WO2016077685A1 - A method for the manufacture of an efficient steel deoxidizer aluminum matrix composite material - Google Patents
A method for the manufacture of an efficient steel deoxidizer aluminum matrix composite material Download PDFInfo
- Publication number
- WO2016077685A1 WO2016077685A1 PCT/US2015/060560 US2015060560W WO2016077685A1 WO 2016077685 A1 WO2016077685 A1 WO 2016077685A1 US 2015060560 W US2015060560 W US 2015060560W WO 2016077685 A1 WO2016077685 A1 WO 2016077685A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- composite material
- aluminum
- manufacture
- free
- steel
- Prior art date
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
- C21C7/04—Removing impurities by adding a treating agent
- C21C7/06—Deoxidising, e.g. killing
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
- C21C7/0006—Adding metallic additives
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
- C21C7/04—Removing impurities by adding a treating agent
- C21C7/076—Use of slags or fluxes as treating agents
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B1/00—Preliminary treatment of ores or scrap
- C22B1/14—Agglomerating; Briquetting; Binding; Granulating
- C22B1/24—Binding; Briquetting ; Granulating
-
- 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/20—Recycling
Definitions
- the invention relates generally to the manufacture of composite materials, and more particularly to a method of manufacturing an aluminum matrix composite material for use as a deoxidizer in steel making.
- Aluminum is one of the most potent deoxidizing (deox) agents and is used for practically all quality flat-rolled steels which comprise about 60% of all steels produced. Aluminum is usually charged into molten steel at two stages of steel making process. First charge, where the bulk of deox aluminum is used, happens at tapping of electric arc furnace (EAF) or basic oxygen furnace (BOF) into a ladle in a form of ingot or cones placed at the bottom of an empty ladle and (or) thrown into tapped steel stream vortex.
- EAF electric arc furnace
- BOF basic oxygen furnace
- LMF ladle metallurgical furnace
- Molten steel surface in the ladle is covered with protective slag, which contains large amounts of iron oxide. Since aluminum has much lower density than molten steel (2.2 vs. 7 g/cm3 at temperature), it floats to the melt surface where it is trapped in slag covering molten steel and the bulk of aluminum (70%>) is exposed to and reacts with oxygen in slag's iron oxide or atmospheric air instead of oxygen dissolved in the steel and therefore is wasted inefficiently.
- a straight forward engineering solution to the problem of aluminum floating to steel surface during deoxidation is to join aluminum with a heavier component, so that it submerges deeper when charged into molten steel.
- a logical choice for heavier component is iron or steel, since it can make joined material heavier without contaminating steel melt. Indeed, if one considers prior art solutions to the problem, such material called ferroaluminum alloy produced via high temperature smelting of iron (or steel) and aluminum is offered on the market since approximately 1970's - see [Deely P.D. "Ferroaluminum - Properties and Uses" in Ferroalloys and Other Additives to Liquid Iron and Steel, ASTM STP 739, J.R. Lampman and A.T.
- ferroaluminum suffers from a few drawbacks that prevented its wide adoption in the industry. Since the alloy is produced using high temperature smelting, it turned out expensive to manufacture due to high energy and furnace maintenance costs, as well as high aluminum losses due to oxidation. Another problem associated with high process temperature is ferroaluminum' s susceptibility to crumbling during its charging into molten steel due to thermal stresses and large brittle complex intermetallic phases present in the microstructure.
- a method for the manufacturing of an aluminum matrix composite material includes the steps of forming a porous free-standing preform comprised of aluminum and iron-rich component, applying heat to the free-standing preform to raise its temperature above the melting point of aluminum and below the melting point of iron-rich component, and applying pressure to densify the free-standing preform to solidify.
- the iron-rich component of the aluminum matrix composite material is steel.
- the aluminum is present in the range of 10-50% of the composite material by weight. Further, in one embodiment of the present method of manufacture, the aluminum is 30% of the composite material by weight.
- Another embodiment of the present method of manufacture provides for a freestanding preform formed by a process of mechanical pressing, briquetting, a container, an inorganic binder or a combination of any of those processes.
- One embodiment of the present method of manufacture provides for a certain amount of heat that is applied to the free-standing preform to raise its temperature over 661 degrees Celsius. In one embodiment, heat is applied to the free-standing preform through a process selected from the group including induction heating, electrical resistance furnace heating, and organic fuel burner furnace heating.
- another embodiment of the present method of manufacture provides that an amount of external pressure is applied to the free-standing preform sufficient for a molten aluminum component to fill substantially all porosity and gaps between the iron-rich components.
- Yet another embodiment of the present method of manufacture is to provide an amount of external pressure to the free-standing preform to densify the preform. The pressure to densify is applied by a means of pressing in a closed die.
- One embodiment of the present method of manufacture provides for the iron-rich component to be selected from a group including ferromanganese, and a mixture of steel and ferromanganese.
- the free-standing preform is bound and supported by a process selected from a group that includes mechanical pressing, inorganic binder, a steel container, and any combination thereof. Further, the amount of heat applied to the freestanding preform is applied through a process that may include induction heating, electrical resistance furnace heating, and organic fuel burner furnace heating.
- One embodiment of the present method of manufacture is to provide a method for the manufacture of an aluminum matrix composite material. The steps include forming a porous free-standing preform comprising of a plurality of fines of aluminum and a plurality of fines selected from the group consisting of: steel, ferromanganese, silicocalcium, calcium carbide, rare earth metals, any ferroalloy other than ferromanganese.
- the new steel deoxidizer material provided in the present method of manufacture may be best described as aluminum matrix composite.
- Composite materials are usually defined as comprising of discrete reinforcement or filler particles or fibers that are contained in, or surrounded by, continuous matrix material.
- metal matrix composites are often referred to as engineered materials.
- Composites reinforcement and matrix are joined together through an engineered manufacturing process and generally speaking do not find themselves in thermodynamic equilibrium, in many cases being chemically inert to each other - for example refractory ceramic particles in aluminum matrix composite.
- casting is where reinforcement particles are first pre-mixed with molten metal and then the mixture is cast into a mold.
- powder metallurgy methods occur when solid reinforcement and matrix particles are mixed, pressed into a shape and then sintered in solid state at high temperature.
- Another well-known widely applied method may be generally described as pressure infiltration technology.
- a dry preform of reinforcement particles is first made, heated up, placed into a die, and then molten matrix metal is poured over the die and infiltrated into the dry preform under external pressure applied to the matrix metal, usually via hydraulic press punch.
- New deoxidizer aluminum matrix composite material described herein is manufactured using a pressure infiltration technology that is radically improved compared to a custom one to make the technology economical to implement and minimize losses of valuable aluminum.
- the new technology aluminum matrix infiltrant does not have to travel from one boundary of a dry preform made of steel particles through a bulk of the preform and all the way to the opposite boundary in order to infiltrate the preform completely.
- Such long travel of molten aluminum necessitates complex and precisely machined dies to avoid aluminum bursting out under pressure, and also carries risk of premature aluminum cool down and incomplete preform infiltration as a result.
- liquid aluminum has to travel only a short distance to fill gaps between steel particles in the preform.
- pre-mixed aluminum is pre-mixed with the steel particles at the stage of preform manufacturing - a step, which also automatically guarantees precise aluminum to steel weight ratio in the new composite deoxidizer.
- the pre-mixed aluminum transitions to liquid state during preform heat-up and only travels distances comparable to average steel particle size to fill gaps around them when the preform is squeezed in a hydraulic press die.
- Such technology may be called in-situ pressure infiltration technology, because aluminum infiltrant is in-situ present in the preform that is being infiltrated.
- a porous free-standing preform shape is formed from crushed turnings, shavings, borings or other substantially small pieces of aluminum mixed with crushed turnings, shavings, borings or other substantially small pieces of steel, wherein the preferred weight fraction of aluminum is close to 30%.
- Formation of the shape is a manufacturing operation that will be known to those skilled in the art, and preferably achieved by mechanical pressing or briquetting.
- the preform shape may be formed using a container, inorganic binder (i.e. sodium silicate), or both to make it free-standing.
- Geometry of the preform shape might vary.
- the geometry may be a cylinder between 20 and 200 millimeters in diameter and between 20 to 200 millimeters in height, and having diameter to height ratio of 1 to 1 or close to it.
- the preform shape is heated to a temperature that is over melting temperature of aluminum, but below melting temperature of steel and for a sufficient time for aluminum component to transition to liquid state.
- Exact heating temperature value might vary. In a preferred embodiment, the temperature range may be between 661 and 800 degrees Celsius. Possible techniques used to heat up the preform shape will be known to those skilled in the art. In a preferred embodiment, the technique may be induction heating, since it is extremely efficient at heating materials that contain ferromagnetic components, specifically carbon steel.
- the heated preform shape is squeezed in an adequately tight volume at a pressure sufficient for in-situ molten aluminum component in the shape to fill practically all porosity and gaps between steel particles, so that the composite becomes near fully dense with a density at least higher than 90 percent of theoretical and preferably higher than 95 percent of theoretical.
- Pressure on the preform should be maintained until the moment where the molten aluminum solidifies.
- Squeezing operation may be performed using wide variety of techniques known to those skilled in the art. In a preferred embodiment, the technique may be pressing in a closed die mounted on a hydraulic press. The die suitable for squeezing operation may be much less complex compared to dies used in custom pressure infiltration technology.
- weight fractions of aluminum in the free-standing porous shape may vary between 10% and 50%.
- the porous freestanding preform shape is formed from crushed turnings, shavings, borings or other substantially small pieces of aluminum mixed with substantially small pieces of ferromanganese, wherein the weight fraction of aluminum is close to 25%.
- the rest of the process steps, including shape heating and heated shape squeezing are substantially the same.
- a rational for substituting steel with ferromanganese is that on one hand, it is known to those skilled in the art that combined effect of aluminum and manganese as deoxidizers is stronger than of either element separately.
- ferromanganese may serve the same functions as steel as far as making aluminum- containing deoxidizer heavier and providing efficient induction coupling during induction heating of the porous free-standing preform shape.
- some of the steel and aluminum in the free-standing porous preform shape may be replaced by additions useful in the steelmaking process, such as silicocalcium, calcium carbide, rare earth metals and other useful additions.
- Such additions may help deoxidize steel even better than aluminum alone, or modify shape and size of oxides and other non-metallic particles suspended in molten steel, making them smaller and more compact, thus improving appearance and mechanical properties of a final flat rolled steel product.
- the new steel deoxidizer aluminum matrix composite material manufactured as described in the preferred embodiment above is used to deoxidize steel at the stage of EAF or BOF tapping into a ladle as direct replacement of aluminum ingot or cone.
- weight ratio of the deoxidizer composite material to weight of aluminum ingot or cone it replaces may be estimated as 1.66 to 1 based on the following considerations. It is known from past industrial practice that non-crumbled ferroaluminum containing close to 30% aluminum by weight saves about 50% of aluminum compared to deoxidation using ingot or cone. Therefore, each kilogram of aluminum ingot or cone may be replaced by 0.5 kilogram of aluminum contained in ferroaluminum, or in case of the present method of manufacture in deoxidizer aluminum matrix composite. For a preferred weight ratio of aluminum to steel of 30 to 70, one may calculate the total weight of new deoxidizer replacing one kilogram of aluminum ingot or cone as 0.5 kilogram multiplied by 100 and divided by 30, which equals 1.66 kilogram.
Abstract
Description
Claims
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
RU2017120546A RU2673252C1 (en) | 2014-11-14 | 2015-11-13 | Method of manufacturing composite material with aluminum matrix - steel deoxidizer |
US15/526,394 US20170321291A1 (en) | 2014-11-14 | 2015-11-13 | A method for the manufacture of an efficient steel deoxidizer aluminum matrix composite material |
CN201580060332.1A CN107075597A (en) | 2014-11-14 | 2015-11-13 | Method for manufacturing effective killer aluminium matrix composite |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201462079558P | 2014-11-14 | 2014-11-14 | |
US62/079,558 | 2014-11-14 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2016077685A1 true WO2016077685A1 (en) | 2016-05-19 |
Family
ID=55955102
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2015/060560 WO2016077685A1 (en) | 2014-11-14 | 2015-11-13 | A method for the manufacture of an efficient steel deoxidizer aluminum matrix composite material |
Country Status (4)
Country | Link |
---|---|
US (1) | US20170321291A1 (en) |
CN (1) | CN107075597A (en) |
RU (1) | RU2673252C1 (en) |
WO (1) | WO2016077685A1 (en) |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6350295B1 (en) * | 2001-06-22 | 2002-02-26 | Clayton A. Bulan, Jr. | Method for densifying aluminum and iron briquettes and adding to steel |
US20020100523A1 (en) * | 1999-04-20 | 2002-08-01 | Subhasish Sircar | Free machining aluminum alloy with high melting point machining constituent and method of use |
RU2269586C1 (en) * | 2004-04-30 | 2006-02-10 | Леонид Павлович Селезнев | Method of preparation of master alloys and deoxidizers |
CN101092657A (en) * | 2007-07-20 | 2007-12-26 | 谢应凯 | Rare earth aluminum based composite alloy in use for steel making |
Family Cites Families (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
RU2192495C2 (en) * | 2000-06-22 | 2002-11-10 | Тен Эдис Борисович | Deoxidizer |
CN1524650A (en) * | 2003-09-18 | 2004-09-01 | 上海华元喷射成形有限公司 | Preparation technology for jet forming and semisolid moulding largescale complex parts |
CN1603030A (en) * | 2003-09-30 | 2005-04-06 | 哈尔滨工业大学 | Pseudo semisolid thixotropy forming method for high-melting-point alloy |
CN101736130A (en) * | 2010-01-22 | 2010-06-16 | 刘巍 | Al-Ca-Fe deoxidant and preparation method thereof |
-
2015
- 2015-11-13 CN CN201580060332.1A patent/CN107075597A/en active Pending
- 2015-11-13 RU RU2017120546A patent/RU2673252C1/en not_active IP Right Cessation
- 2015-11-13 WO PCT/US2015/060560 patent/WO2016077685A1/en active Application Filing
- 2015-11-13 US US15/526,394 patent/US20170321291A1/en not_active Abandoned
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20020100523A1 (en) * | 1999-04-20 | 2002-08-01 | Subhasish Sircar | Free machining aluminum alloy with high melting point machining constituent and method of use |
US6350295B1 (en) * | 2001-06-22 | 2002-02-26 | Clayton A. Bulan, Jr. | Method for densifying aluminum and iron briquettes and adding to steel |
RU2269586C1 (en) * | 2004-04-30 | 2006-02-10 | Леонид Павлович Селезнев | Method of preparation of master alloys and deoxidizers |
CN101092657A (en) * | 2007-07-20 | 2007-12-26 | 谢应凯 | Rare earth aluminum based composite alloy in use for steel making |
Also Published As
Publication number | Publication date |
---|---|
US20170321291A1 (en) | 2017-11-09 |
RU2673252C1 (en) | 2018-11-23 |
CN107075597A (en) | 2017-08-18 |
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