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2023年 30卷 03期
刊出日期：2023-03-25
综述
论著
综述
405
Dong-xiang Meng, Ru-fei Wei, Fei-hu Zhang, Hong-ming Long, Yuan-yuan Zhou
Resource utilization of flue gas calcium-based desulfurization ash: a comprehensive review
Hot!
Calcium-based desulfurization ash (CDA) is mainly produced in dry and semi-dry flue gas desulfurization processes. The property of CDA is extremely unstable because its main component, calcium sulfite, makes it difficult to be directly applied to the field of building materials. The modification of desulfurization ash can be realized by high-temperature oxidation and wet oxidation. After modification, CDA can be widely used in building materials. Hydrothermal oxidation has broad development prospects because it can complete the oxidation of CDA and the removal of impurity elements at the same time. CDA can be used to prepare high value-added products of calcium sulfate whiskers and ecological rubber fillers.
2023 Vol. 30 (03): 405-418 [
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419
Xiao-dong Lv, You-ling Hou, Yun-tao Xin, Wei Lv, Xue-wei Lv
Effects of Na2CO3 on reduction mechanism and kinetics of iron during deep reduction of ilmenite concentrate
High-quality upgraded titanium slag obtained through semi-molten reduction with the addition of Na
2
CO
3
is important for the fluidizing chlorination process to produce TiO
2
pigments. The key is the effect of Na
2
CO
3
on the reduction behavior of iron. Therefore, the effects of Na
2
CO
3
on reduction mechanism and kinetics of iron during deep reduction of ilmenite concentrate were studied. The results indicated that the metallization ratio of the reduced sample increased with increasing temperature, time, and dose of Na
2
CO
3
. The addition of Na
2
CO
3
significantly accelerated the reduction of iron in the ilmenite concentrate and promoted the growth of iron particles. However, the addition of Na
2
CO
3
produced sodium iron titanates; thus, the metallization ratio of the sample decreased with an increase in the temperature and time when the temperature was above 1200 °C and the time was more than 30 min. When the doses of Na
2
CO
3
were 0, 3, and 6 wt.%, the reduction of iron was controlled by the interfacial chemical reaction, both the interfacial chemical reaction and diffusion, and diffusion, respectively, and the apparent activation energies were 134.91, 64.89, and 120.82 kJ/mol, respectively.
2023 Vol. 30 (03): 419-428 [
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429
Peng Liu, Si-yu Gong, Yu-wen Chao, Bing-guo Liu, Li-bo Zhang, En-hui Wu
Kinetic study on microwave-enhanced direct reduction of titanomagnetite concentrate with coal
Titanomagnetite concentrate is one of the important titanium resources. The apparent activation energy (Ea) of the direct reduction of titanomagnetite concentrate was composed of two parts (average activation energy:
, where
is the lattice energy of titanomagnetite concentrate, and
is the activation energy of step 1 for the reduction of titanomagnetite concentrate in the route of
. Ea (583.43 kJ/mol),
(426.4 kJ/mol), and
(157.0 kJ/mol) were calculated by the model-free methods based on thermogravimetry and Dmol3 module. Combined with the analysis of activation energy fluctuation and the shifting trend of related mechanism functions, the reduction kinetic system with three main characteristics, namely nucleation, diffusion and concentration fluctuation, was established. In addition, the scanning electron microscopy comparison analysis of the samples from microwave reduction and conventional reduction shows that microwave heating could realize the microstructure Ti–Fe separation and reduce the lattice energy of the titanomagnetite concentrate, thus enhancing the reduction process by 7.68% from the perspective of activation energy.
2023 Vol. 30 (03): 429-445 [
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446
Xiao-hui Fan, Zhi-an Zhou, Shu Wang, Min Gan, Zhi-yun Ji, Xu-ling Chen, Zhi-yuan Tian
Mineralization characteristics of pellets prepared by ultrafine magnetite concentrate: influence on metallurgical property and improving method
The reducing property of pellets prepared by ultrafine magnetite concentrate (UMC) and improving method were revealed. The results show that the reduction degree of UMC pellets is only about 56% compared with that of pellets prepared from ordinary iron ore concentrate with relatively coarse particle size, which is significantly lower than the general reduction degree of about 70%. When the composite binder composed of bentonite and organic binder was added, the reduction degree was significantly increased to 69.66%. The revealed mechanism shows that the reduced pellets with common bentonite have a concentric structure, the oxidation gap between the inner and outer layers is obvious, and the outer dense oxide layer hinders the oxidation and reduction of the inner layer. After adding the composite binder, the organic components significantly improved the internal porosity of the pellets and the aggregation degree of ultrafine iron ore concentrate particles in the granulation process, forming a porous structure. The non-uniform double-layer structure is eliminated, and the increased pores are conducive to the internal diffusion of CO, and finally the reduction degree of pellets is increased to the level equivalent to that of ordinary magnetite pellets.
2023 Vol. 30 (03): 446-455 [
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456
Hua-bin Gao, Jue Tang, Man-sheng Chu, Shu-yu Zhong, Zheng-gen Liu
Effects of MgO/Al2O3 and CaO/SiO2 ratios on viscosity of high titaniumbearing blast furnace slag
The effects of MgO/Al
2
O
3
and CaO/SiO
2
ratios on the viscosity, break-point temperature, and viscous activation energy of a high titanium-bearing slag were studied. The results showed that both the viscosity and the break-point temperature of the slag decreased with the MgO/Al
2
O
3
ratio increasing from 0.50 to 0.65, the viscous activation energy decreased gradually, and the thermal stability became better. In addition, with an increase in CaO/SiO
2
ratio from 1.12 to 1.22, the main viscous units in the slag depolymerized and the viscosity of slag decreased. However, the break-point temperature of slag showed an increasing tendency. The viscous activation energy decreased gradually and the thermal stability became better. The basic phase in the experimental high titanium-bearing slag was pyroxene, and its amount increased with increasing the MgO/Al
2
O
3
ratio while decreased with increasing the CaO/SiO
2
ratio.
2023 Vol. 30 (03): 456-464 [
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465
He-bin Jin, Xue-you Wang, Yun-bo Wang, Shi-song Wang, Xu-bin Zhang, Sheng-ping He
Variation of meniscus shape and initial steel solidification under different steel–slag interfacial tension in continuous casting mold of slab
A two-dimensional model was applied to investigate the influence of the interfacial tension between the steel and the slag on the behavior of the meniscus in continuous casting mold of slab. The shape of the meniscus and phenomena near the meniscus were revealed, and the profile of the slag rim and the depth of the solidified meniscus and oscillation marks with different interfacial tension of the steel and slag were compared. With the increase in the interfacial tension, the size of the curved meniscus increased, while the curvature and the height of the local meniscus close to the mold decreased. Besides, the thickness of the slag rim, solid slag and total slag near the meniscus had the tendency to increase, and the bottom of the slag rim became lower and thicker. With the increase in the interfacial tension from 0.1 to 2.5 N/m, the location of the largest heat flux near the meniscus decreased from 10.0 to 2.5 mm above the initial level of the steel, and the largest heat flux was within 3.52–4.58 MW/m
2
. Meanwhile, the largest depth of the solidified meniscus decreased from 3.3 to 2.3 mm, and the depth of oscillation marks decreased, which was conducive to the shallow hook at the subsurface of the slab, and the improvement of surface cleanliness of the slab.
2023 Vol. 30 (03): 465-474 [
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475
Joong-Ki Hwang
Strain hardening rate dependency of deformation shape, strain distribution, and contact pressure during wire flat rolling
The effect of the strain hardening exponent (
n
) of a material on the changes in shape, strain inhomogeneity, and contact pressure was investigated during wire flat rolling to understand its effect on the deformation behavior of a flat-rolled wire and to determine the optimal working conditions with materials. The deformation behaviors of wires with various n values were systematically compared using finite element method. The shape of the deformed wire was found to depend on the n value of the material. Both the contact width and lateral spreading of the wire decrease with increasing n, resulting in a large reduction in area with the n value. The strain homogeneity of the wire increases with the n value of the wire. The improvement in the strain homogeneity with the n value is attributable to two factors: a lower strain concentration in the central region and a higher overall elongation as n increases. In addition, the average effective strain of the wire cross section decreases with the n value of a material during wire flat rolling. The contact pressure distribution on the surface of the wire differs significantly depending on the n value. In materials with a low n value, the contact pressure exhibits a higher value at the entry and edge zones of the contact surface. By contrast, materials with high n values exhibit a higher contact pressure at the exit zone. This behavior can be explained by the strain hardening behavior of the material during wire flat rolling.
2023 Vol. 30 (03): 475-486 [
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487
Wei Wang, Cheng Cheng, Li Wan, Jie Tao, Xun-zhong Guo, Chun-mei Liu
Effect of die structure parameters on deformation behavior of bent tube in free bending process
The bending section of tube between the bending die and the guider is in a less constrained state during the free bending process. The free bending dies have the important impact on the plastic deformation behavior and the forming quality of tube. To study the evolution law of the deformation behavior of tube with the die structure parameters and optimize the free bending die parameters, the free bending experiments and the corresponding numerical simulations were carried out. The design principle of free bending die was illustrated. The free bending experiment was conducted to verify the reliability of the numerical simulation method. Based on the numerical simulation results, the influence of the distance between the center point of bending die and the front end of guider on the forming quality of bent tube is more obvious than that of the fillet of guider. However, the fillet of bending die hardly affects the stress and strain distribution and the evolution of the wall thickness. Finally, the free bending experiments with the newly determined free bending dies were conducted. The ultimate bending radius of bent tube is reduced and the forming quality is improved.
2023 Vol. 30 (03): 487-503 [
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504
Fei-fei Li, An-rui He, Yong Song, Xiao-qing Xu, Shi-wei Zhang, Yi Qiang, Chao Liu
MDA-JITL model for on-line mechanical property prediction
Mechanical performance prediction is the key to the transformation and upgrading of steel enterprises to intelligent manufacturing. Due to time-varying manufacturing data, the traditional prediction model of mechanical properties of hotrolled strip may cause performance degradation or even failure in its use. An MDA-JITL model was thus proposed to handle the modeling problem of complex time-varying data. Relevant parameters were first chosen and normalized. Then, a distance measurement method combining the importance of data attributes and time characteristics was designed to select the most suitable samples for on-line local modeling. After that, using the chosen dataset, a linear local model was created to predict target sample. Finally, an uncertainty evaluation method was designed to evaluate the uncertainty of prediction results. Furthermore, the appropriate dataset partition and off-line simulation experiment scheme were created based on the peculiarities of hot-rolling production. The suggested model performs much better than the classic global model when applied to actual production data from a steel plant. The stability of its prediction accuracy is demonstrated in a simulation prediction for up to five months. Moreover, there is a high link between the uncertainty evaluation metrics and the prediction error of the model, reducing the field sampling rate by 30% in industrial applications in the latest year.
2023 Vol. 30 (03): 504-515 [
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516
Cheng Yuan, Yu Liu, Guang-qiang Li, Yong-shun Zou, Ao Huang
Interaction between microporous magnesia castable and 38CrMoAl steel
The microporous magnesia refractory shows a promising application prospect as tundish lining due to excellent thermal insulation and slag resistance. The effect of interaction between microporous magnesia castable and 38CrMoAl steel containing 0.876 wt.% Al on the cleanliness of 38CrMoAl steel was studied and compared with that of fused magnesia castable. The results show that the micropores in the microporous magnesia castable can promote the formation of dense and continuous MgO-Al
2
O
3
layer, which can inhibit the further pollution of molten steel by refractories, whereas the MgO-Al
2
O
3
layer formed in test of fused magnesia castable is not continuous. After 30 min holding, the total oxygen content in the steel samples for the test of microporous magnesia castable is only 42.2% of that for the test of fused magnesia castable. The inclusions in the steel samples for the test of microporous magnesia castable are also less than those for the test of fused magnesia castable. It shows that microporous magnesia castable is a promising tundish refractory for the preparation of clean high-Al steel.
2023 Vol. 30 (03): 516-524 [
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525
Jun-yu Liu, Cheng-song Liu, Rui-juan Bai, Wei Wang, Qing-bo Wang, Hua Zhang, Hong-wei Ni
Morphological transformation of elongated MnS inclusions in non-quenched and tempered steel during isothermal heating
Elongated MnS inclusions in rolled non-quenched and tempered steel tend to cause the mechanical anisotropy of steel, deteriorate the mechanical properties and degrade the quality and service life of the steel products. To reveal the mechanisms of morphological transformation of strip-shaped MnS inclusions during isothermal heating, the effects of heat treatment time and temperature on the morphology, number density and size distribution of elongated MnS inclusions were systematically studied and discussed. A diffusion couple experiment was also conducted to clarify the diffusion mode of MnS inclusions. The experimental results showed that with the increase in isothermal heating time (from 0 to 10 h at 1473 K) and temperature (from 1173 to 1573 K for 3.0 h), the number density and average aspect ratio of MnS inclusions generally showed an increase and decrease trend, respectively, while the area fraction remained stable and only slightly fluctuated around 0.4%. In the diffusion couple, after the isothermal heating at 1473 K for 3.0 h, the elements Mn and S in the steel near the steel–MnS interface were very stable without any concentration gradient. The morphology change sequence of the elongated MnS inclusions in the rolled non-quenched and tempered steel during the isothermal heating was strip→cylinderization → spindle → spheroidization. Relationship between the diameter of MnS inclusion and the spacing between two MnS inclusions after splitting, and the fitting goodness of different n values under different experimental time and temperature confirmed that the driving force for the transformation of MnS inclusions during the isothermal heating was surface diffusion, instead of volume diffusion.
2023 Vol. 30 (03): 525-536 [
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537
Min Qi, Hong-yan Wu, Ying Dong, Lin-xiu Du
On hot deformation behavior and workability characteristic of 42CrMo4 steel based on microstructure and processing map
In order to determine the safe region of 42CrMo4 steel during hot working and obtain excellent workability, the hot deformation behavior at the temperatures of 850–1150 °C and the strain rates of 0.01–10 s
-1
was investigated through single-pass compression test of thermo-simulation. Through observing and analyzing the true stress–strain curves, the conclusion may be drawn that the flow stress value increases with the decrease in deformation temperature and the increase in strain rate. Raising temperature and reducing strain rate are conductive to dynamic recrystallization (DRX) nucleating and growing, but adiabatic heating caused by higher strain rate can also promote it. Since the Zener–Hollomon (
Z
) value and dynamic recrystallized grain size (DDRX) have completely opposite trends with deformation condition parameters, the expression of Z value and DDRX can be determined as:
. The processing map and instability map constructed at a strain of 0.9 show that the suitable window for hot working with a true strain of 0.9 is in the temperature range of 970–1150 °C and strain rate range of 0.01–0.25 s
-1
, as well as at the temperature of 1150 °C and strain rate range of 0.25–10 s
-1
. The instability phenomenon appears in the process interval of 850–1096 C and 0.22–10 s
-1
.
2023 Vol. 30 (03): 537-547 [
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548
Xue-kui Lian, Yong Li, Yi Xiong, Yong-li Wu, Shun Han, Tian-tian He, Chun-xu Wang, Feng-zhang Ren
Effect of annealing time on microstructure and mechanical properties of cryorolled AISI 310S stainless steel
AISI 310S stable austenitic stainless steel was subjected to 90% cryorolling and then annealed at 800 C for 2–60 min. The effect of annealing time on the microstructure and mechanical properties was studied by optical microscopy, scanning electron microscopy, transmission electron microscopy, microhardness and tensile test. The results show that the grain size of AISI 310S stainless steel is refined to the nanometer level after 90% cryorolling, and the grain size is approximately 20 nm. With the increase in annealing time, the degree of grain recrystallization occurs more fully and completely, as the grain begins to grow and then tends to stabilize. The strength and hardness of the annealed specimens decrease with increasing annealing time, while elongation tends to increase. When the annealing time is 10 min, the yield strength increases by about 2 times compared to that of the original austenite (unrolled), and the elongation is also above 20%, which is the best preparation process for ultra-fine grain austenitic stainless steel under this experimental condition. As the annealing time treatment increases, the fracture morphology changes from mixed quasi-cleavage and ductile fracture (after cryorolling) to ductile fracture (after annealing).
2023 Vol. 30 (03): 548-556 [
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557
Ji-xin Hou, Fu-lin Zhang, Zhi-xin Xia, Yun-he Yu, Hai-ying Fu, Shu-hai Huang, Qian An, Chi Zhang
Unsteady state precipitation of M23C6 carbides during thermal cycling in reduced activation steel manufactured by laser melting deposition
The temperature field distribution and thermal history of Fe-9Cr2WVTa reduced activation steel prepared by laser melting deposition (LMD) have been calculated with Gaussian and Ring laser beams, and the nucleation and growth behaviors of M23C6 precipitates in the 1st, 7th and 19th layers have been calculated using the modified classical nucleation theory and Svoboda Fischer Fratzl Kozeschnik model. The energy distribution shows W-shape with Ring laser beam while it shows V-shape with Gaussian laser beam, which results in the more uniform M23C6 size in the same layer with Ring laser beam. Precipitates in the bottom (i.e., the 1st layer) have the minimum size and the size increases with the layer number with Gaussian and Ring laser beams. The temperature history, the instantaneous nucleation rate and the size evolution of M23C6 have been systematically discussed. The results indicate that the nucleation, growth and re-dissolution of precipitates in reduced activation steel depend on the amount of energy absorbed in the thermal cycle during LMD. The continuous accumulation of energy during the thermal cycle leads to larger M23C6 at the top area. The unsteady state precipitation dynamics of M23C6 carbides during thermal cycling are consistent with the simulation results.
2023 Vol. 30 (03): 557-568 [
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569
Ming Zhong, Lei Jiang, Hang-yu Bai, Somnath Basu, Zhan-jun Wang, Cong Wang
Simulating molten pool features of shipbuilding steel subjected to submerged arc welding
Submerged arc welding process has been simulated to investigate the molten pool features of EH36 shipbuilding steel. One case only involved the surface tension model, and another one involved both the surface tension model and the interface tension model. The role of interface tension during welding is revealed, and the evolution of molten pool morphology is understood by comparing the surface temperature distribution, surface tension and interface tension distribution, and the streamline of the molten pool for the two cases. When the interface tension model is disregarded, a flow conducive to the outward expansion is formed in the surface area of the molten pool, resulting in a small weld depth-to-width ratio. After applying the interface tension model, the expanding outward flow is restrained, which leads to a deep penetration morphology with a large weld depth-to-width ratio due to the inward flow governed by the Marangoni forces. The simulation results involving the interface tension model have been verified with satisfactory predictability.
2023 Vol. 30 (03): 569-579 [
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580
Zhi-wei Lian, Tian-en Peng, Shuang Hu, Bo He, Xue-wen Hu, Tao Zhu, Bo Jiang
Insight on corrosion behavior of a Cu–P–Cr–Ni steel with different Ni contents by electrochemical and periodic immersion corrosion experiments
Corrosion behavior of Cu–P–Cr–Ni weathering steels with different nickel contents was studied by periodic immersion corrosion test for 72 h. The mass loss method was used to evaluate the weatherability of weathering steel. The rust layers formed on weathering steel were characterized by scanning electron microscopy, X-ray diffraction, electron probe microanalysis, X-ray photoelectron spectroscopy, and electrochemical measurements. The results of periodic immersion corrosion test for 72 h showed that the mass loss rates of Cu–P–Cr–0.14Ni steel and Cu–P–Cr–0.04Ni steel were 1.57 and 1.61 g/(m
2
h), respectively. According to the electrochemical experiment, the corrosion potentials of the two tested steels at the initial stage of corrosion were - 0.6852 and - 0.7037 V, respectively. With the corrosion time reaching 72 h, the corrosion potential difference between the two tested steels was gradually reduced. In the initial stage, NiO was formed in the rust layer and can dramatically promote the crystallization of corrosion products to improve the stability of the rust layer. After periodic immersion corrosion test for 72 h, Ni element had no obvious effect. At this time, it was mainly the enrichment of Cu and Cr elements in the form of CuO and Cr2O3 in the rust layer that could further protect the matrix.
2023 Vol. 30 (03): 580-590 [
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591
Rong Zhu, Mai Wang, Zhen-li Mi, Qi Zhang, Xiao-yu Yang, Yong-gang Yang, Yan-xin Wu
Effects of nano-ceramic additives on high-temperature mechanical properties and corrosion behavior of 310S austenitic stainless steel
A novel approach to reduce Ni content for the 310S austenitic stainless steel was proposed. The nano-ceramic additive (L) was applied to 310S steel to replace part of Ni element and reduce the cost. By means of thermal simulation, X-ray diffraction, field emission scanning electron microscopy, and electron backscattered diffraction, the effects of nanoceramic additives on high-temperature mechanical properties and corrosion behavior of the 310S steel were studied. The results indicate that the morphology and density of the (Fe, Cr)
23
C
6
carbides are varied, which play an important role in the high-temperature mechanical properties and corrosion behavior. After adding nano-ceramic additives, the high-temperature tensile strength and yield strength are improved simultaneously, in spite of a slight decrease in the total elongation. During high-temperature corrosion process, the mass gain of all the samples is parabolic with time. The mass gain is increased in the 310S steel with nano-ceramic additive, while the substrate thickness is significantly larger than 310S steel. The more stable and adherent FeCr
2
O
4
spinel form is the reason why the high-temperature corrosion resistance was increased. The (Fe, Cr)
23
C
6
carbides distribution along grain boundaries is detrimental to the high-temperature corrosion resistance.
2023 Vol. 30 (03): 591-600 [
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601
Rui Wang, Dao-hong Wang, Peng Zhang, Zhi-qing Yang, Jing-jing Liang, Jin-guo Li
Effect of boron addition on microstructure and mechanical properties of an additively manufactured superalloy
The effect of boron addition (0.010, 0.015, and 0.020 wt.%) on the microstructure and mechanical properties of an additively manufactured superalloy was examined. The as-built microstructure was investigated by scanning electron microscopy and transmission electron microscopy. The results demonstrate that boron precipitates as M3B2 boride at the grain boundary. The increase in boron content increases the amount of c/c0 eutectic and the size and fraction of M3B2 boride. Boron creates nanoscale fine borides at grain boundaries, which significantly reinforces grain boundaries. The mechanical property analysis indicated that the addition of boron improved the tensile ductility at 760 C and stress rupture properties at 760 C/780 MPa. However, with the excessive addition of boron, the mechanical property was reduced.
2023 Vol. 30 (03): 601-609 [
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