US3908732A - Methods of producing large steel ingots - Google Patents

Methods of producing large steel ingots Download PDF

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Publication number
US3908732A
US3908732A US427085A US42708573A US3908732A US 3908732 A US3908732 A US 3908732A US 427085 A US427085 A US 427085A US 42708573 A US42708573 A US 42708573A US 3908732 A US3908732 A US 3908732A
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US
United States
Prior art keywords
ingot
electrode
steel
slag
producing large
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US427085A
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English (en)
Inventor
Lloyd R Cooper
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Heppenstall Co
Original Assignee
Heppenstall Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Heppenstall Co filed Critical Heppenstall Co
Priority to US427085A priority Critical patent/US3908732A/en
Priority to CA195,130A priority patent/CA1013543A/en
Priority to FR7410721A priority patent/FR2255121B1/fr
Priority to GB1411574A priority patent/GB1468223A/en
Priority to IT50051/74A priority patent/IT1004104B/it
Priority to AU67604/74A priority patent/AU474999B2/en
Priority to AT557474A priority patent/ATA557474A/de
Priority to JP49110657A priority patent/JPS5216849B2/ja
Application granted granted Critical
Publication of US3908732A publication Critical patent/US3908732A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D7/00—Casting ingots, e.g. from ferrous metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/02—Use of electric or magnetic effects
    • Y—GENERAL 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49972—Method of mechanical manufacture with separating, localizing, or eliminating of as-cast defects from a metal casting [e.g., anti-pipe]
    • Y10T29/49975—Removing defects
    • Y10T29/49977—From center of ingot to leave hollow blank

Definitions

  • This invention relates to improvements in the methods of producing large steel ingots, and particularly the method of producing ingots to provide a solid large steel ingot free of the central cavity or pipe common to large ingots, as described initially in the disclosures of United States letters Pat. No. 3,603,374.
  • the patent further describes how the ingot thus formed is set up in a remelting station, with a steel electrode in position, and electroslag remelting the steel electrode, along with a portion of the adjacent wall of the ingot body, to form a central zone of progressively remelted, refined and resolidified steel within the original teemed ingot.
  • the resulting solid ingot body may then be hot trepan punched under the forging press, removing the central core weighing approximately 3 per cent of the ingot body weight.
  • This central trepan punched core contains the initial ingot pipe cavity.
  • the resulting axial hole is then filled by electroslag remelting a steel electrode in the axial hole along with a controlled portion of the side wall of the central hole in the ,ingot body.
  • the progressive remelting, refining and resolidification of the central zone by electroslag remelting of the steel electrode and the adjacent portion of the wall of the ingot" body provides the desired steel cleanliness and soundness, the same as if the additional sinkhead weight had been used.
  • the yield of forged product from the poured weight of steel in the ingot body (without an added sinkhead) may be per cent to per 'cent more than the yield of forged product from the total poured weight of steel in the ingot with the added sinkhead.
  • FIG. 5 is a plot of the of FIG. 4;
  • FIG. 6 is a plot of the lines to the right of line A A lines to the left of line AA
  • FIGS. 7, 8, 9 and 10 shows FIGS. 5 and 6 matched along the parting line A-A of FIG. 4 according to different energy systems;
  • FIG. 1 l is a section through an ingot showing the several parameters taken into consideration in controlling energy input and proportional melt rate.
  • the first method is a simple empiricaltechnique of shaping the outside of the ingot blank, before trepan punching, so that the heat losses will be at least partially equalized, and so that the resulting depth of penetration of the melted zone along the length of the ingot will be progressively in proportion to 'the crosssectional dimension of the ingot.
  • the resulting remelted central zone will also assume a form that is essentially cylindrical within the resulting forged piece. This is shown in FIGS. 2(A) and (B).
  • This method is simple and useful, as long as the electrical parameters of current and voltage at the electrode are controlled to provide the proper vertical depth of liquid metal pool under the slag according to the known paramcters for electroslag remelting, in order to obtain the desired resolidification characteristics.
  • the second method of controlling the extent of melt penetration within the ingot blank depends on a continuous balance of energy input, and material melted throughout the course of the remelting cycle.
  • the energy input to be controlled will include the electrical energy through the electrode and the slag, as well as heat supplied'to the ingot blank before and during the remelting cycle.
  • the amount of electrical energy required to melt iron can be determined from calculations for the heat content (expressed as calories/moi) at the ambient temperature and at the temperature achieved after melting.
  • the heat content of liquidiron at l600 C. (29l2 F.) is'calculated to be l8,550 calories/moi above the heat content of iron at 25 C. (77 F.). This is equivalent to "an electrical energy of 385.9 kWh/metric ton required to raise the temperature from solid iron at'25 C. to the liquid state at l60() C.
  • FIG. 3 shows graphically the relationship, for a given power input, between the steel melted from the electrode and the steel melted from the ingot body according to three representative energy requirements of 400, 800, or 1200 kWh/metric ton according to this invention.
  • the effect is shown of the temperature of the ingot body on the amount of ingot that is melted by a given set of conditions.
  • the ,inside of the ingot (axial hole) is 300 mm radius (diameter of 600 mm 23.6 inches) and the size of the electrode is 205 mm radius (diameter of 410 mm 16.2
  • the graph shows that with the power input of 1560 kw, for a requirement of 1200 kWh/metric ton, the melting rate of 1300 kg/hour is equal to a melting rate, for the 205 mm radius, of 1260 mm per hour to till the 300 mm radius axial hole without melting any of the ingot wall. This would be indicated by a ram travel (electrode clamp) of 675 mm per hour. (Point A). I An observed ram travel of 240 mm per hour is equivalent to 450 mm per hour electrode melt rate (Point B) for the same power input of 1560 kw, and the electrical energy requirement of 1200 kWh/metric ton.
  • This melting of the electrode consumes only part of the power input (556 kw) and the remainder (1004 kw) is used to melt the portion of the ingot wall, to lesser or greater depth according to the temperature of the steel. If the ingot is at 25 C., the melting zone penetrates to 503 mm radius (Point C), if at 600 C., it penetrates to 550 mm radius (Point D) and if at 900 C., to 610 mm radius (Point E).
  • Direct readings of the ram travel, for the power input, show the amount of penetration of the melt zone into the wall of the ingot blank according to the temperature of the steel.
  • the rate of ram travel can then be adjusted, either by power drive, or the current setting on the panel, to increase or decrease the rate of melting the electrode as compared with melting the wall of the ingot.
  • the energy balance of the system can be monitored constantly, in order to regulate the rate at which the molten steel rises'in the axial hole of the ingot, and thereby the total cross-section of liquid steel that is formed within the ingot central zone.
  • FIGS. 5 and 6 show the image from these two slides. These slides can be matched, along the parting line AA, according to any known energy requirement of a system, as shown in FIGS. 7, 8 and 9. If they are placed on a logarithmic graph background, with the interrelationship for ram travel and electrode melt rate, the result of FIG. 10 complies with the graph of FIG. 3, for 1560 kw, and 1200 kWh/metric ton, for the same size electrode and axial hole.
  • new master curves of FIG. 4 are prepared and transferred to new slide rules.
  • the new process can be controlled easily during the course of the remelting operation, for any size of ingot and electrode.
  • the total metal fill in the axial hole, at any time, is the sum of:
  • the metal from the starter plate and the metal chips is shown as the solid area filling the bottom end of the axial hole, up to the line iM-M.
  • the distance of this fill can be determined by weighing these metals before the start of the melt.
  • the metal melted from the electrode is shown as filling the axial hole above the line M-M up to the line Above the line H-l-I, and up to the line F-F",'(the top of the metal fill), the liquid ,metal within the origi- (S D )t D H
  • the height of metal fill from the electrode (as shown in the report for Tests l and ll) can be expressed as where,
  • the thickness of the slag layer and the distance up to the top of the metal pool can be determined by an insulated probe from the open top of the ingot.
  • the other terms can be measured directly.
  • the calculation for the diameter S of the liquid slag layer is based on the assumption that the outer sur- "face of the slag (at the slag/metal interface) is that of a vertical cylinder wall.
  • the contact surface is curved (logarithmic or conic: section of an ellipse or a parabola),'and the true value for S willbe slightly greater than determined by the above formula.
  • the foregoing formula is sufficiently accurate and provides the ⁇ necessary control criteria.
  • the improved method of producing large steel ingots with higher yield from poured weight to wrought product comprising the steps of a. Casting a steel ingot to the final desired size, with all of the cast steel weight in the ingot body and free from sinkhead on top of the ingot body,

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Treatment Of Steel In Its Molten State (AREA)
  • Continuous Casting (AREA)
US427085A 1973-12-21 1973-12-21 Methods of producing large steel ingots Expired - Lifetime US3908732A (en)

Priority Applications (8)

Application Number Priority Date Filing Date Title
US427085A US3908732A (en) 1973-12-21 1973-12-21 Methods of producing large steel ingots
CA195,130A CA1013543A (en) 1973-12-21 1974-03-15 Methods of producing large steel ingots
FR7410721A FR2255121B1 (fr) 1973-12-21 1974-03-28
GB1411574A GB1468223A (en) 1973-12-21 1974-03-29 Methods of producing large steel ingots
IT50051/74A IT1004104B (it) 1973-12-21 1974-04-03 Procedimento per la produzione di grossi lingotti di acciaio
AU67604/74A AU474999B2 (en) 1973-12-21 1974-04-05 Methods of producing large steel ingots
AT557474A ATA557474A (de) 1973-12-21 1974-07-05 Verfahren zum herstellen von stahlblocken
JP49110657A JPS5216849B2 (fr) 1973-12-21 1974-09-27

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US427085A US3908732A (en) 1973-12-21 1973-12-21 Methods of producing large steel ingots

Publications (1)

Publication Number Publication Date
US3908732A true US3908732A (en) 1975-09-30

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US427085A Expired - Lifetime US3908732A (en) 1973-12-21 1973-12-21 Methods of producing large steel ingots

Country Status (8)

Country Link
US (1) US3908732A (fr)
JP (1) JPS5216849B2 (fr)
AT (1) ATA557474A (fr)
AU (1) AU474999B2 (fr)
CA (1) CA1013543A (fr)
FR (1) FR2255121B1 (fr)
GB (1) GB1468223A (fr)
IT (1) IT1004104B (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9700936B2 (en) 2013-12-30 2017-07-11 Inteco Special Melting Technologies Gmbh Method and plant for the production of long ingots having a large cross-section

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5748045Y2 (fr) * 1976-06-23 1982-10-21

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3603374A (en) * 1969-02-10 1971-09-07 Heppenstall Co Methods of producing large steel ingots

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3603374A (en) * 1969-02-10 1971-09-07 Heppenstall Co Methods of producing large steel ingots

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9700936B2 (en) 2013-12-30 2017-07-11 Inteco Special Melting Technologies Gmbh Method and plant for the production of long ingots having a large cross-section

Also Published As

Publication number Publication date
IT1004104B (it) 1976-07-10
GB1468223A (en) 1977-03-23
FR2255121A1 (fr) 1975-07-18
AU6760474A (en) 1975-10-09
AU474999B2 (en) 1976-08-05
CA1013543A (en) 1977-07-12
JPS5095128A (fr) 1975-07-29
FR2255121B1 (fr) 1980-06-20
ATA557474A (de) 1978-03-15
JPS5216849B2 (fr) 1977-05-12

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