INNOVATIONS
CASTING
CONFERENCE REPORT
PERSPECTIVES
Two pages of the latest product innovations for steelmakers
Near Net Shape Casting explained by WMG, University of Warwick
Cloudy days in Rio at Alacero’s 57th annual conference
Bloom Engineering’s David Boyce answers our questions
www.steeltimesint.com March 2017 - Vol.41 No2
STEEL TIMES INTERNATIONAL – March 2017 – Vol.41 No.2
ARCELORMITTAL’S ENVIRONMENT-FRIENDLY FURNACE STI Cover march.indd 1
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INNOVATIONS
Spray nozzles for continuous casting Lechler’s new air mist nozzle, the Billetcooler FLEX, is characterised by its constant spray angle over the entire turn-down ratio, says Lechler. In addition, the liquid distribution can be set dynamically, according to the strand format, by controlling water and air pressures. Lechler claims that these ‘innovative features’ offer greater process flexibility as local heat extraction can be increased or reduced. “This means an additional actuator for optimal cooling is now available,” claims the company.
Lechler has also developed water-only nozzles for secondary cooling. Its new full cone series 490 nozzles, which have large free cross-sections, provide the nozzles with ‘true non-clogging characteristics’. Reduced nozzle clogging means higher operational safety and improved product quality due to more uniform cooling and reduced maintenance costs. For further information, log on to www.lechler.de
A reproducible method of heating and testing Primetals Technologies’ automatic thermocouple checker is claimed to offer operators of continuous casting plants a standardised and reproducible method of heating and testing thermocouples in the copper plates of molds. Unlike conventional test methods – such as those reliant upon gas torches – potential damage of the copper plates is eliminated. Each thermocouple belonging to a mold is tested under identical conditions and almost fully automatically, Primetals explains. Uniform heating of the couples can identify defective elements and determine poor thermal contact caused by soiling or insufficient pressing force on the thermocouple. For quality management purposes, measured data gathered can be stored for later evaluation. Temperature distribution in the mold is measured with the aid of thermocouples and must be as precise as possible to ensure
that any sticking in the mold is quickly detected. Sticking can lead to openings in the cast shell, resulting in damage averaging 100,000 euros. Thermocouples have traditionally been tested by various manual methods including the use of gas torches. Individual thermocouples are heated up to different extents, making interpretation of the measured results difficult. Moreover, heating of thermocouples can damage the copper plates of the molds. The use of blow heaters can result in a lower effective heating output on the copper plate and extend the time needed for measurement. Primetals’ automatic thermocouple checker detects defective thermocouples and poor contact between the thermocouple and the copper plate. The computer-aided test process supports optimum installation of thermocouples, which reduces to a minimum the replacement
of molds and thus reduces maintenance. Measured data gathered can be stored for later evaluation. The system’s measurement arm is moved to a defined thermocouple column for testing and then automatically heats one thermocouple after the other; the temperature reached is measured. Once testing of the copper plate is completed, a report is generated to indicate correct or defective functioning of the thermocouples. Narrow and broad sides of molds can be tested equally and it can test one single mold plate or check the complete mold. The automatic thermocouple checker is delivered as a transportable unit. The basic system consists of a heating arm that is mounted on a linear guide and a measuring and evaluation unit and is connected to the thermocouple connectors on the mold. For further information, log on to www.primetals.com
Castolin’s XuperCOAT for best-in-class mould wear resistance in continuous casting Mould coatings are a crucial part in continuously improving product quality and reducing operating cost in the continuous steel casting process. Already 30 years ago, Monitor Coatings (UK), part of Castolin Eutectic, first developed a high performance ceramic composite coating technology XuperCOAT. It delivers best-in-class results in terms of mould life time, cast product quality and caster operating costs. Continuous developments of the technology now enable the application of such coatings on all types of moulds including bloom and billet tubes.
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XuperCOAT coatings, capable of functioning in extreme environments of high temperature, abrasion, fatigue and friction, show significant technical and commercial advantages compared to other thermal spraying systems. XuperCOAT, it is claimed, demonstrates superior results such as higher thermal conductivity, hardness and ductility due to minimal phase transformations, thermal shock resistance and surface finish and lower friction due to thermochemical post treatment. Stainless and carbon steel longs and flats producers reported yield increases in cast steel on the same mould in the range
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Precise, Reliable, Repeatable
Too Hot to Handle? No Problem with Polytec
of 2 to 8 fold compared to other solutions. With such low wear rates, there are marked improvements in the downstream surface quality of the billets and slabs, while the integrity of the original copper mould asset remains maintained. Moreover, customers identified additional benefits of the application of XuperCOAT such as improved cast product quality due to less star and corner crack defects, less strand shape issues, stickers and sticker breakouts as well as reduced operating cost thanks to lower consumption of copper moulds and mould flux powder and fewer wear-related enforced stoppages. Furthermore, XuperCOAT, being compliant with European Legislation (REACH), is claimed to be the most efficient and reliable alternative for steel makers moving away from electroplating, which will soon become obsolete under those regulations. Castolin Eutectic will be present from 8 - 11 May 2017 at AISTECH in Nashville, USA, and from 26 - 29 June 2017 at the European Continuous Caster Conference in Vienna, Austria.
Non-contact Length and Speed Measurements Improve yield, reduce scrap, and increase profits. Polytec’s Laser Surface Velocimeters measure surface velocity and length from a safe distance without contact. Measure with Confidence! Learn more: www.velocimeter.us
For further information, log on to www.castolin.com POLAZ-17004_LSV_engl_87x265mm.indd 1
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