Journal of Iron and Steel Research International最新文献

Pinless friction stir spot welding (P-FSSW) was performed to manufacture Mg/steel lap joints. Orthogonal tests for P-FSSW of Mg/steel were investigated, and the main factors affecting the properties of Mg/steel lap joints were derived. The shear force of the Mg/steel lap joints gradually increased and then decreased as the welding time increased. Maximum shear force was 5.3 kN. Fe–Al intermetallic compound (IMC) was formed at the Mg/steel interface near the steel side, and Mg–Al IMCs were formed at the Mg/steel interface near the Mg alloy side. Mg/steel lap joint was transformed from an initial solid-state welding to fusion-brazing welding as the welding time increased. No hole defects were formed in Mg/steel solid-state welding joints, whereas hole defects appeared in Mg/steel fusion-brazing welding joints. The temperature field of Mg/steel lap joints was simulated to analyze hole defects generated during the welding process. Hole defects can be eliminated by changing the spindle deflection angle, and the shear force decreased. Excessive spindle deflection can also lead to failure to form a stable joint. Hole defects were removed because the spindle deflection angle reduced the interfacial reaction temperature, and a solid-state welding joint was formed, which resulted in an absence of fusion-brazing welding hole formation.

Ti₃SiC₂ ceramic and SUS430 ferritic stainless steel were welded by the transient liquid phase (TLP) diffusion bonding method using an Al interlayer at 850–1050 °C in vacuum. The evolution of phase and morphology at the interface and bonding strength were systematically investigated. The results show that Ti₃SiC₂ and SUS430 were well bonded at 900–950 °C. Three reaction zones were observed at the interface. At the joint interface area adjacent to alloy, the alloy completely reacted with liquid Al to form Al₈₆Fe₁₄. At Ti₃SiC₂/Al interface, Ti and Si diffused outward from Ti₃SiC₂ into the molten Al to form Fe₃Al + Al₅FeSi + TiAl₃ zone. Adjacent to Ti₃SiC₂ matrix, Ti₃Si(Al)C₂ + TiC_x zone was formed by the loss of Si. The evolution mechanism of TLP-bonded joints was discussed based on the interface microstructure and product phases. In addition, the tensile strength of the joint increased with increasing bonding temperature. The corresponding maximum value of 59.7 MPa was obtained from SUS430/Al (10 μm)/Ti₃SiC₂ joint prepared at 950 °C.

Lightweight refractories for the working lining of high-temperature furnaces play an important role in the smelting of advanced steels and superalloys. To prepare lightweight refractories for the working lining of high-temperature furnaces, the synthesis of lightweight aggregates is the basis. Recently, the research on the synthesis of lightweight aggregates with high service temperature, low thermal conductivity, high strength, and good slag resistance has received widespread attention. The available literature on the synthesis of lightweight aggregates was summarized, including corundum, mullite, mullite–corundum, spinel, corundum–spinel, cordierite, cordierite–mullite, calcium hexaluminate, corundum–calcium hexaluminate, bauxite, magnesia, magnesia-based, and forsterite-based aggregates. Finally, the future development trend of lightweight aggregates was proposed.

We proposed a new technique route of directional solidification for the manufacture of super slab. A 7-t laboratory-scale thick slab was casted and characterised for trial. To further understand the process, the evolution of the multiple physical fields during the directional solidification was simulated and verified. Similar to the convectional ingot casting, a negative segregated cone of equiaxed grains was formed at the bottom, and a seriously positive segregated region was formed beneath the top surface of the slab. Specific measures on the lateral walls, base plate, and free surface were strongly recommended to ensure that the slab is relatively directionally casted. A water-cooling copper base plate accelerates the solidification rate and the columnar growth along the vertical direction. It inhibits the sedimentation of equiaxed grains and enlarges the columnar zone. Based on the simulation analysis, it can be concluded that the directional solidification technique route is promising to manufacture super slab with lower segregation level, and less porosities and inclusions.

The phase volume fraction has an important role in the match of the strength and plasticity of dual phase steel. The different bainite contents (18–53 vol.%) in polygonal ferrite and bainite (PF + B) dual phase steel were obtained by controlling the relaxation finish temperature during the rolling process. The effect of bainite volume fraction on the tensile deformability was systematically investigated via experiments and crystal plasticity finite element model (CPFEM) simulation. The experimental results showed that the steel showed optimal strain hardenability and strength–plasticity matching when the bainite reached 35%. The 3D-CPFEM models with the same grain size and texture characters were established to clarify the influence of stress/strain distribution on PF + B dual phase steel with different bainite contents. The simulation results indicated that an appropriate increase in the bainite content (18%–35%) did not affect the interphase strain difference, but increased the stress distribution in both phases, as a result of enhancing the coordinated deformability of two phases and improving the strength–plasticity matching. When the bainite content increased to 53%, the stress/strain difference between the two phases was greatly increased, and plastic damage between the two phases was caused by the reduction of the coordinated deformability.

Understanding the phase equilibria of the Fe₃O₄–Cr₂O₃–CaO system is essential for the efficient recycling of stainless steel pickling sludge. The isothermal section of this system at 1473 K under oxygen partial pressure of 0.15 Pa was investigated. Key experiments on the relevant binary systems were conducted using a combination of equilibrium-quenching techniques, X-ray diffraction, high-resolution transmission electron microscope, and electron probe microanalysis. These systems were rigorously assessed using the CALPHAD (CALculation of Phase Diagram) method, incorporating the present experimental data. The liquid phase was modeled using the ionic two-sublattice model, represented as (Ca²⁺, Cr³⁺, Fe²⁺)_P(O²⁻, Va, FeO_1.5)_Q, where Va represents vacancy, and P and Q denote the number of sites on the cation and anion sublattices, respectively. To ensure electroneutrality, the values of P and Q adjust according to the composition of the mixture. From this, the isothermal section of the Fe₃O₄–Cr₂O₃–CaO system at 1473 K under the specified oxygen partial pressure was obtained based on the thermodynamic parameters of the binary systems. The present experimental data and calculation results hold significant implications for the comprehensive recycling of stainless steel pickling sludge.

Obtaining a reasonable mold flow field for casting slabs with different sections is challenging by solely modifying the nozzle structure and continuous casting process. Research was conducted on small-sectioned (1000 mm × 220 mm) and large-sectioned (3250 mm × 220 mm) slab continuous casting molds with a fixed nozzle form (concave bottom nozzle, side port inclination angle of 0°). A three-dimensional electromagnetic model is established to analyze the current frequency, installation position, and rotation angle under the active deceleration mode and acceleration mode. The results indicate that, regardless of the deceleration mode for small-sectioned slabs or the acceleration mode for large-sectioned slabs, the magnetic flux density in the mold decreases with increasing current frequency. However, the maximum electromagnetic force initially increases and then decreases, suggesting that both electromagnetic modes have the same optimal current frequency (3 Hz). The optimal mechanical design parameters for the deceleration mode of electromagnetic variable flow device (EM-VFD) with the small-sectioned slab are as follows: installation position Z = 115 mm and rotation angle of 15°, ensuring that the maximum electromagnetic force is applied to the nozzle jet area. For the acceleration mode of the large-sectioned slab EM-VFD, the optimal mechanical design parameters are as follows: Z = 115 mm and rotation angle of 10°, ensuring that the maximum electromagnetic force is applied to 1/4 and 3/4 areas of the wide face. These findings indicate that the new electromagnetic variable flow device, which can actively adjust the flow rate and angle of the steel even under given working conditions, provides the possibility for reasonable control of the mold’s flow field.

The distinctive distribution of acoustic emission (AE) characteristic parameters generated during tensile testing of low-temperature tempered AISI 4140 steel was investigated. Two clusters of acoustic emission signals were distinguished using power-law distribution fitting and k-means clustering methods. These clusters were identified as resulting from dislocation motion during yielding and dislocation entanglement during uniform plastic deformation. The conclusion is further confirmed by transmission electron microscopy images at different strains. In particular, the unique "arch-shaped" distribution of the acoustic emission energy during yielding implies a change in unusual dislocation motion modes. The effect of carbide precipitation was qualitatively discussed as not considering the primary cause of the formation of this arch-shaped distribution. The evolution of dislocation motion modes during yielding of low-temperature tempered martensite was elucidated by comparing the significant difference in cumulative energy values during yielding of annealed and low-temperature tempered specimens. Dislocations emit from Frank–Read or grain boundary sources and slip along short free paths, contributing to the initial increase in AE signals energy. Subsequently, the primary source of acoustic emission energy “arch-shaped” peak during yielding was generated by the avalanche behavior of accumulated dislocations, leading to the accelerated dislocation motion.

To elucidate the formation mechanisms of burn-on sand and metal penetration during sand casting, some laboratory experiments were carried out at different temperatures (1813, 1833, 1853, and 1873 K) and holding time (20, 40, 60, and 90 min) to simulate the interaction between ZG13Cr9Mo1VNbN stainless steel and chromite sand. The results demonstrate that the defects primarily consist of a mixture of the liquid phase, chromite, and metal. The main components of the liquid phase are SiO₂, MnO, MgO, Cr₂O₃, FeO, and Al₂O₃, and the formation of Cr₂O₃ through interfacial redox reactions has been discovered. The presence of a liquid phase plays a pivotal role in influencing burn-on sand and metal penetration. Interface reactions are prioritized, with burn-on sand maintaining a predominant influence. As the liquid phase quantity within the sand escalates, there is a corresponding incremental rise in the incidence of metal penetration. Even a minimal presence of the silicon element in steel can impact the liquid phase’s formation. Moreover, the decomposition or dissolution of chromite sand is a significant factor in the development of burn-on sand and metal penetration. Thus, a thorough investigation into the conditions and contributing factors of this phenomenon is essential for its effective management and mitigation.

The iron oxide (FeO) content had a significant impact on both the metallurgical properties of sintered ores and the economic indicators of the sintering process. Precisely predicting FeO content possessed substantial potential for enhancing the quality of sintered ore and optimizing the sintering process. A multi-model integrated prediction framework for FeO content during the iron ore sintering process was presented. By applying the affinity propagation clustering algorithm, different working conditions were efficiently classified and the support vector machine algorithm was utilized to identify these conditions. Comparison of several models under different working conditions was carried out. The regression prediction model characterized by high precision and robust stability was selected. The model was integrated into the comprehensive multi-model framework. The precision, reliability and credibility of the model were validated through actual production data, yielding an impressive accuracy of 94.57% and a minimal absolute error of 0.13 in FeO content prediction. The real-time prediction of FeO content provided excellent guidance for on-site sinter production.