dong Wang, Zheng-hua Tang, Su-fen Xiao, Charles W. Siyasiya, Tao Wei
Effects of final rolling temperature and coiling temperature on precipitates and microstructure of high-strength low-alloy pipeline steel
Hot!
The strength-to-weight ratio is an important property of high-strength low-alloy (HSLA) steel in pipeline, whose precipitation strengthening can be improved. The final rolling temperature (FRT) and coiling temperature (CT) are the key process parameters in the control of precipitates and microstructure. Continuous cooling rate was fixed at 10 ℃/s, and the effects of deformation and coiling temperatures on precipitates and microstructure of Ti–Nb microalloyed HSLA steel were investigated through thermo-mechanical controlled processing on Gleeble 3500. The microstructure is mainly acicular ferrite with high density dislocation and several microns scale. The size and volume fraction of the precipitates were studied under transmission electron microscopy. The results showed that the diameter of the precipitates was in the range between 4 and 240 nm. The optimized combination of parameters is FRT of 820 ℃ and CT of 550 ℃, and the volume fraction of precipitates obtained under this process is 0.59%.
2022 Vol. 29 (08): 1236-1244 [
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1245
Zhen Liu, Li Gong, Chi Zhang, Zheng-dong Liu, Zheng-zong Chen, Yun-he Yu
Effect of annealing and cooling rate on toughness of G115 heat-resistant steels
Hot!
The effects of annealing before normalizing and different cooling ways, i.e., air cooling, quenching, and water mist cooling after normalizing on the toughness of G115 steels were investigated. The impact tests showed that the annealed samples had better toughness compared to the unannealed samples for three cooling ways. Microstructure observations revealed that the annealed samples had a more uniform grain distribution, smaller size and area fraction of M23C6 particles along the grain boundaries, and lower dislocation density than those in the unannealed samples, which performed together for good toughness. Among three cooling ways, air cooling gave the best toughness due to the smallest occupancy of M23C6 particles in the grain boundaries. Thus, the combination of annealing conducted before normalizing and air cooling selected after normalizing can improve the toughness a lot of G115 steels.
2022 Vol. 29 (08): 1245-1256 [
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1257
Fei Zhu, Li Yang, Feng Chai, Xiao-bing Luo, Cai-fu Yang, Zheng-yan Zhang
Effect of modifying matrix microstructures and nanosized precipitates on strengthening mechanisms and ductile-to-brittle-transitiontemperature in a 1000 MPa Ni–Cr–Mo–Cu steel
Hot!
A superior combination of yield strength (1001 MPa) and - 20 ℃ impact toughness (166 J) was obtained in Nb–V–Timicroalloyed Ni–Cr–Mo–Cu steel treated by direct quenching and tempering route (DQT). The tested steels treated by DQT route and re-austenitization and tempering route (QT) were compared with each other in terms of mechanical properties and microstructures characterized by optical microscopy, transmission electron microscopy, X-ray diffraction, electron back-scattered diffraction method and so on. Strength and Vickers hardness of the tested steel treated by the above two routes vary with isothermal aging temperature (400–600 ℃), shown as under-aged state, peak-aged state and overaged state. All DQT specimens show higher strength and Vickers hardness than QT specimens with the same aging condition. Furthermore, the largest difference of yield strength between DQT and QT specimens was shown in DQT600 and QT600 specimens. DQT600 or QT600 specimens refers to direct quenched (DQ) or quenched (Q) specimens isothermally aged at 600 ℃. The main disparities in quenched microstructure between DQ and Q specimens are mainly in morphology of prior austenite grains, dislocation density of martensite matrix and solution amount of Nb and Mo elements dissolving in martensite matrix, which play key roles in affecting microstructure and mechanical properties of DQT and QT specimens. Higher dislocation density of matrix and finer average diameter of both MC (M is any combination of Nb, Mo and V) and Cu-rich particles were shown in DQT600 specimens than in QT600 specimens. Strengthening from dislocations and nanosized MC and Cu-rich particles mainly leads to the largest difference of yield strength between DQT600 and QT600 specimens. In addition, strong dislocation strengthening and precipitation strengthening in DQT600 specimen also elevated its ductile-to-brittle-transition-temperature, compared with QT600 specimen.
2022 Vol. 29 (08): 1257-1276 [
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1277
Yan Wang, Li-guang Zhu, Jin-xia Huo, Qing-jun Zhang, Yao-guang Wu, Wei Chen, Shuo-ming Wang
Relationship between crystallographic structure of complex inclusions MgAl2O4/Ti2O3/MnS and improved toughness of heat-affected zone in shipbuilding steel
Hot!
In accordance with the minimum degree of disregistry mechanism in oxide metallurgy, the intragranular acicular ferrite (IAF) generated by microalloying elements in austenite was studied. Herein, the effect of Mg treatment on the microstructure and toughness of the heat-affected zone (HAZ) in shipbuilding steel was investigated. Mg treatment produced inclusions that influenced the formation of acicular ferrite in the microstructure. This refined the HAZ microstructure and improved its toughness. Electron backscatter diffraction was used to determine the oxides of titanium and the MgO Al2O3 or MgAl2O4 complex inclusions that induced the formation of IAF. MnS precipitated on MgAl2O4 on a specific habit plane and in a specific direction. MnS had a specific orientation relationship with MgAl2O4, i.e., f100gMgAl2O4 //{100}MnS. The 35-mm-thick plate obtained in the industrial test after welding at a welding heat input of 120 kJ/cm had an average impact absorbed energy of 282.7 J at - 40 ℃ and 2 mm from the weld joint in the HAZ. The twodimensional disregistry index between inclusions can be used as the basis for controlling their distribution and adsorption force. Microalloy addition in the order of Al–Mg–Ti is key to obtaining abundant dispersion and fine nucleation in austenite.
2022 Vol. 29 (08): 1277-1290 [
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1291
Hong-bo Liu, Ju Kang, Xiu-juan Zhao, Cai-dong Zhang, Zhang-guo Lin, Hong-yong Yao, Zhi-qiang Tian, Zhan-li Liu, Jie Li, Chao Li
Influence of Ca treatment on particle–microstructure relationship in heat-affected zone of shipbuilding steel with Zr–Ti deoxidation after high-heat-input welding
Hot!
The effects of Ca treatment on the particle, microstructure, and toughness of heat-affected zone (HAZ) of shipbuilding steel with Zr–Ti deoxidation after high-heat-input welding were investigated. The simulated welding at a high-heat-input welding of 200 kJ/cm was carried out using Gleeble-3800 welding simulation. Then, particle characteristics were characterized using an Aztec-Feature automatic particle analysis system. Additionally, an in-situ observation experiment was performed to study the relationships between particle and microstructure by high-temperature confocal laser scanning microscopy (HT-CLSM). The results indicated that the average HAZ toughness at -40 ℃ was increased from 183 to 290 J by adding 0.0026 wt.% Ca. Meanwhile, the formation of acicular ferrite ratio was increased from 49.34% to 60.28% due to the addition of Ca. The scanning electron microscopy results clearly showed that CaO–Al2O3–TiOx–ZrO2–MnS particles could act as effective nucleation sites for the formation of acicular ferrite, which has been verified by the observation of the particle–microstructure relationship under HT-CLSM. Furthermore, particle characterization results show that the cumulative frequency of particles with the size of 1–3 lm was 33.2% in HAZ of Zr–Ti shipbuilding steel but 66.2% in HAZ of Zr–Ti–Ca shipbuilding steel.
2022 Vol. 29 (08): 1291-1298 [
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1299
De-fa Li, Hang-yu Dong, Cheng-yang Hu, Kai-ming Wu, Serhii Yershov, Oleg Isayev
Erosion–corrosion resistance of Mo–Ti- and Ni–Cr–Mo-alloyed medium-carbon martensitic steels: a critical analysis of synergistic effect of erosion and corrosion
Hot!
Grain refinement renders Mo–Ti-alloyed medium-carbon martensitic steel to exhibit high hardness, high strength, and good toughness, but the erosion–corrosion resistance of steel in a corrosive slurry environment is not known. Mo–Ti-alloyed medium-carbon martensitic steel is compared with Ni–Cr–Mo-alloyed medium-carbon martensitic steel, and the erosion– corrosion resistance of those two steels under impingement by NaCl solution with gravels has been investigated. Three components, pure-corrosion rate, pure-erosion rate, and synergistic effect of erosion and corrosion (SEEC) of erosion– corrosion rate, were quantified. The pure-corrosion and pure-erosion rates of Mo–Ti-alloyed steel were higher than those of Ni–Cr–Mo-alloyed one; however, its erosion–corrosion rate was relatively lower because of a weak SEEC. Surface plastic deformation and work hardening due to gravel impingement were the essential reason for SEEC, which could be reduced by grain refinement, and consequently, Mo–Ti-alloyed steel with finer grains had better erosion–corrosion resistance. Grain refinement could be an effective way to improve the erosion–corrosion resistance of martensitic steels.
2022 Vol. 29 (08): 1299-1311 [
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1312
Xin Dai, Yue-feng Chen, Peng Wang, Li Zhang, Bin Yang, Lian-sheng Chen
Mechanical and fatigue properties of SA508-IV steel used for nuclear reactor pressure vessels
Hot!
The mechanical and fatigue properties of SA508-IV steel with martensite and granular bainite, respectively, were studied. The mechanical tests results showed that the ultimate tensile strength and impact toughness of the specimen with martensite were 830 MPa and 158 J, respectively, and those of the specimen with granular bainite were 811 MPa and 115 J, respectively. The former had higher tensile strength and impact toughness than the latter. The impact tests results showed that the former belonged to typical dimple fracture, while the latter belonged to brittle fracture. The fatigue tests results showed that the fatigue life of the specimen with martensite was 2717 cycles, and that of the specimen with granular bainite was 1545 cycles under the strain amplitude of ± 0.45%. The specimen with martensite had fewer crack initiation points, narrower fatigue striations separation, and larger volume fraction of high-angle grain boundaries than the latter. The fewer crack initiation points meant fewer fatigue cracks, the narrower fatigue striations separation meant slower crack propagation rate, and the larger volume fraction of high-angle grain boundaries could more effectively hinder fatigue crack propagation. Based on these facts, the fatigue life of the specimen with martensite was higher than that of the specimen with granular bainite.
2022 Vol. 29 (08): 1312-1321 [
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1322
Fa-yun Lu, Hong-yuan Wan, Xin Ren, Li-ming Huang, Hai-lin Liu, Xin Yi
Mechanical and microstructural characterization of additive manufactured Inconel 718 alloy by selective laser melting and laser metal deposition
Hot!
The direct comparison of the microstructure and tensile properties of Inconel 718 fabricated by selective laser melting (SLM) or laser metal deposition (LMD) has been carried out. In the as-built state, LMD-fabricated specimens show lower tensile yield strength and fracture elongation than SLM-fabricated specimens due to the coarser solidification microstructure, including grains, cellular dendrites and Laves phases. This is mainly because the cooling rate of the LMD process is 2 to 3 orders lower than that of the SLM process. Upon the same heat treatment, both yield strengths of SLMand LMD-fabricated specimens are enhanced significantly. Notably, LMD-fabricated specimens exhibit simultaneous improvement in the strength and ductility, which is mainly attributed to the presence of small granular Laves phases and uniformly distributed nanoscale c00 strengthening phases. The results could serve as a guidance for selecting suitable postheat treatment routes for specific additive manufacturing process to attain excellent strength–ductility synergy.
2022 Vol. 29 (08): 1322-1333 [
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1334
Yu-xuan Liu, Shuai-jiang Yan, Cheng-song Zhang, Da-zhi Chen, Qin Xu, Guo-dong Cui
Preparation and compression behavior of Fe–Ni–P/porous-Fe/Fe–Ni–P composites
Hot!
Porous-Fe–N alloys designed for light weight or energy absorption are inevitably facing the compromise of deteriorated mechanical properties. To optimize their mechanical properties, here a novel Fe–Ni–P/porous-Fe/Fe–Ni–P composite with sandwich structure was fabricated by spark plasma sintering and further strengthened via cryogenic treatment. Based on the principle of solid phase sintering and transient liquid phase sintering, porous core and dense outer layers formed simultaneously after co-sintering. The as-fabricated samples show excellent compressive strength of 1708 MPa, and after cryogenic treatment, due to the sufficient martensitic transformation, Fe–Ni–P outer layers show substantially increased hardness from 246.7 to 386.6 HV0.1 while the porous-Fe core remains unchanged. And the compressive strength maintains 1424 MPa despise the aggravated incongruity of deformation. The ratio of constituent microhardness R has been proposed to represent the hardness matching, and with decreasing R, the incongruity of deformation is intensified, and the nominal compressive strength is reduced.
2022 Vol. 29 (08): 1334-1341 [
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