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In the process of producing 1Cr13 stainless steel， serious longitudinal cracks breakout and transverse dents appear in the casting billet. FactSage8.2 thermodynamic software was used to calculate ternary and quadruple phase diagrams to design the ingredient of the protective slag. At the same time， the solidification characteristics of 1Cr13 stainless steel were calculated. As this steel is a peritectic steel， it will produce a sharp volume contraction during the solidification process， resulting in longitudinal cracks in the weak part of the blank shell. In order to avoid the dents and longitudinal crack caused by the uneven raw shell， the basicity of the protective slag should be improved， the crystallization property of the protective slag should be improved， and the heat transfer control ability of the protective slag should be improved too.The basicity of the new protective slag is 1.5， the slag is 6%MgO， 2%Li2O， 16%Al2O3， 8%Na2O， 3%B2O3， 10%CaF2. The melting point of the original slag of 1Cr13 stainless steel is 1155 ℃， the constant temperature viscosity is 0.442 Pa·s， and the transition temperature is 1140 ℃. The melting point of the new protective slag is 1120 ℃， the viscosity is 0.304 Pa·s， the transition temperature is 1171 ℃， and the crystallization temperature is 1270 ℃. After actual production， the surface quality of the casting billet is obviously improved.

The effect of rare earth Y on precipitates and textures of the grain-oriented silicon steels, the composition, morphology, size, quantity of inclusions and texture evolution of hot-rolled and cold-rolled oriented silicon steel containing rare earth Y were studied using transmission electron microscopy, field emission scanning electron microscope, and electron backscatter diffraction. The results show that there are mainly spherical or ellipsoidal Y2O2S precipitates in the Y bearing silicon steel. Rare earth treatment effectively improves the precipitates’ morphology and restrains the precipitation of the long-strip MnS in the hot-rolled plate. Meanwhile, the microstructure is more uniform, and the recrystallized grains on the surface and the fiber structure in the central layer are larger after hot rolling compared with Y-free steel. Furthermore, with the addition of rare earth Y, the unfavorable brass texture and rotational cube texture in the hot-rolled plate are reduced. Meanwhile, the number of shear bands is increased and the strength of the favorable {111} 〈112〉 texture is improved in the cold-rolled plate, which helps develop the Goss texture during the annealing process.

In order to study the effect of cold-rolling deformation and rare earth Y on the microstructure and texture of 3.0% Si-oriented silicon steel, the microstructure and texture of cold-rolled oriented silicon steel with 60, 72, and 86% deformation are analyzed using electron backscatter diffraction and image analysis software. The experimental results show that the deformation band becomes narrower and the distribution of shear bands becomes denser with increasing cold-rolling deformation. Compared to the Y-free steel, cold-rolled sheet containing rare earth Y has greater shear bands. The pinning effect of rare earth Y hinders the dislocation movement, which leads to the increase of kernel average misorientation value and shear bands. With the increase of cold-rolling deformation, the texture concentrates on α and λ. This is mainly due to the change from {100} 〈001〉 to {001} 〈110〉, intensifying λ texture, and the change from {111} 〈112〉 to {111} 〈110〉, thus strengthening the α texture. The texture strength of cold-rolled sheets can be decreased by rare earth Y. But the γ texture strength in cold-rolled sheets containing Y is significantly higher than in those without Y. The γ texture strength can reach up to 7.3, and the strong points are mainly {111} 〈112〉. This is because the number of inclusions in steel increases with the addition of rare earth Y. In the process of grain nucleation, the {111} oriented grains nucleate heterogeneously on the inclusions. It forms a large number of {111} oriented grains and improves the γ texture strength.

Shrinkage porosity is a typical internal defect in the continuous casting billet, which occurs frequently and is difficult to solve. To explore the influence factors of central shrinkage porosity, a novel unsteady thermomechanical coupling analysis algorithm is developed based on the billet solidification characteristics, and the central shrinkage behavior during the ending solidification process is simulated. Results show that when the casting speed increases from 1.6 to 2.8 m·min−1 and the center outward displacement is reduced from 9.20 × 10−2 mm to 5.8 × 10−2 mm, it means casting speed has a significant effect on the formation of shrinkage porosity, and for this caster, the higher casting speed is more suitable for the secondary cooling zone. Without the changes in the solidification structure, when the superheat degree of molten steel increases from 10 to 40°C, the center outward displacement value decreases from 7.12 × 10−2 mm to 6.91 × 10−2 mm. In that case, the superheat degree has no obvious effect on the center displacement value.

In this article, physical and numerical simulation of the flow field in flexible thin slab caster funnel mold at high casting speed is carried out with a five-hole submerged entry nozzle (FHSEN), and characteristics of the flow field on funnel mold liquid level under different casting speeds (4, 5, and 6 m·min−1) and different submerged depths (130, 160, and 190 mm) are studied by comparing with the new submerged entry nozzle (NSEN) designed. Physical simulation is based on the funnel mold prototype. Numerical simulation is carried out based on FLUENT software, and industrial experiments of two kinds of submerged entry nozzle are also carried out. The results show that in the case of both physical and numerical simulation, the maximum surface velocity of the FHSEN funnel mold is 0.58 m·s−1, and the funnel mold liquid level is prone to slag entrapment. The NSEN funnel mold’ maximum surface velocity is 0.37 m·s−1. Compared with the FHSEN, the NSEN funnel mold’ maximum surface velocity decreases by 0.21 m·s−1, and funnel mold surface velocity decreases significantly. Finally, the accuracy of simulation results is verified by industrial tests, and it is also show that NSEN can greatly reduce funnel mold surface velocity and probability of slag entrapment.

The growth rate of the shell thickness in the funnel mold for ultrahigh-speed continuous casting of steel has a significant effect on the shell surface quality. By using the node temperature inheritance algorithm, a three-dimensional transient thermal conductivity model of the liquid steel solidification inside the mold was established, and the effects of casting temperature and speed on the heat transfer behavior of the thin slab were investigated. The results show that with an increase in the casting speed from 4.0 to 6.0 m·min−1, the maximum thickness of the shell at mold exit was reduced from 26 to 12.8 mm, and the maximum temperature of the slab surface at mold exit increased from 1,210 to 1,305°C. However, the increase of casting temperature from 1,550 to 1,560°C had little effect on the surface temperature and thickness of the slab shell.

The hot tensile tests were conducted in this study to investigate the effects of Nb, B, Mo, and V on hot ductility of 25CrMo alloy steel in a temperature range of 650–850°C with strain rates of 0.005 and 0.5 s−1. Besides, the influences of ferrite transformation and precipitates on hot ductility were also investigated by the use of SEM and TEM. Thermo-Calc and J Mat Pro were used for calculating equilibrium precipitates and CCT curves, respectively. The results indicated that the hot ductility is deteriorated with the addition of 0.04% Nb due to Nb(C,N) particles and ferrite transformation. The addition of B inhibits ferrite transformation and improves hot ductility. The hot ductility is improved with increasing strain rate from 0.005 to 0.5 s−1 due to the nucleation and growth behavior of ferrite. The fast strain rate promotes nucleation of ferrite; however, the ferrite has no sufficient time to grow up. The addition of Mo inhibits ferrite transformation and improves hot ductility. The addition of 0.12% V has no obvious effect on ferrite transformation. The hot ductility has deteriorated a little with the addition of 0.12% V due to the solution V that increases stress during hot deformation.

Research on intragranular acicular ferrite inclusions has demonstrated that high-melting-point oxide MgAl2O4 cores and composite inclusions precipitated by Ti2O3 adhesion can be used as effective nucleation particles in oxide metallurgy. However, the microscopic mechanism underlying this adsorption behavior remains unclear. Hence, in this study, the adsorption and polymerization mechanisms of Ti2O3 on the MgAl2O4(100)Mg- and MgAl2O4(111)O3(Mg)-terminal surfaces in steel were studied using first-principles calculations based on density functional theory. The calculation based on the first principles of DFT and performed by the CASTEP code under plane wave basis set. The exchange correlation energy and correlation effects were described by generalized gradient approximation (GGA) using the Perdew–Burke–Ernzerhof (PBE) function. Spin polarization was considered in all calculation. Ultrasoft pseudopotentials (USPP) was employed to describe the electron-ion interactions. The energy cutoff for the plane wave basis was set at 620 eV in the current work. For the Brillouin zone sampling, we carried out 3 × 3 × 3 k-points mesh for MgAl2O4 bulk using the method of Monkhorst-Pack. A vacuum layer of 20.0 Å is added above the top surface of MgAl2O4 to eliminate the interaction of the normal periodic repetition of the surfaces. In all the surface calculations, the use of symmetry in bulk crystal was failed and k-point grids is set to 3 × 3 × 1. The results of this study revealed that when the most stable adsorption positions of Ti2O3 on the surface of MgAl2O4(100)Mg- and MgAl2O4(111)O3(Mg)-terminal are located at TAl and FMg, the adsorption energy is the highest and the most stable. The most stable adsorption configurations are located on vertical and parallel (P1) surfaces. Through comparative analysis, the best surface for Ti2O3 adsorption was found to be the MgAl2O4(111)O3(Mg)-terminal surface, and the adsorption behavior mainly occurred on the first layer of atoms on the surface. The best adsorption configuration was P1, and the best adsorption mode occurred when Ti2O3 formed three rings connected in pairs with the surface and embedded in the surface of the MgAl2O4(111)O3(Mg)-terminal. This study provides insights into the adsorption polymerization mechanisms of MgAl2O4–Ti2O3 complex inclusions in steel that could facilitate the fabrication of novel low-melting-point oxides and sulfides. [ABSTRACT FROM AUTHOR]

Soft-contact of molten steel can be achieved by applying a high-frequency electromagnetic field above the mold of continuous casting, which can effectively eliminate surface defects and achieve billets with no cracks and no oscillation marks. It also has some influence on the mold flux. In this study, the effect of a high-frequency electromagnetic field (20 kHz) on a mold flux flow field was simulated using a finite element software, and the slag film was extracted using a slag film simulator. The effect of the high-frequency magnetic field on the microstructure of the mold flux was analyzed using X-ray diffraction, Raman spectroscopy, and mineral phase testing. The results show that the high-frequency electromagnetic field disrupts the orderly movement and increases the movement rate of the liquid flux. The precipitate phase of the slag film did not change, but the silicate dimer Q 1 decreased, the chain Q 2 increased, and the network degree was increased. The slag film structure changed from the original two-layer form of crystalline layer–glass layer into a three-layer form of crystal layer–glass layer–crystal, and the crystallization ratio increased by 35% on average. The grain-size melilite granularity was reduced from the original 0.12 to 0.005 mm.

Scrap steel serves as the primary alternative raw material to iron ore, exerting a significant impact on production costs for steel enterprises. With the annual growth in scrap resources, concerns regarding traditional manual inspection methods, including issues of fairness and safety, gain increasing prominence. Enhancing scrap inspection processes through digital technology is imperative. In response to these concerns, we developed CNIL-Net, a scrap-quality inspection network model based on object detection, and trained and validated it using images obtained during the scrap inspection process. Initially, we deployed a multi-camera integrated system at a steel plant for acquiring scrap images of diverse types, which were subsequently annotated and employed for constructing an enhanced scrap dataset. Then, we enhanced the YOLOv5 model to improve the detection of small-target scraps in inspection scenarios. This was achieved by adding a small-object detection layer (P2) and streamlining the model through the removal of detection layer P5, resulting in the development of a novel three-layer detection network structure termed the Improved Layer (IL) model. A Coordinate Attention mechanism was incorporated into the network to dynamically learn feature weights from various positions, thereby improving the discernment of scrap features. Substituting the traditional non-maximum suppression algorithm (NMS) with Soft-NMS enhanced detection accuracy in dense and overlapping scrap scenarios, thereby mitigating instances of missed detections. Finally, the model underwent training and validation utilizing the augmented dataset of scraps. Throughout this phase, assessments encompassed metrics like mAP, number of network layers, parameters, and inference duration. Experimental findings illustrate that the developed CNIL-Net scrap-quality inspection network model boosted the average precision across all categories from 88.8% to 96.5%. Compared to manual inspection, it demonstrates notable advantages in accuracy and detection speed, rendering it well suited for real-world deployment and addressing issues in scrap inspection like real-time processing and fairness. [ABSTRACT FROM AUTHOR]

Longitudinal crack defects are a frequent occurrence on the surface of thin slabs during the high-speed continuous casting process. Therefore, this study undertakes a detailed analysis of the solidification characteristics of hyper-peritectic steel thin slabs. By establishing a three-dimensional heat transfer numerical model of the thin slab, the formation mechanism of longitudinal cracks caused by uneven growth of the initial shell is determined. Based on the mechanism of longitudinal crack formation, by adjusting the performance parameters of the mold flux, the contradiction between the heat transfer control and lubrication improvement of the mold flux is fully coordinated, further reducing the incidence of longitudinal cracks on the surface of the casting thin slab. The results show that, using the optimized mold flux, the basicity increases from 1.60 to 1.68, the F- mass fraction increases from 10.67% to 11.22%, the Na2O mass fraction increases from 4.35% to 5.28%, the Li2O mass fraction increases from 0.68% to 0.75%, and the carbon mass fraction reduces from 10.86% to 10.47%. The crystallization performance and rheological properties of the mold flux significantly improve, reducing the heat transfer performance while ensuring the lubrication ability of the molten slag. After optimizing the mold flux, a surface detection system was used to statistically analyze the longitudinal cracks on the surface of the casting thin slab. The proportion of longitudinal cracks (crack length/steel coil length, where each coil produced is about 32 m long) on the surface of the thin slab decreases from 0.056% to 0.031%, and the surface quality of the thin slab significantly improves. [ABSTRACT FROM AUTHOR]

The materials charged into a converter comprise molten iron and scrap steel. Adjusting the ratio by increasing scrap steel and decreasing molten iron is a steelmaking raw material strategy designed specifically for China's unique circumstances, with the goal of lowering carbon emissions. To maintain the converter tapping temperature, scrap must be preheated to provide additional heat. Current scrap preheating predominantly utilizes horizontal tunnel furnaces, resulting in high energy consumption and low efficiency. To address these issues, a three-stage shaft furnace for scrap preheating was designed, and Fluent software was used to compare and study the preheating efficiency of the new three-stage furnace against the traditional horizontal furnace under various operational conditions. Initially, a three-dimensional transient multi-field coupling model was developed for two scrap preheating scenarios, examining the effects of both furnaces on scrap surface and core temperatures across varying preheating durations and gas velocities. Simulation results indicate that, under identical gas heat consumption conditions, scrap achieves markedly higher final temperatures in the shaft furnace compared to the horizontal furnace, with scrap surface and core temperatures increasing notably with extended preheating times and higher gas velocities, albeit with a gradual decrease in heating rate as the scrap temperature rises. At a gas velocity of 9 m/s and a preheating time of 600 s, the shaft furnace achieves the highest waste heat utilization rate for scrap, with scrap averaging 325 °C higher than in the horizontal furnace, absorbing an additional 202 MJ of heat per ton. In the horizontal preheating furnace, scrap steel exhibits a heat absorption efficiency of 35%, whereas in the vertical furnace, this efficiency increases notably to 63%. In the vertical furnace, the waste heat recovery rate of scrap steel reaches 57%. [ABSTRACT FROM AUTHOR]

A beam blank is ideal for H-beam production, but there are more defects in/on beam blanks than other common blanks. The study of the H-beam blank quality assurance system has great significance for production to determine the key factors causing defects and optimise the casting process parameters. Experimental analysis and numerical simulation, based on an actual production process, were used as research methods. The former was used to test and analyse the cracks, inclusions, and the flux in the mould to determine the preliminary factors causing defects in a beam blank. The latter was used to simulate the flow and temperature fields and the movement of inclusions to determine the key factor leading to defects and to optimize the casting process parameters. Online implementation of the recommendations of this project was developed, which proved that it is very useful and efficient to control surface cracks on the web and enhance cleanliness of an H-beam blank.

A novel 3D conductive heat transfer model was developed based on node temperature inheritance. Heat transfer of the mold and billet could be analyzed synchronously. In the model, heat transfer in the copper wall was in a steady state, whereas heat transfer in the billet was in a transient state. The temperature distribution indicated that the maximum temperature on the copper wall reached approximately 30 mm below the meniscus. The results were in better agreement with industrially measured data than those of traditional 2D heat transfer models. The model was applied to study the effect of water scale on heat transfer of a billet mold. When the scale thickness increased from 0 to 0.5 mm, the maximum temperature on the copper wall increased from 174 °C to 364 °C, which will lead to mold deformation and peeling of the coating. In addition, the shell thickness slightly decreased with increasing scale thickness.

Precise control of inclusion and molten steel compositions during ladle-furnace refining is important to obtain high-quality steel. Mass-transfer behavior affects these compositions. A model was developed to investigate the mass transfer occurring between molten steel, slag, inclusions, and the refractory during ladle-furnace refining, using two-film theory to describe the reactions. A coupled-reaction model based on the CaO–Al2O3–MgO–SiO2–FeO–P2O5 slag and Mn–Si–Al–Ca–Mg–P–S–O steel systems was applied to describe the reactions between molten steel and slag; the reactions between the refractory lining and slag or steel were described using average industrial erosion rate data. The model was used to calculate changes in the compositions of molten steel and slag, oxygen activity at the slag–molten steel interface, and composition of the inclusions. The calculated results agreed with operational results for a 100 t ladle furnace at the Tangsteel plant in China.

Endless rolling urgently requires an increase in the casting speed of continuous casting. For the continuous casting process of a high-casting-speed billet, the heat flux of the mold would be much higher, requiring a stronger cooling performance and longer mold life to match the high-speed casting. Mold material, thickness, and slot structure have a great influence on the casting speed. To design a more efficient billet casting mold, a three-dimensional thermal-stress-coupled analysis model of a 150 mm × 150 mm mold was established in this research to analyze the thermal state of a mold with high casting speed; in addition, the material, thickness, and water slot structure, which pertain to the mold cooling performance, were also studied. The results show that the billet mold of Cu-Ag with a thinner thickness and right-corner water slot is better in terms of casting speed. Regarding the material, the Cu-Ag mold has a higher thermal conductivity efficiency; its hot surface temperature is 4.89 °C lower, its equivalent stress is 7 MPa lower, and its longitudinal deformation is 0.0023% lower compared with the deoxidized phosphorus copper mold. Regarding the thickness, the thinner mold has a 60.76 °C lower hot surface temperature, its equivalent stress is 340 MPa lower, and its longitudinal deformation is 0.0443% lower compared with the thicker mold. For the water slot structure, the mold with the right-angled water slot has a 2.895 °C lower hot surface temperature, its equivalent stress is 37 MPa lower, and its longitudinal deformation is 0.0039% lower compared with the mold with a rounded-corner water slot. [ABSTRACT FROM AUTHOR]