Danieli Centro Met

High-speed SBQ casting of blooms up to 500 mm dia at Nucor Memphis, USA

Nucor Memphis is one of the largest minimill projects delivered by Danieli in the USA and further consolidates the partnership between Nucor and Danieli that has been in place since the 1970s.

More than one year ago the first heat was cast at the Nucor Steel Memphis facility. The caster was part of the complete Minimill upgrade project that included upstream of the CCM a new mono-bucket AC Electric Arc Furnace, the upgrade of the existing Ladle Furnace and Vacuum Degasser, and downstream the upgrade of the Rolling Mill. The available casting sections are 10.5 (267 mm), 12.25 (311 mm), 13.5 (343 mm), 16.25 (412 mm) and 20.125 (511 mm). The Caster can feed the Rolling Mill directly via a hot-charge system, or the blooms can be cooled either via conventional process or slow cooling. The casters high throughput also allows selling as-cast blooms on the market. This Caster can reach a throughput of about 150 sht/h on a three-strand configuration. It has the same productivity of a conventional caster with a four-strand configuration. The maximum speed reached for each of the above sections is respectively 69 ipm, 51 ipm, 42 ipm, 29 ipm and 19 ipm on a productivity base of nearly 50 sht/h/strand. The caster is designed to cast high-quality steel grades for applications such as forging, quality rings, axis, piping etc. The mold tube features an innovative design (Power Mold) with drilled channels for the cooling water, which enable very uniform cooling of cast product. This mold guarantees high stability of the casting process and high productivity thanks to low temperature on the mold wall and as consequence of a very low deformations. It also reduces the mold wearing in the lower part in comparison to the conventional mold tube, increasing significantly the mold life.

Edited by C. Travaglini
[ Danieli Centro Met ]

N. Kapaj M. Sattolo
[ Danieli Corporation ]

Main caster data The caster has a threes-strand configuration with four unbending points. The strand distance is 5.9 feet. The ladle capacity is 90 sht. The existing ladle turret and tundish cars have been reused. Tundish capacity is 24.8 sht and the working level 31.5. The flow of liquid steel from the tundish to the mold is controlled by stopper-rod system, electromechanically actuated. A monolithic submerged entry nozzle avoids the reoxidation of liquid steel. A hydraulic oscillating table guarantees a tight control of the mold movement and, as a consequence, the quality of the cast product and the stability of the casting process. A new design concept of the mold tube is used here (named Power Mold Danieli patent). Its main features and advantages will be described in the following paragraph. The mold length is 30.7. The level of the steel in mold is measured by a conventional radioactive system. In order to improve the internal quality of as-cast blooms a two stirrers configuration is used (M-EMS and F-EMS). A key point for the surface quality of the cast product is the uniformity of the secondary cooling. A proper cooling of the bloom along the casting strand is very important because,on one hand, it promotes a uniform growth of the solidifying shell and, on the other

Main features of the Power Mold will be shown hereafter. In order to avoid the precipitation of aluminum nitride and carbon nitride at the exit of the withdrawal/ straightening area, a quenching system have been provided. It is important mainly for the section that follows the direct charge route. This paper will present the work carried out for the optimization of the technological parameters and some aspects of the caster design for achieving the productivity and quality targets. It will also present the quality results of the cast product, particularly some metallurgical results such as internal segregation, central porosity, surface and internal quality etc. It also will present some results on the geometrical tolerances of the rounds, such as round diameter, ovality, end squareness, cutting length, camber, etc.

1 General view of the caster. 2 Schematic presentation of the nozzle arrangement (45 degree shifting).

hand, it can reduce the risk of cracks generation due to a nonuniform growth of the solidyfing shell in the mold. The secondary cooling for rounds must be more uniform than other bloom shapes. Here, in order to achieve such uniformity it is adopted a four-nozzle arrangement with 45 degree shifting between the adjacent rows as presented schematically in the following figure (fig. 2). The above described configuration guarantees a uniform cooling on the whole surface of the cast round.
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High-speed SBQ casting of blooms at Nucor Memphis

Mold features The Power Mold has a configuration with drilled channels for water cooling (Figure 3). The same kind of configurations has been used for over 10 years for the casting of rectangular and square sections (1). Some of the concept design for rounds are presented previously. The described configuration showed the following main advantages: > Intensive and uniform cooling. A drilled channels configuration guarantees a very uniform temperature distribution on each cross section of copper tube, a fundamental condition for having a very uniform shell growth along the mold. In the following figure it can be seen that the temperature distribution on the copper wall in contact to the steel is uniform. There is in fact no need for water jackets and consequently conveyor alignment issues are completely eliminated. > Very high rigidity. Its deformation is quite limited in comparison to a conventional mold (Figure 4), thanks to lower temperatures on the mold wall and the external part not subjected to the heat transfer with the liquid steel. Low temperatures on the copper wall avoid the copper recrystalization, too. A limited mold deformation guarantees an excellent geometrical shape of the cast round, and also an appropriate inner taper, as consequence less possibility for crack generation on the rounds. The efficient cooling of the mold determines a longer life in comparison to a conventional mold. The experience has shown that the life could be two to three times longer. The bottom wearing is very limited. In the following figure the mold wearing after 450 heats is shown. The mold configuration has additional positive influence of on the casting process and the round quality: > good surface quality (shallow oscillation marks) thanks to very limited deformation > low stressing of the inner coating (low deformation - long life) > no particular attention to the mold assembly is required. The cooling in the mold is always uniform independently to the mold assembly. > for each casting conditions, no risk of water boiling.

3 Temperature distribution on the mold tube (Finite element method analysis).

Calculation domain

Table 1
Steel grade 10B05M 1018M6 10V45A 1045M1 1050M1 1050M2 1117M1 1141M1 1144M1 1518M1 1522M1 4130M1 4140M1 4145M1 8620M1 A350L1 A350L2 A572M1 A572M2 A707M1 C 0.05 0.18 0.49 0.48 0.50 0.53 0.18 0.40 0.44 0.18 0.20 0.31 0.41 0.46 0.22 0.19 0.17 0.20 0.17 0.15 Mn 0.30 0.75 0.88 0.80 0.80 0.75 1.20 1.50 1.50 1.00 1.00 0.58 0.95 1.05 0.80 1.20 1.20 1.17 1.33 1.24 P(max) 0.015 0.020 0.025 0.020 0.028 0.030 0.040 0.040 0.040 0.015 0.020 0.015 0.025 0.020 0.025 0.015 0.015 0.020 0.015 0.015 S(max) 0.020 0.025 0.030 0.025 0.025 0.025 0.130 0.130 0.330 0.008 0.020 0.010 0.015 0.013 0.025 0.008 0.010 0.050 0.012 0.010 Si 0.10 0.20 0.30 0.25 0.20 0.20 0.20 0.20 0.20 0.20 0.25 0.30 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.28 Cu(max) 0.17 0.25 0.25 0.25 0.15 0.15 0.25 0.25 0.25 0.20 0.25 0.25 0.25 0.25 0.25 0.15 0.25 0.25 0.15 0.23 Ni 0.10 0.25 0.20 0.15 0.15 0.25 0.25 0.25 0.25 0.17 0.25 0.25 0.25 0.25 0.50 0.18 0.15 0.25 0.20 0.15 Cr 0.10 0.20 0.15 0.15 0.15 0.20 0.20 0.20 0.20 0.12 0.15 1.10 1.05 1.00 0.45 0.13 0.15 0.20 0.20 0.20 Mo 0.02 0.03 0.05 0.06 0.05 0.10 0.10 0.10 0.10 0.07 0.08 0.23 0.20 0.28 0.20 0.06 0.05 0.06 0.06 0.10 V 0.030 0.040 0.110 0.020 0.020 0.020 Cb B Al 0.0045 0.005 0.025 0.025 0.025 0.025 0.005 0.005 0.005 0.03 0.025 0.025 0.025 0.025 0.025 0.025 0.025 0.018 0.015 0.03 Ti N 0.006 0.008 0.012 0.012 0.018 0.018 0.018 0.007 Sn (max) 0.020 0.011

0.020 0.020

0.020 0.050

0.020 0.020

0.0005

Power mould

0.020 0.040 0.015 0.010 0.010 0.010 0.015 0.014

0.010 0.070 0.020 0.052 0.100 0.065

0.010 0.018 0.020 0.030 0.020

0.0005 0.0005 0.0005

0.0050

0.050 0.050

0.020

Table 2
Diameter (inch) Casting speed (ipm) Productivity per strand (sht/h) Productivity for threes trands (sht/h) 10.5 69.3 49.5 148.5 12.25 51.2 49.6 148.8 13.5 42.2 49.7 149.1 16.25 29.2 49.7 149.1 20.125 18.9 49.7 149.1

Lateral displacement of the midle points (mm)

0.20 0.15 0.10 0.05 0.00 0 0.05 meniscus

4 Mold deformation.

6 Surface quality of cast rounds: a) round 10.5" b) round 20.125".

ll the advantages mentioned here make possible to cast constantly with higher speed in comparison with a conventional mold.

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Caster performances and round quality

200 400 600 800 1000

Distance from the mould top (mm)

Conventional Mould Power Mould

5 Mold wearing after 450 heats.

Optimizing casting parameters makes it possible to cast all SBQ steel grades successfully, with high productivity per each strand. The quality of the cast product is according to the standards requested by the customers, with minimum rejection rates In the Table 1 are presented some of the steel grades that are continuously cast, mainly steel grades for applications such as forging, quality rings, axis, piping etc. The casting performances for all steel grades are as presented in the Table 2. Note the high productivity per strand (50 sht/h). After the optimization of the above parameters the surface quality results are quite good. No evidence of any depression or cracks. In general the surface looks quite smooth (Figures. 6). The oscillation marks are quite regular. From the start, internal quality has generally been quite good (Figure 7). No evidence

6a

6b
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High-speed SBQ casting of blooms at Nucor Memphis

7a

7b

7 Surface quality of cast rounds: a) steel grade 4145 b) steel grade EN35B (C=0.16, Mn=1.25, Si=0.35, V=0.01, Nb=0.01.

Specimen B01 B02 B03 B04 B05 B06 B07 B08 B09 B10 B11 B12

C 0.18 0.20 0.21 0.19 0.18 0.19 0.21 0.18 0.18 0.19 0.20 0.18

Si 0.20 0.20 0.20 0.20 0.20 0.19 0.20 0.19 0.20 0.20 0.20 0.19

Mn 1.22 1.26 1.27 1.23 1.21 1.22 1.27 1.22 1.24 1.25 1.27 1.20

P 0.013 0.014 0.015 0.013 0.012 0.012 0.016 0.012 0.015 0.014 0.015 0.011

S <0.0025 <0.0025 0.0028 0.0026 <0.0025 <0.0025 0.0025 <0.0025 0.0025 <0.0025 <0.0025 <0.0025

Cr 0.085 0.087 0.088 0.086 0.085 0.085 0.088 0.086 0.087 0.087 0.088 0.085

Ni 0.049 0.050 0.049 0.049 0.048 0.047 0.049 0.047 0.048 0.049 0.047 0.046

9 Results of chemical analysis on a cross section for the round 20.125".

of any crack or other internal defects is seen, also on ternary grades. Thanks to the optimization of the electromagnetic stirring parameters and other casting parameters, the central porosity is minimized (Figure 8). In order to investigate on the segregation, the Breda laboratory (Italy) carried out some chemical analyses by the emission spectroscopy on cross sections of round of diameter 20.125 of steel grade LF2. The specimens were obtained on a cross section as presented in the Figure 9. The results of analyses have shown that the steel is quite homogenous across the transversal section. Figure 9 presents the results for one cross section. The casting technology for rounds requires more uniform cooling along the whole line, in comparison with shapes like rectangular and square. Otherwise, depressions and longitudinal cracks can be generated, and compromise the quality of the product and the stability of process (breakout events due to the shell rupture initiated by longitudinal cracks). The first solidification on the meniscus is fundamentally important. An uneven heat transfer will generate longitudinal cracks and depression. The mold fluxes play a very important role to reduce considerably the peak of the heat flux as consequence the uneven heat transfer. During the start-up phase different mold fluxes were tested, in order to tune the process and prevent longitudinal crack formation and rupture along the mold area. In order to achieve a uniform heat transfer the mold flux characteristics has been modified, mainly the basicity index and the viscosity.

8 Central portion of a longitudinal section for a round of diameter 20.125" (grade 4140).

A mold flux that has a high tendency to generate excessive slag rim on the meniscus area could affect surface quality. In this case it is necessary to change the mold flux parameters (mainly the crystallization temperature). An inappropriate mold flux in the best case, where no cracks or depression are generated, could grow a non-uniform shell that may

generate some of the same longitudinal cracks in a downward direction, due to thermal stressing and/or deformation. In this case a very uniform secondary cooling could not avoid the cracks generation. A first solidification without the presence of the cracks and depressions is fundamental but not the only parameter that guarantees quality for cast rounds The heat transfer along the mold, the secondary cooling arrangement, the secondary containment and the force distribution on the withdrawal/straightening units, also are very important. The heat transfer in the mold must be uniform along the whole length. Only in such a way it is possible to have a sound and uniform solidifying shell. As explained in the above paragraph, the Power Mold guarantees a very uniform cooling for each casting condition thanks to drilled channels and the external part of the copper not involved by the heat transfer. Instead, in a conventional mold the heat transfer could be non-uniform due to some assembly problem (a non constant gap for the water passage), boiling phenomena, or an excessive deformation of the mold. The nonuniform heat transfer could be more severe for long sequences because there is no possibility to check the mold state (water gap, water cleanness etc.) The secondary cooling arrangement determines the quality of the cast rounds. The arrangement adopted in this caster, a four nozzle arrangement with 45 shifting between adjacent rows, guarantees a very uniform cooling. It avoids the generation of the longitudinal cracks in this area. However, a very uniform cooling in the secondary area does not always avoid the nonuniform deformation of the solidifying shell, for

example, in cases when a non-uniform solidifying shell is already generated in the mold (due to inappropriate mold fluxes and non-uniform cooling in the mold). A non-uniform cooling of the solidifying shell in the secondary cooling area could generate ovality also. Its existence will depend on the non-uniformity of the solidifying shell and the intensity of the secondary cooling. In conclusion it can be said that, in order to guarantee good quality cast rounds it is fundamentally important to: > make a very uniform shell in the mold > guarantee further uniform cooling in the secondary cooling area Midway cracks, generated by a poor balance of the secondary cooling. The intensity of the secondary cooling down the mold length must be set in such a manner so as to avoid any excessive temperature rebound of the round surface; otherwise midway cracks will be generated. Central cracks. The pressure applied in the withdrawal/ straightening units is a very important parameter for guaranteeing well-formed cast rounds. The distribution of the forces on the withdrawal/straightening units determines the inner quality. An excessive force can generate some central cracks. It is important that the force distribution among the ithdrawal/straightening units to be managed in such a way that higher concentration of force can be applied where the solidifying shell is thicker and cooler. The shape and the length of the cast round are guaranteed for the contractual values (Table 3).

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Table 3 Diameter (inch) 10.5 13.5

Dim. tolerance (inch) Ovality (inch) contract achived contract achived 0.125 0.077 0.251 0.231 average average 0.145 0.097 0.311 0.153 average average

Camber (inch) contract achived 0.500 0.275 average 0.500 0.304 average

Cutting legh (inch) contract achived 1 1 average 1 1 average

End of squareness (inch) contract achived 0.311 0.131 average 0.374 0.152 average

Conclusions For more than one year the new caster at Nucor Memphis has been producing highquality steel grades for a wide range of a pplications, such as forging, ring rolling, axis, piping etc. The cast rounds satisfy all the requirements and standards. The caster achieves high productivity on a three-strand configuration. It guarantees the same productivity of a conventional plant but has one fewer strand. The surface and internal quality are excellent, exhibiting no presence of any crack or other defects connected to the casting process. The geometrical aspects of rounds match the tight contractual values. The round quality is achieved by keeping under control all the casting parameters. The casting of rounds, due to their shape, requires more uniform cooling than other casting shapes. The Power Mold, a new mold design with drilled channels, has a very

The following geometrical parameters are measured and compared to these values: > > > > > diameter tolerances ovality camber end squareness cutting length

and secondary area, cooling (uniform or not) of a non-uniform solidifying shell, or deformation in the withdrawal/ straightening units. The diameter measurements on the cross section are made in four directions: > outradius - inradius. > 90 to the above direction. > 45 clockwise to the outradius/inradius direction. > 45 anti-clockwise to the outradius/inradius direction. The flat part of the round due to the pressure exerted by the withdrawal/straightening units results are very limited. For example, the round 12.25 varies in the range 1.97 to 2.36 (Figure 10). The camber has been measured for 4.92 feet of the round length and results for all rounds nearly half of the contractual values.

The ovality is generated by the deformation of the round along the casting process. It can be generated by some thermal or mechanical actions on the solidifying shell, mainly in the mold; and further developed along the secondary area; or, sometimes it can be generated and developed only in the secondary cooling area and on the withdrawal/straightning units. In particular, it can be generated by the following variables: inappropriate mold dimensions, mold wearing and deformation, wrong alignment of the foot rolls, non-uniform cooling of the solidifying shell in the primary

efficient and uniform cooling system that makes it possible to grow a sound and uniform solidifying shell, and at the same time to increase process stability. Other parameters that are fundamental for achieving good quality product and a stable casting process are the mold fluxes, the secondary cooling arrangement and the deformation entity of the round along the casting line. The mold fluxes play a fundamental role for the surface quality of rounds and further for the stability of the process. The secondary cooling design avoids thermal stressing of the solidifying shell down the mold. The arrangement of the secondary cooling adopted in this caster, a four-row nozzles arrangement with 45 shifting between the adjacent rows, is an important factor for rounds quality. Also, the control strategy of the force distribution through the withdrawal/straightening units has avoided the generation of the internal cracking.

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Flat rolled surface by the RD units

10 Flat rolled surface for round 12.25.

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