US3682711A - Method of melting steel - Google Patents

Method of melting steel Download PDF

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US3682711A
US3682711A US41971A US3682711DA US3682711A US 3682711 A US3682711 A US 3682711A US 41971 A US41971 A US 41971A US 3682711D A US3682711D A US 3682711DA US 3682711 A US3682711 A US 3682711A
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steel
formula
carbon
final
chemistry
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Howard W Bennett
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Armco Inc
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    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21CPROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C7/00Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/4998Combined manufacture including applying or shaping of fluent material
    • Y10T29/49988Metal casting

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  • This invention relates to a unique method of controlling the final mechanical properties of carbon-bearing steel plates, bars and shapes at a very early stage in processing, i.e. the melting stage.
  • X 4.5 to 7.5, preferably equal to 6
  • Y 4 to 6, preferably equal to 5 2:12 to 18, preferably equal to 15.
  • a heat of molten steel can be quickly adjusted by varying one or more of the elements included in the formula. This will save time in shaping up a heat prior to casting or tapping, and minimize rejected heats due to large differences between projected and actual mechanical properties.
  • the figure is a graph of aim A.E.F. vs. aim tensile strength of a semi-killed steel plate, with final plate thiokness superimposed thereover.
  • the present invention contemplates a system for melting steel for use as plates, bars and shapes, which system permits the manufacturing mill to sell the steel products to a tighter mechanical property range.
  • the system also means lower costs as the melting operator can take advantage of the melt-in residuals, and control the final properties at the desired levels.
  • the system herein is based upon the recognition each of the elements carbon, manganese, chromium, molybdenum, nickel, copper, vanadium and columbium, has on developing the strength in carbon bearing steels.
  • the system in very simple terms prorates the other elements contained in the steel with respect to the percent carbon, based on the effects of each element content on mecham'cal properties.
  • the formula for the system is as follows:
  • this invention contemplates an expanded range for the several divisors as follows:
  • the formula and figure are used in the following way.
  • the chemistry (preliminary determination) of the molten steel is incorporated into the formula.
  • changes are effected therein so as to bring the A.E.F. to the level desired, within i.05 and preferably :.02, for the production of steel plate of a given thickness having the specified mechanical properties, more specifically tensile strength, within relatively narrow limits, i.e. i5 k.s.i. (34.5 MN/mF).
  • the system for melting steel as taught herein is directed to those steelswhich are characterized as hot rolled steel plates, bars and shapes, and which vary in size from about to 8" (.48 to 20 cm.). That is, they are usually sold in the hot rolled condition.
  • the system as proposed is applicable to heat treated ferrous products although a modified curve would be required for heat treated products.
  • the size and shape of the mill treated product would affect the shape of the curve.
  • the curve would vary slightly from the figure, which is adapted for use with plates.
  • a melter is provided with the necessary data concerning the final mill product, i.e. type of steel or chemistry limits, mechanical property limits, and mill product size, among other detainls of processing. Therefore, for this illustration, assume the following data:
  • the melter To bring the A.E.F. up to the desired aim value, the melter must add one or more elements, preferably carbon and manganese, to effect the adjustment. However, by using the formula herein, the melter is relatively free to select the amount, type and number of elements to be added.
  • a final chemistry may be taken to detect any changes in the residual levels, and to determine the carbon and manganese contents. In this illustration, it would not be unusual to find about .12% manganese, and about .10% carbon in said tap chemistry.
  • the aim A.E.F. will be reached thereby assuring the desired tensile strength within the specification range of 75/85 k.s.i. (517/586 MN/m. For example, if manganese is increased to about 1.00%, the A.E.F. from residuals will be. raised from .08 to about .25. To reach the aim A.E.F. of .47, 27 points of carbon, or .27% is needed (an increase of about .17% over tap chemistry).
  • ferrous mill product is a semi-killed carbon steel Whose final thickness varies between about .64 to 2.54 cm., and that said aim A.E.F. is determined from the accompanying figure.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Heat Treatment Of Steel (AREA)

Abstract

A METHOD FOR CONTROLLING WITHIN PREDETERMINED LIMITS THE FINAL MECHANICAL PROPERTIES OF STEEL PLATES, BARS AND SHAPES, AT THE MELTING STAGE OF SAID STEEL BY EQUATING THE CHEMISTRY THEREOF TO THE TENSILE STRENGTH BY MEANS OF THE FORMULA:

WHERE THE DIVISORS ARE PREFERABLY X=6, Y=5, AND Z=15, BUT MAY VARY BETWEEN ABOUT, X=4.5 TO 7.5, Y=4 TO 6, AND Z=12 TO 18, SO THAT THE A.E.F. IS CHANGED TO FALL WITHIN A LIMITED RANGE OF A CALCULATEED AIM A.E.F. FOR SAID TENSILE STRENGTH.

Description

Aug. 8, 1972 v H. w. BENNETT METHOD OF MELTING STEEL Filed June 1, 1970 INVENTOR/S ms \zsc ax 15255 362B 2% 590m $5 8 R93 E 33 8 o 9 om Om 9 E33 HE H -Eo N Om mk dl :wwas mkqdl r Om HOWARD W BENNETT l/l/fl,
ATTORNEYS United States Patent 3,682,711 Patented Aug. 8, 1972 US. Cl. 148-2 5 Claims ABSTRACT OF THE DISCLOSURE A method for controlling within predetermined limits the final mechanical properties of steel plates, bars and shapes, at the melting stage of said steel by equating the chemistry thereof to the tensile strength by means of the formula:
where the divisors are preferably X:6, Y:5, and Z:15, but may vary between about, X=4.5 to 7.5, Y=4 to 6, and Z=12 to 18, so that the is changed to fall within a limited range of a calculateed aim A.E.F. for said tensile strength.
BACKGROUND OF THE INVENTION This invention relates to a unique method of controlling the final mechanical properties of carbon-bearing steel plates, bars and shapes at a very early stage in processing, i.e. the melting stage.
It will be appreciated that where a minimum of processing steps are applied to a steel to afiect the metallurgical properties thereof, advantage must be taken during the few opportunities presented. While the chemistry of the steel represents a prime situation to eifect property control, heretofore such an accurate system has not been known.
But before reviewing the prior art attempts to control final properties, it will be recalled that carbon steel plate for example, such as ASTM A572 Grade 42, is sold primarily based on minimum strength levels. Experience has shown that even where the chemistry is within specification limits, mechanical properties may vary from below the minimum to well in excess thereof. The latter is also an undesirable situation as too much strength may present fabricating difficulties.
And, since such steel plates as noted above are frequently sold in the hot reduced condition, i.e. without property modifying heat treatments, the prior art practitioners attempt to limit property variations solely by specifying chemical composition. In addition, it was necessary to establish separate specifications for different thicknesses for each grade or strength of steel. The method of melting, whether by open hearth, BOF or electric furnace, may also be a factor in writing the specifications. But even with such elaborate measures, heats were missed thereby giving rise to abnormally large material and processing costs.
Up until the present time no one was fully cognizant of an inexpensive, yet accurate way of controlling final mechanical properties at the melting stage. Such steels were normally made by melting within a specified chemistry rangeeach controllable element such as carbon, manganese and silicon having its own range. Little attention was paid to residual elements such as chromium, molybdenum, nickel and copper, and the cumulative effect was not considered. Thus, even when a steel met the chemistry limits, it was possible for the mechanical properties to be out of range because of all elements being high in their range or vice versa. With the current development, a system has been found to predict and/or control the final mechanical properties of carbon steel plates, bars and shapes through a correlation of the effects of residual elements and intentional alloy additions on the properties.
SUMMARY OF THE INVENTION The present development is based upon a method of utilizing and predicting the effect of such residual elements as chromium, molybdenum, nickel, copper, as well as the additions such as vanadium, columbium and manganese on the final mechanical properties of carbon bearing steel plate. By the use of an alloy equivalent formula, hereinafter referred to as A.E.F., in melting heats of steel, advantage can be taken of the melt-in residuals. This permits much better control of final properties. Also, cost reduction can be made by using lesser amounts of elements than would normally be made.
In the melting of the steel, whose chemistry by weight comes within the following:
Percent maximum Carbon 0.60
Manganese 2.00 Chromium and molybdenum 0.75 Nickel and copper 0.75 Columbium 0.06
Vanadium 0.15
Silicon 1.00 Iron Balance, except for normal residuals and additives such as boron, titanium, zirconium, etc., a preliminary determination of the chemistry is made prior to the casting or tapping from the furnace. Based upon a predetermined A.E.F. as calculated from prior data, or in the case of steel plate from the accompanying figure, the chemistry is adjusted by varying one or more of the recited elements. Said adjustment is controlled by the following formula:
X=4.5 to 7.5, preferably equal to 6 Y=4 to 6, preferably equal to 5 2:12 to 18, preferably equal to 15.
By following this formula, a heat of molten steel can be quickly adjusted by varying one or more of the elements included in the formula. This will save time in shaping up a heat prior to casting or tapping, and minimize rejected heats due to large differences between projected and actual mechanical properties.
BRIEF DESCRIPTION OF THE DRAWING The figure is a graph of aim A.E.F. vs. aim tensile strength of a semi-killed steel plate, with final plate thiokness superimposed thereover.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Before discussing the details of the preferred embodiment of this invention, it must be acknowledged that metallurgical formulas, to predict performance of materials in service, do exist. Thus, it is not the intention herein to assert that the present invention was the first to recognize a weighted relationship between chemistry and performance. However, the discovery is significant in that it is the first to use during melting the total percentage of additives and residuals to make adjustments in one or more elements to achieve the desired strength level.
The formulas which have been developed and applied in the metal fabricating field are empirical and based on actual experiences of individual mills, research laboratories, etc. One of the more common ones is the carbon equivalent (C.-E.) employed by fabricators to predict the weldability of steel. In the case of new steels, or ones with which they are not familiar, the fabricator can use the OE. to set up welding procedures for the steel. However, this is a measure of the final product and not a control step in producing steel.
Another area where formulas have been applied is in the area of determining hardenability of ferrous products. Specifically, methods have been devised for calculating the Jominy curve for a given steel. Equipped with this knowledge, a designer can more effectively heat treat the steel. However, the method is admittedly not precise as the elfect of the elements making up the chemistry is not independent of one another throughout the chemical range permitted by the specification being used. As an example, there is an interaction between carbon and certain of the alloying additions. Further, the effect of a given addition is not constant over a broad percentage range. Nevertheless, such a formula is helpful in determining hardenability.
Contrary to some aspects of the preceding, the present invention contemplates a system for melting steel for use as plates, bars and shapes, which system permits the manufacturing mill to sell the steel products to a tighter mechanical property range. The system also means lower costs as the melting operator can take advantage of the melt-in residuals, and control the final properties at the desired levels.
The system herein is based upon the recognition each of the elements carbon, manganese, chromium, molybdenum, nickel, copper, vanadium and columbium, has on developing the strength in carbon bearing steels. By the formula to be given hereinafter, the system in very simple terms prorates the other elements contained in the steel with respect to the percent carbon, based on the effects of each element content on mecham'cal properties. The formula for the system is as follows:
Note.Formula valid for steels whose chemistry by weight comes within the following:
residuals and additives such as boron, titanium, zirconium, etc. While the formula is valid for those steels falling within the above chemistry, it can be simplified to the extent of semi-killed steels vs. silicon killed steels. In the former, only a slight amount is present, i.e. up to about .10%. On the other hand, silicon killed steels may contain as much as .3 Thus, the formula may be simplified to the extent of deleting the silicon factor in determining tensile strength of semi-killed steels. In the preferred formula, the divisors are as follows: X='6, Y=5, and Z=15. However, it is recognized that variations in mill practices, product shapes, alloys and other factors will differ from one manufacturing mill to another.
Therefore, this invention contemplates an expanded range for the several divisors as follows:
X=4.5 to 7.5 Y=4.0 to 6.0 Z=l2.0 to 18.0.
One additional factor which warrants discussion is the relationship of thickness to final mechanical properties. For convenience in helping to understand the effect of thickness, reference is made to the figure. In general, for a given strength level, as the section thickness increases, higher aim A.E.F. values are sought. The figure, which is applicable to semi-killed steel plates, plots aim .AIE.F. against final steel plate tensile strength, with plate thicknesses superimposed thereover.
The formula and figure are used in the following way. The chemistry (preliminary determination) of the molten steel is incorporated into the formula. Then changes are effected therein so as to bring the A.E.F. to the level desired, within i.05 and preferably :.02, for the production of steel plate of a given thickness having the specified mechanical properties, more specifically tensile strength, within relatively narrow limits, i.e. i5 k.s.i. (34.5 MN/mF).
It is pertinent to compare the A. E.-F. formula used in this invention with a well known measure of weldability as represented by the formula by Winterton:
Mn Ni N0te.-As the C.=E. approaches or exceeds .55, the problem of weldability increases.
This -C.E. formula has obvious similarities but there are some important difierences. For example, molybdenum and vanadium are additive factors in the current formula and negative factors in the CE. formula; they are also 10 times more significant in their contribution to than in their eflect on C. -E. Colum'bium is equal to carbon in strengthening effect but does not even appear in the CE. formula.
Up to this point, little has been said about the types or grades of steel to which this invention relates, except as to the maximum limits placed on the specified elements. In general, the system for melting steel as taught herein is directed to those steelswhich are characterized as hot rolled steel plates, bars and shapes, and which vary in size from about to 8" (.48 to 20 cm.). That is, they are usually sold in the hot rolled condition. The system as proposed is applicable to heat treated ferrous products although a modified curve would be required for heat treated products. Likewise, the size and shape of the mill treated product would affect the shape of the curve. Thus, for hot rolled bars and shapes, the curve would vary slightly from the figure, which is adapted for use with plates.
It should be apparent from the A.E.F. formula herein that the carbon is considerably more eifective than the residual elements. Nevertheless, they do, exert an influence on final mechanical properties. Unfortunately, the precise influence was not recognized such that reliance was placed solely on the carbon content. As a result, heats were lost and/or subsequently diverted for excessive mechanical properties. With the present invention, such problems can be avoided.
For convenience, but without desiring to so restrict the invention, consider the preferred A.'E.F. formula and the accompanying figure in the following illustration.
Under typical mill operating conditions, a melter is provided with the necessary data concerning the final mill product, i.e. type of steel or chemistry limits, mechanical property limits, and mill product size, among other detainls of processing. Therefore, for this illustration, assume the following data:
(a) Type steel-semi-killed carbon steel plate having a final chemistry falling within Carbon .35 maximum. Manganese .85-1.20%. Phosphorus .025% maximum. Sulfur 060% maximum. Silicon .10% maximum. Copper .60% maximum. Nickel .60% maximum. Chromium .25% maximum. Molybdenum .25% maximum. Iron Balance.
(b) Tensile strength75/ 85 k.s.i. (517/586 MN/m?) (c) Mill productHR steel plate /2" thick (d) Aim A.E.F.=.47
Percent Copper .25 Nickel .20 Chromium .15 Molybdenum .10
Since copper, nickel and molybdenum are not oxidizible and will not change during the refinement of the heat, and chromium will change only slightly through the action of oxygen, a portion of the A.E.F. formula will be fixed. Thus, the balance needed to bring the A.E.F. value up to the aim A.E.F. may be readily determined by simple arithmetic. In utilizing the preferred formula taught herein, a substitution of the above residuals will yield an A.E.F.=.08.
- To bring the A.E.F. up to the desired aim value, the melter must add one or more elements, preferably carbon and manganese, to effect the adjustment. However, by using the formula herein, the melter is relatively free to select the amount, type and number of elements to be added.
Just prior to tapping the heat, a final chemistry may be taken to detect any changes in the residual levels, and to determine the carbon and manganese contents. In this illustration, it would not be unusual to find about .12% manganese, and about .10% carbon in said tap chemistry. By adjusting the two elements, whose final content will provide the missing factors in the A.E.F. formula, the aim A.E.F. will be reached thereby assuring the desired tensile strength within the specification range of 75/85 k.s.i. (517/586 MN/m. For example, if manganese is increased to about 1.00%, the A.E.F. from residuals will be. raised from .08 to about .25. To reach the aim A.E.F. of .47, 27 points of carbon, or .27% is needed (an increase of about .17% over tap chemistry).
By following this formula, and anticipating normal elemental recoveries consistent with present steel making practice, one can provide a mill product having the desired strength within :5 k.s.i. (34.5 MN/m. For instance, while 1.00% is the aim for manganese, it could vary within the specification range, thereby changing the final A.E.F. The final carbon is more predictable even though some variation from aim is to be expected. Nevertheless, even with such variation, predictable results can be secured. That is, a final actual A.E.F. within :05 of aim A.E.F., will yield a mill product having a tensile strength within the specification range of 75/ k.s.i. (517/586 M-N/m.
While the above illustration has been simplified for the purpose of providing an exemplary embodiment, it should be apparent various combinations of changes may be effected by the melter to achieve the desired results. For instance, vanadium and/or columbium may be added with a concurrent reduction in carbon. On the other hand, where residuals are low, additions may be made with full knowledge on their effectiveness in increasing the strength of the final steel product.
Accordingly, since modifications are contemplated, particularly by those skilled in the art after reading these specifications, no limitation is intended to be imposed herein except as set forth in the appended claims.
What is claimed is:
1. In a method for controlling the final tensile strength of ferrous mill products within 134.5 MN/rn. of a predetermined value at the melting stage thereof, wherein a cast ferrous body is rolled into a mill product having a thickness between about 0.48 cm. to 20 cm. and said product is not given any subsequent property modifying heat treatments and where the final chemistry falls essentially by weight within the following limits;
Percent maximum Carbon 0.6
Manganese 2.00 Silicon 1.00 Chromium and molybdenum 0.75 Nickel and copper 0.75 Columbium 0.06
Vanadium 0.15 Iron Balance where the divisors may vary between about, X=4.5 to 7.5, Y=4 to 6, Z=l2 to 18, so that the A.E.F. is changed to fall within a range of :005 of a calculated aim A.E.F. for said predetermined value of tensile strength.
2. The method claimed in claim 1 wherein said divisors are X=6, Y=5, and Z: 15.
3. The method claimed in claim 1 wherein said thickness varies between about .64 to 5.08 cm.
4. The method claimed in claim 3 wherein said ferrous mill product is a semi-killed carbon steel Whose final thickness varies between about .64 to 2.54 cm., and that said aim A.E.F. is determined from the accompanying figure.
5. The method claimed in claim 1 wherein said predetermined value varies between about 414 to 620 MN/ m? for said mill products in the hot reduced condition.
References Cited UNITED STATES PATENTS 1,838,425 12/1931 Marsh 75129X 3,310,441 3/1967 Mandich l4 836 OTHER REFERENCES Quest, C. F., and T. S. Washbum: Tensile Strength and Composition of Hot-rolled Plain Carbon Steels, Trans. AIME, 1940, v. 140, pp. 489-496.
Mottley, Charles M.: The Application of Statistical Methods to the Development and Quality Control of High Tensile Steel, 1. Am. Soc. Naval Engrs., 1945, v. 57, pp. 21-55.
Mudd Series, Seeley W.: Basic Open Hearth Steelmaking, A.I.M.M.E., New York, 1951, pp. 500-504.
F. B. Pickering and T. Gladman: BISRA conference on carbon steels, Harrogate, May 1963, pp. 10-25.
K. J. Irvine and F. B. Pickering: Low-carbon steels L. DEWAYNE RUTLEDGE, Primary Examiner J. E. LEGRU, Assistant Examiner US. Cl. X.R. 75-129; 148-36
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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0255106A2 (en) * 1986-07-28 1988-02-03 Sächsische Edelstahlwerke GmbH Freital Process for the production of corrosion-resistant steels and castings
EP0150244B1 (en) * 1984-01-28 1988-09-21 VEB Stahl- und Walzwerk "Wilhelm Florin" Hennigsdorf Process for producing steels from scrap contaminated by at least one of the elements chronium, copper, molybdenum and nickel

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0150244B1 (en) * 1984-01-28 1988-09-21 VEB Stahl- und Walzwerk "Wilhelm Florin" Hennigsdorf Process for producing steels from scrap contaminated by at least one of the elements chronium, copper, molybdenum and nickel
EP0255106A2 (en) * 1986-07-28 1988-02-03 Sächsische Edelstahlwerke GmbH Freital Process for the production of corrosion-resistant steels and castings
EP0255106A3 (en) * 1986-07-28 1988-06-08 Veb Edelstahlwerk 8. Mai 1945 Freital Process for the production of corrosion-resistant steels and castings

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