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Casting Powders Book 1st ed. 2017 [Hardback]

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  • Formāts: Hardback, 535 pages, height x width: 235x155 mm, 151 Illustrations, color; 171 Illustrations, black and white; XIX, 535 p. 322 illus., 151 illus. in color., 1 Hardback
  • Izdošanas datums: 29-Oct-2018
  • Izdevniecība: Springer International Publishing AG
  • ISBN-10: 3319536141
  • ISBN-13: 9783319536149
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Casting Powders Book 1st ed. 2017Palielināt
  • Formāts: Hardback, 535 pages, height x width: 235x155 mm, 151 Illustrations, color; 171 Illustrations, black and white; XIX, 535 p. 322 illus., 151 illus. in color., 1 Hardback
  • Izdošanas datums: 29-Oct-2018
  • Izdevniecība: Springer International Publishing AG
  • ISBN-10: 3319536141
  • ISBN-13: 9783319536149
Citas grāmatas par šo tēmu:
Permanent link: https://www.kriso.lv/db/9783319536149.html
Keywords:
This book deals with casting powders and explains how they work and how they are best used to minimise defects in the ninety per-cent of world steel production that is continuously cast. The factors affecting various aspects of powder performance are described and different defects, their causes, and means of avoiding them are considered.Providing the first comprehensive coverage of mould powder properties and uses, the text treats theoretical and practical matters and gives direct advice on problem solving. Drawing on a wealth of scientific and technological research, represented by its extensive references, The Casting Powders Book shows readers how they can design and create mould powders optimised to fulfill the necessary functions of:lubrication of steel shells and reduction of shell-mould friction;absorption of inclusions floating up from the steel;chemical insulation of steel from carbon-rich mould powder;and protection of the steel meniscus from oxidation and therma

l insulation to prevent surface freezing. Thermophysical properties and heat-transfer processes are also given detailed attention and case studies illustrate the methods and materials described.The Casting Powders Book is designed to be a periodic reference that can be dipped into as the need arises. Readers from different backgrounds are well-served by the depth and variety of content:engineers trouble-shooting a continuous-casting process interested in how mould fluxes can minimise defects and process problems and how their performance is in turn affected by casting parameters;academic scientists interested in the the theoretical aspects and properties of mould fluxes and slag films; orengineers working with ingot casting processes; and many others will find this book an invaluable resource.

1. Introduction and Overview.- 2. Slag Infiltration, Lubrication and Frictional Forces.- 3. Heat Transfer in the Mould and Shell Solidification.- 4. How to Manipulate Slag Behaviour in the Mould.- 5. Effect of Casting Variables on Mould Flux Performance.- 6. Different Types of Mould Powders.- 7. Fluxes for Ingot Casting.- 8. Manufacture of Mould Fluxes.- 9. Properties of Mould Fluxes and Slag Films.- 10. Selection of Mould Fluxes and Special Mould Fluxes for Continuous Casting.- 11. Using Mould Fluxes to Minimise Defects and Process Problems.
1 Introduction and Overview
1(18)
1.1 Introduction
2(1)
1.2 The Continuous Casting Process for Steel
2(2)
1.3 The Introduction of Casting Powders
4(2)
1.4 Mould Powder Behaviour in the Mould
6(1)
1.5 Slag Film and Slag Rim Characteristics
7(3)
1.5.1 Slag Film
7(2)
1.5.2 Slag Rim
9(1)
1.6 Casting Conditions
10(3)
1.6.1 Casting Speed (Vc)
10(1)
1.6.2 Metal Flow
11(1)
1.6.3 Mould Dimensions
12(1)
1.6.4 Oscillation Characteristics
12(1)
1.6.5 Steel Grade
12(1)
1.6.6 Ar Flow Rate
13(1)
1.7 Physical Properties of Mould Slags
13(1)
1.8 Fluctuations in the Process
14(1)
1.9 Definitions
14(2)
1.9.1 Powders, Slags, Fluxes
14(1)
1.9.2 Powder Consumption Terms
14(1)
1.9.3 Temperature
15(1)
1.9.4 Viscosity
16(1)
References
16(3)
2 Slag Infiltration, Lubrication and Frictional Forces
19(40)
2.1 Introduction
20(1)
2.2 Powder Consumption (Q)
21(20)
2.2.1 Various Powder Consumption Terms
22(1)
2.2.2 Measurement of Powder Consumption
23(1)
2.2.3 Methods Used to Understand Slag Infiltration Mechanisms
23(7)
2.2.4 Problems Arising from Poor Powder Consumption
30(1)
2.2.5 Optimum Casting Conditions
30(2)
2.2.6 Factors Affecting Powder Consumption
32(9)
2.3 Slag Infiltration During the Oscillation Cycle
41(3)
2.4 Empirical Equations for Calculating Powder Consumption
44(10)
2.4.1 Frictional Forces
45(3)
2.4.2 Factors Affecting Frictional Forces in the Mould
48(6)
2.5 Summary
54(1)
References
55(4)
3 Heat Transfer in the Mould and Shell Solidification
59(50)
3.1 Introduction
60(3)
3.1.1 Heat Flux
62(1)
3.2 Horizontal Heat Flux
63(22)
3.2.1 Heat Transfer Mechanisms Involved in Horizontal Heat Transfer
63(2)
3.2.2 Interfacial Thermal Resistance (Rcu/si)
65(6)
3.2.3 Factors Affecting the Horizontal Heat Flux
71(9)
3.2.4 Measurement and Calculation of Heat Fluxes
80(5)
3.3 Shell Solidification and Growth
85(2)
3.4 Variability in Heat Flux
87(9)
3.4.1 Variations in Heat Flux (QHor) During the scillation Cycle
88(1)
3.4.2 Thermal Gradient Variations Arising from Metal Flow and Other Causes
88(3)
3.4.3 Mould Level Variations
91(1)
3.4.4 Carbon Content of Steel
92(2)
3.4.5 Thermal Gradients in the Mould
94(1)
3.4.6 Fracture of Slag Films
95(1)
3.5 Vertical Heat Flux
96(6)
3.5.1 Heat Transfer Mechanisms Involved in Vertical Heat Transfer
96(1)
3.5.2 Factors Affecting Vertical Heat Transfer
97(5)
3.6 Summary
102(1)
References
103(6)
4 How to Manipulate Slag Behaviour in the Mould
109(38)
4.1 Introduction
110(1)
4.2 Vertical Heat Flux and Thermal Insulation of Bed
111(5)
4.2.1 Vertical Heat Flux
111(3)
4.2.2 Thermal Insulation of the Bed
114(2)
4.2.3 Measurements of Thermal Insulation of Powders
116(1)
4.2.4 Ways of Improving the Thermal Insulation of the Bed
116(1)
4.3 Melting Rate of the Powder (mr)
116(4)
4.3.1 The Effect of Mould Powder Properties on Melting Rate
118(1)
4.3.2 The Effect of Casting Conditions on Melting Rate
119(1)
4.3.3 Ways of Increasing Melting Rate
119(1)
4.4 Depth of Molten Slag Pool
120(5)
4.4.1 Molten Slag Pool
120(2)
4.4.2 Importance of Depth of Molten Slag Pool
122(1)
4.4.3 Factors Affecting Slag Pool Depth
122(2)
4.4.4 The Effect of Casting Speed and Oscillation Characteristics
124(1)
4.4.5 The Effect of Thermal Insulation of Bed on Pool Depth
125(1)
4.4.6 Ways of Increasing the Melting Rate
125(1)
4.5 Powder Consumption (Q) and Liquid Film Thickness (d{)
125(6)
4.5.1 Reasons for Controlling Powder Consumption
126(1)
4.5.2 Factors Affecting Powder Consumption
127(4)
4.5.3 Ways of Controlling the Powder Consumption
131(1)
4.6 Solid Slag Film and Horizontal Heat Flux
131(4)
4.6.1 Reasons for Control of Slag Film Thickness and Horizontal Heat Flux
132(1)
4.6.2 Factors Affecting of Slag Film Thickness and Horizontal Heat Flux
132(3)
4.6.3 Measurement of Horizontal Heat Flux
135(1)
4.7 Crystallinity in Slag Film
135(4)
4.7.1 Importance of Crystallinity to the Casting Process
136(1)
4.7.2 Factors Affecting
137(2)
4.7.3 Ways of Increasing Crystallinity in Slag Film
139(1)
4.8 Delaying Solidification and Shortening the Length of Shell
139(3)
4.8.1 Factors Affecting Shell Length
140(1)
4.8.2 Ways of Controlling the Length of Meniscus/Shell
140(2)
4.9 Summary
142(1)
References
142(5)
5 Effect of Casting Variables on Mould Flux Performance
147(30)
5.1 Introduction
148(1)
5.2 Mould Characteristics
148(2)
5.2.1 Mould Dimensions
148(2)
5.2.2 Mould Length (Lmould)
150(1)
5.2.3 Mould Taper (Lmould)
150(1)
5.2.4 Mould Coatings
150(1)
5.3 Casting Speed (Vc)
150(3)
5.3.1 Effect of Casting Speed on Powder Consumption
151(1)
5.3.2 Effect of Casting Speed on Heat Transfer
151(1)
5.3.3 Effect of Casting Speed on Metal Row Turbulence
152(1)
5.3.4 Effect of Casting Speed on Negative Strip Time
152(1)
5.4 Oscillation Characteristics
153(3)
5.4.1 Effect of Oscillation Characteristics on Powder Consumption
154(1)
5.4.2 Effect of Oscillation Characteristics on Heat Flux
155(1)
5.4.3 Effect of Oscillation Characteristics on Oscillation Mark Depth (DOM)
156(1)
5.5 Mould-Level Control
156(2)
5.6 Metal How
158(2)
5.7 Fluctuations in Processes
160(2)
5.8 Application of Electromagnetic Devices
162(4)
5.8.1 Electromagnetic Stirring (EMS)
162(1)
5.8.2 Level Magnetic Field (LMF)
163(1)
5.8.3 Electromagnetic Casting (EMC)
164(1)
5.8.4 Electromagnetic Braking (EMBr)
165(1)
5.9 Steel Grade
166(5)
5.9.1 Peritectic Steels
166(4)
5.9.2 High-Al Steels
170(1)
5.10 Water Flow Rate
171(1)
5.11 Argon Flow Rate
172(1)
References
172(5)
6 Different Types of Mould Powders
177(46)
6.1 Introduction
178(8)
6.1.1 Functions Carried Out by Mould Powder
179(1)
6.1.2 Criteria Affecting Selection of Mould Powders
180(6)
6.2 Selection of Mould Fluxes
186(32)
6.2.1 Conventional Mould Powders
187(7)
6.2.2 Pre-melted Fluxes
194(1)
6.2.3 Starter Powders
195(1)
6.2.4 Exothermic Fluxes
196(2)
6.2.5 Fluoride-Free Powders
198(7)
6.2.6 Reduced F-Powders
205(1)
6.2.7 C-Free Powders
205(1)
6.2.8 Powders for High-Speed Casting and Thin Slab Casting
206(2)
6.2.9 Powders for Casting Round Billets
208(1)
6.2.10 Powders for Casting Beam Blanks
208(1)
6.2.11 Non-Newtonian Powders
209(1)
6.2.12 Powders for Casting TRIP and TWIP Steels
210(7)
6.2.13 Powders for Casting Stainless Steels
217(1)
6.2.14 Powders for Casting Steels with Rare Earths
218(1)
6.3 Summary
218(1)
References
219(4)
7 Fluxes for Ingot Casting
223(48)
7.1 The Ingot Casting Process
224(7)
7.1.1 Classification of Ingot Cast Steels
225(3)
7.1.2 Ingot Casting of Killed Steels
228(3)
7.2 Aspects of Importance for Ingot Casting Quality
231(14)
7.2.1 Surface Quality
231(9)
7.2.2 Inner Quality
240(2)
7.2.3 Macro Segregation (Hot Top Insulation)
242(3)
7.3 History of the Development of Mould Powders for Ingot Casting (and CC)
245(8)
7.3.1 Development of Mould Powders for Continuous Casting
250(1)
7.3.2 Development of Synthetic Mould Powders
251(1)
7.3.3 Development of Granulated Powders
252(1)
7.3.4 Today's Situation Regarding Mould Powders for Ingot Casting
253(1)
7.4 Selection of Mould Powders for Ingot Casting
253(9)
7.4.1 Important Properties of the Mould Powder
253(2)
7.4.2 Important Properties of the Mould Powder Slag
255(3)
7.4.3 Selection of Mould Powders in Regard to Steel Grade
258(4)
7.5 Application Techniques for Mould Powders
262(4)
7.6 Use of Mould Powders to Minimise Defects and Process Problems
266(2)
7.6.1 Laps and Ripple Marks
266(1)
7.6.2 Entrapped Oxides
266(1)
7.6.3 Slag Patches
267(1)
7.6.4 Porosity
267(1)
7.6.5 Cracks
268(1)
7.6.6 Bottom-End Defects
268(1)
References
268(3)
8 Manufacture of Mould Fluxes
271(14)
8.1 Introduction
271(1)
8.2 Raw Materials
272(4)
8.2.1 Selection of Carbon Additions to Mould Powders
274(1)
8.2.2 Reactions During Melting and Cooling of Mould Powders
275(1)
8.3 Manufacturing
276(4)
8.4 Quality Control at the Manufacturer
280(1)
8.5 Information Provided by the Manufacturer
280(2)
8.6 Delivery Control by the Steel Makers
282(1)
References
283(2)
9 Properties of Mould Fluxes and Slag Films
285(108)
9.1 Introduction
287(1)
9.2 Structure of Slags
287(12)
9.2.1 Effect of Individual Slag Components on Structure
287(5)
9.2.2 Parameters to Represent the Structure of Slags
292(3)
9.2.3 Effect of Cations
295(2)
9.2.4 Effect of Temperature on Properties
297(2)
9.3 Crystallisation in Mould Fluxes
299(16)
9.3.1 Importance of Crystallisation to the Process
299(1)
9.3.2 Crystalline Phases Formed in Slag Films
300(3)
9.3.3 Crystallisation Process
303(2)
9.3.4 Crystallisation Kinetics
305(3)
9.3.5 Effects of Crystallisation
308(2)
9.3.6 Methods of Determining Fraction of Crystalline Phase in Slag Films
310(3)
9.3.7 Tests to Simulate Formed in Slag Film
313(1)
9.3.8 Empirical Rules to Calculate the Crystal Fraction in Slag Films
313(1)
9.3.9 Data for fcrys
314(1)
9.4 Physical Properties of Mould Slags
315(45)
9.4.1 Thermodynamic Properties and Liquidus Temperatures (Tliq)
315(3)
9.4.2 Break Temperature (Tbr)
318(2)
9.4.3 Glass Transition Temperatures (Tg)
320(1)
9.4.4 Viscosities (η)
321(6)
9.4.5 Thermal Conductivities
327(14)
9.4.6 Interfacial Tension (γms1) and Surface Tension (γs)
341(9)
9.4.7 Density (ρ) and Thermal Expansion Coefficient (α)
350(4)
9.4.8 Heat Capacity (Cp) and Enthalpy (HT-H298)
354(6)
9.5 Optical Properties of Mould Slags
360(3)
9.5.1 Refractive Indices (n) [ 53, 55, 206, 278, 279]
361(1)
9.5.2 Absorption Coefficients (α) [ 53, 55, 56, 59, 110, 206, 211, 212, 280, 281]
361(1)
9.5.3 Reflectivity, Transmissivity and Emissivity
362(1)
9.6 Thermomechanical Properties of Mould Slags
363(1)
9.6.1 Thermomechanical Tests
363(1)
9.6.2 Stress Relaxation
364(1)
9.7 Dissolution of Oxides, Nitrides and Carbides in Mould Slags
364(8)
9.7.1 Origin of Inclusions
365(1)
9.7.2 Mechanism of Inclusion Removal
366(1)
9.7.3 Transport of Inclusions to the Slag/Metal Interface
366(3)
9.7.4 Transport Through Slag/Metal Interface
369(1)
9.7.5 Dissolution of Inclusions
370(2)
9.8 Other Tests Used on Mould Powders
372(4)
9.8.1 Bulk Density
372(1)
9.8.2 Flowability
373(1)
9.8.3 Permeability Index
374(1)
9.8.4 Thermal Insulation
374(2)
9.8.5 Measurement of Moisture and Hydrogen
376(1)
9.9 Comparison of Properties of Powders Used in Ingot--(IC) nd Continuous Casting (CC)
376(6)
9.9.1 Differences in Properties of Mould Powders Used in CC and IC
377(2)
9.9.2 Tasks Carried Out by Powders Used in Continuous- and Ingot Casting
379(1)
9.9.3 Properties and Characteristics of Powders Used in Continuous and Ingot Casting
379(1)
9.9.4 Conclusions from Comparison of CC and IC Mould Powders
379(3)
9.10 Summary
382(1)
References
383(10)
10 Selection of Mould Fluxes and Special Mould Fluxes for Continuous Casting
393(24)
10.1 Introduction
394(1)
10.2 Selection of Mineral Compositions of Mould Powder for Given Casting Conditions
395(10)
10.2.1 Effect of Mould Geometry on Mould Powder Selection
396(2)
10.2.2 Effect of Casting Conditions on Mould Powder Selection
398(1)
10.2.3 Effect of Steel Grade on Mould Powder Selection
399(1)
10.2.4 Routines to Differentiate Between Steel Grades
400(3)
10.2.5 Plots of Tbr as a Function of Slag Viscosity
403(1)
10.2.6 Other Casting Conditions Affecting Powder Consumption
404(1)
10.3 Selection of Carbon Components of Mould Powders
405(1)
10.4 Mould Powder Selection for Special Conditions
406(7)
10.4.1 Thin-Slab Casting
408(1)
10.4.2 Round Billets
409(1)
10.4.3 Mould Powder Selection for Moulds with Large "Corner" Regions
409(1)
10.4.4 Casting High-Al (Trip, Twip) Steel Grades
410(1)
10.4.5 Fluoride-Free Powders
411(1)
10.4.6 Reducing SEN Erosion Rates
412(1)
10.4.7 Minimising Carbon Pick-up
412(1)
10.4.8 Minimising Scale Formation
413(1)
10.5 Summary
413(1)
References
414(3)
11 Using Mould Fluxes to Minimise Defects and Process Problems
417(1)
11.1 Introduction
418(1)
11.2 Longitudinal Cracking
418(12)
11.2.1 Type of Steel
419(2)
11.2.2 Heat Flux
421(3)
11.2.3 Lubrication and Powder Consumption
424(1)
11.2.4 Metal Flow, Use of EMBr, EMC and EMS
425(1)
11.2.5 Causes and Mechanisms
426(2)
11.2.6 Ways of Dealing with Longitudinal Cracking
428(2)
11.3 Longitudinal Corner Cracking
430(4)
11.3.1 Published Information
430(1)
11.3.2 Causes, Mechanisms
430(3)
11.3.3 Ways of Dealing with Longitudinal Comer Cracking
433(1)
11.4 Sticker Breakouts
434(12)
11.4.1 Factors Affecting Sticker Breakouts
435(7)
11.4.2 Causes, Mechanisms
442(1)
11.4.3 Ways of Dealing with Sticker Breakout
443(3)
11.5 Oscillation Marks (OM's)
446(15)
11.5.1 Characteristics of Oscillation Marks
446(2)
11.5.2 Mould Oscillation
448(1)
11.5.3 Factors Affecting Depth of OM's (DOM)
449(7)
11.5.4 Causes, Mechanisms
456(3)
11.5.5 Ways of Dealing with Deep OMs
459(2)
11.6 Transverse and Comer Cracking
461(8)
11.6.1 Factors Affecting Transverse Cracking
463(4)
11.6.2 Ways of Dealing with Transverse and Comer Cracking
467(2)
11.7 Star Cracking
469(2)
11.7.1 Factors Affecting Star Cracking
469(2)
11.7.2 Ways of Dealing with Star Cracking
471(1)
11.8 Depressions
471(8)
11.8.1 Longitudinal Depressions
471(5)
11.8.2 Transverse Depressions
476(1)
11.8.3 Off-Comer Depressions
477(2)
11.9 Overflows
479(1)
11.9.1 Factors Affecting Overflows
479(1)
11.9.2 Causes, Mechanisms
480(1)
11.9.3 Ways of Dealing with C-Type Effects
480(1)
11.10 Slag, Gas Entrapment and Sliver Formation
480(31)
11.10.1 Metal Flow Conditions Leading to Entrapment
481(12)
11.10.2 Slag Entrapment
493(7)
11.10.3 Gas Entrapment
500(6)
11.10.4 Inclusion Capture, Sliver Formation
506(5)
11.11 Formation of Scales
511(4)
11.11.1 Factors Affecting Scale Formation
512(2)
11.11.2 Causes, Mechanisms
514(1)
11.11.3 Ways of Dealing with Scaling
514(1)
11.12 Carbon Pick-up
515(3)
11.12.1 Factors Affecting Carbon Pick-up
515(1)
11.12.2 Causes, Mechanisms
516(1)
11.12.3 Ways of Dealing with Carbon Pick-up
517(1)
11.13 SEN Erosion
518(6)
11.13.1 Factors Affecting SEN Erosion Rates
520(1)
11.13.2 Causes, Mechanisms
521(1)
11.13.3 Ways of Dealing with SEN Erosion
522(2)
11.14 Fluorine Emissions
524(1)
11.14.1 Factors Affecting Fluoride Emissions
524(1)
11.14.2 Ways of Dealing with Fluoride Emissions
525(1)
11.15 Summary
525(2)
References
527
Correction to: The Casting Powders Book 1
Ken Mills worked at the National Physical Laboratory, Teddington from 1963-1999 and has been in the Department of Materials, Imperial College from 1995-present.  His primary interest at NPL was in the measurement of the physical properties of materials involved in high temperature processes (metals, slags and refractories). He has been working on mould powders for continuous casting for more than 35 years and formed the UK Working Group on Casting Powders and was a member of the Europ. Coal & Steel Committee on Theoretical Steelmaking for  more than 10years. During his time at NPL he became interested in the factors affecting the continuous casting process and the mechanisms responsible for process problems and defects. His interest in this area has led to the awards of the Bessemer Gold Medal (2013) and Honorary Membership of the Iron and Steel Institute of Japan (2003). At Imperial College he lectured in Process Metallurgy and in Heat and Fluid flow.  His research at ImperialCollege has been largely focused on continuous casting with research on i. the properties and performance of continuous casting slags  ii.  mathematical modelling of the process. However, other steelmaking related projects were also carried out. In recent years he has revived his interest in the estimation of physical models of slags and metals (for use in the macro model) from their chemical composition. He has published three books, more than 200 journal papers and has contributed in chapters to several books. He is the most cited author in this field of mould powders. Carl-Åke Däcker, now working as Senior Scientific Advisor previously being Manager of the Materials& Process Development Department at Swerea KIMAB. In his work at the Institute he has dedicated most of his own research on mould powder development in close co-operation with the Swedish steelmakers and published around 10 conference papers in this field. In 2012 he was awarded Professor Hasse Fredriksson award for many years research of mould powder properties and its effect on continuous cast blanks surface quality. Before joining the Institute he worked 24 years with research, in the Swedish industry. 12 years at the Metallurgical Department at SSAB in Oxelösund where casting was an important issue, 7 years at Rockwool AB where he worked with raw-materials and melting of Rockwool glass.