SCIENTIFIC PROCEEDINGS XXIII INTERNATIONAL SCIENTIFIC TECHNICAL CONFERENCE "FOUNDRY 2016" ISSN 1310-3946

IMPROVING THE CASTING PROCESS OF PERITECTIC STEEL GRADES

Prof. dr. E. Chickarev1, Post grad. st. C. Y. Hu 2, Prof. dr. O. Isayev2, Prof. dr. O. Hress2, Prof. dr. K. M. Wu 2
1. Priazovskyi State Technical University, Mariupol 87500, Ukraine
2. International Research Institute for Steel Technology, Wuhan University of Science and Technology, Wuhan 430081, China

Abstract: Longitudinal cracking when continuous casting of peritectic steels was studied in this work. Dependency of slab scarfing volume
and surface cracking on the steel chemical composition was investigated. The optimum casting speed and taper parameter of the mold were
determined based on analytical modeling and statistical analysis of surface cracks observed in industrial billets. It was shown that
longitudinal cracks on peritectic slabs could be reduced when the Mn to S ratio was kept above ~150. Such surface defects were decreased
to 30-35 % by optimizing the steel composition, melt temperature and casting speed. Also by using an optimum taper of the mold the scarfing
volume was reduced to 32-36 %.
KEYWORDS: LONGITUDINAL CRACKS, PERITECTIC STEEL GRADES, MOULD TAPER

1. Introduction The cracks are usually curved (wavy) and vary in length from a
few centimeters up to several meters in some cases. Longitudinal
One of the most important components that is essential for the cracks are usually formed in the central part of the mold. The
smooth operation of the continuous casting machine (CCM) and defects usually appear at the beginning of the continuous casting.
optimal quality of continuously cast billets, is the water-cooled mold The low carbon (<0.08%) slabs with > 1.1 % manganese sometimes
which absorbs 10 % to 30 % of total the heat. Continuous casting of have relatively short longitudinal cracks of about 100 mm long.
peritectic steels with about 0.1% C is particularly difficult since It is difficult to detect longitudinal cracks on the slabs
these steels are prone to the formation of longitudinal cracks and immediately after casting. These defects are often associated with
surface defects. Despite recent advances in the continuous casting small inhomogeneities located near the surface of the slab. Previous
technology, the quality of cast billets and their surface condition in a research showed [7], leads to the formation of cracks. The
number of cases remain problematic; especially casting rolled probability of longitudinal cracks formation in the peritectic steels
products for critical applications. billets depends on the variation in the withdrawing speed [3].
The problem of improving the surface quality of continuously Previous work showed that the formation of longitudinal
cast slabs with a mass fraction of carbon is close to 0.1%, and there cracks in the continuously cast peritectic steels was due to the
is at present. volumetric change during δ to γ transformations [8, 9]. It was also
The mechanism of heat transfer between the billet and the shown that the formation of cracks can be reduced by (1) stabilizing
mold is an important issue because the conditions of heat exchange slag penetration into the gap between the mold and the billet, (2)
depends on the performance of the caster and the quality of surface controlling the casting nozzle, and (3) reducing the time required to
and subsurface layers of the cast billet. Understanding the establish a steady casting speed.
mechanisms of heat transfer between the billet and the mold is It is also of interest to improve the surface quality of
essential for designing an optimum mold [1, 2]. continuously cast billets by addition of surface-active elements
Peritectic medium-carbon steels exhibit an anomalous decrease and/or reducing the concentration of harmful impurities.
of the heat flux on the mold surface due to the surface roughness of The chemical composition of the steel, particularly carbon
the solidifying shells, whereas ultra-low carbon steels exhibit large content has a significant effect on the formation probability of
heat flux despite their large surface roughness. Such difference is longitudinal cracks, e.g. carbon concentration between 0.10 to 0.14
caused by the fact that the surface roughness of ultra-low carbon wt.%. is reported to be undesirable.
steels arises from δ/γ transformation which occurs somewhat later The tendency of crack formation in steels depends of on the
than the completion of solidification [3]. ferritic potential Fp as defined in Eq. (1) [10]:
The degree of peritectic solidification is a strong indicator of
the cracking tendency of steel during continuous casting. To predict Fp = 2.5 (0.5-[Ceq]), (1)
the crack susceptibility of regular carbon steel slabs, the
characteristic index of solidification shrinkage (RV), which is where
determined by the volume shrinkage of the peritectic solidification
and the remaining liquid phase after the peritectic solidification, is Ceq= [%C] + 0.04[%Mn] + 0.1[%Ni] + 0.7[%N] - 0.14[%Si] –
proposed as a means of evaluating the cracking tendency [4]. - 0.04[%Cr] - 0.1[%Mo] - 0.24[%Ti] - 0.7[%S]. (2)
Slight variation of C or Mn, in the order of 0.04%, promoted
significant changes in the evolution of phases during solidification. For fully ferritic steels Fp is above 1 (e.g. Fp = 1.25 for pure δ
The variation in the C content has a larger influence than that of Mn - iron). If Fp < 0, the steel is fully austenitic.
on the evolution of phases, however, the Mn microsegregation In addition, the taper and heat transfer condition have a
generated at high cooling rate can promote a change in the significant influence on the formation of crack.
solidification mode from hypo to hyper-peritectic. Cracking This paper presents the results of statistical analysis carried out
susceptibility observed in the hypo-peritectic steel is not only on the formation of surface cracks by taking in account the
generated by differences in the mechanical behavior δ and γ phases, overheating of the melt in the tundish and the mold taper when
but also by the liquid inability to compensate the contraction casting various grades of steels.
associated to the peritectic transformation [5].
The possibility of cracking increased with increasing sulfur
content and the carbon content at which longitudinal surface 2. Experimental method
cracking frequency is maximized decreased because brittle
temperature range extended to the lower temperatures. The effect of All of the studied steel grades melted in oxygen converter with
the steel composition on the formation of longitudinal cracks using a capacity of 350 tons, finishing on the chemical composition and
the non-equilibrium phase diagram has not been reported yet, and a refining were carried out on the ladle furnace.
more quantitative and systematic study must be made to interpret the The casting was performed on double-stream curved
surface cracking phenomena [6]. continuous casting machine producing slabs with cross-sections
from 220×1250 to 250×1850 mm2.

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SCIENTIFIC PROCEEDINGS XXIII INTERNATIONAL SCIENTIFIC TECHNICAL CONFERENCE "FOUNDRY 2016" ISSN 1310-3946

Experiments and quality control of continuously cast slabs was 12

carried out for a wide range of steel grades with carbon FP=0.88-0.92
10
concentration in the range of 0.08 to 0.19 wt.% and manganese

Fraction of slabs with

longitudal cracks, %
concentration of 0.60 to 1.75 wt.%. Three types of steel samples
8
were investigated in this work; plain carbon steels, microalloyed-
steels with 0.03 to 0.05 wt.% of Nb, and microalloyed-steels with
6
0.02 to 0.04 wt.% of Nb plus 0.050 to 0.120 wt.% of V.
The total volume of investigated heats for analysis was 1800 FP=0.86-0.87
4
heats.
2 FP<0.86

3. Results and discussion 0

0 0,005 0,01 0,015 0,02 0,025

[S], % mass.
3.1. Statistical analysis of industrial billets
It is established that ferritic potential is quite sensitive to Fig. 2 - Effect of sulfur content on surface crack index in steels with
variations in the steel composition and can be used to predict the various ferritic potentials.
occurrence of surface defects in rolled products Figure 1 shows the On the basis of statistical analysis of industrial heats, shown in
results of a statistical analysis of the relationship between fraction of Fig.3, a manganese to sulfur ratio above 150 should be sufficient to
slab with longitudinal cracks and ferritic potential of corresponding substantially reduce longitudinal cracking in continuously-cast
heats. It is clear that the variation in the concentration of alloying billets. A similar result, but less pronounced, was observed for
elements significantly affected the amount of surface scarfing (see correlation of the primary sorting slabs on longitudinal cracks and
Fig. 1). ratio [Ca]/[S].
16
30

14
Fraction of slabs with longitudal

Fraction of slabs with

longitudal cracks, %
25

12
20
y = 0.00392e10.76
10
cracks, %

15
8

10
6

5
4
50 70 90 110 130 150 170 190 210
0
0,8 0,82 0,84 0,86 0,88 0,9 0,92 0,94 [Mn]/[S], % mass., in rolled sheets
Ferritic potential Fig. 3 - Influence of manganese to sulfur ratio on surface
Fig. 1 - Influence of ferritic potential on longitudinal cracks in a longitudinal crack index in peritectic steels, each point represents
peritectic steel grades, each point represents the average of 100 the average of 100 heats.
heats.
However, the possibility of varying the chemical composition
For example, an increase in the mass fraction of carbon from of the metal is very limited; therefore, it is more practical to reduce
0.11-0.12% to 0.13-0.14% decreased the volume of surface scarfing the extent of cracking by optimizing the casting parameters such as
by third. For the steel with 0.14-0.16 wt.% carbon the optimal mass the taper and heat transfer conditions in the mold.
fraction of manganese was 1.35-1.50% (i.e. the largest value of Analysis of the continuous casting of peritectic steels using a
Ferritic Potential). The decrease in the mass fraction of manganese curvilinear slab caster (220x1250mm to 300x1850 mm) showed that
to 1.23-1.35 % (at the same mass fraction of carbon) significantly overheating of the metal in the tundish can increase the chance of
affected the surface crack index. longitudinal cracking (see Fig. 4). Thus, given the narrow range of
In addition, the fraction of continuously cast billets with cracks chemical composition for this family of steels, it is advisable to
increases with the sulfur content in the steel, because the formation reduce overheating in the tundish in order mitigate cracking problem.
of inclusions of manganese sulphide between dendrites depends on Additional benefit of reducing tundish temperate is having more
the ratio [Mn]/[S] (a typical example of the formation of manganese uniform solidification of the shell.
sulphide on the surface in dendritic spaces is presented in Reference
10
[10]).
Fraction of slabs with longitudal

Fig. 2 shows the steel with a mass fraction of carbon over 0.12% 9,5

(i.e. high Ferrite Potential) the amount of scarfing was increased and 9

for a group of heats with high ferritic potential impact of the mass 8,5
fraction of sulfur affects more. 8
cracks, %

7,5

6,5

5,5

5
10 15 20 25 30 35

Overheating (T-Tliq) in the tundish, K

Fig. 4 - Effect of tundish superheating on surface crack index in a
continuously cast peritectic steel billets, each point represents the
average of 100 heats.

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SCIENTIFIC PROCEEDINGS XXIII INTERNATIONAL SCIENTIFIC TECHNICAL CONFERENCE "FOUNDRY 2016" ISSN 1310-3946

3.2. Calculation of optimal mould taper 4. Conclusions

However, changing overheating of the metal entails a change
in the speed of casting. This is especially important for peritectic Based on analytical modeling and statistical analysis of the
steel grades due to the strong dependence of the heat flux in the surface cracks observed in industrial billets, the optimum casting
mold from the mass fraction of carbon with a sharp decline in it for parameters for peritectic steels were determined The proposed
peritectic steels [4]. formulas were used to optimise withdrawing speed and mold taper.
Optimum casting speed, which depends on the heat flux and The outcomes were crosschecked against the industrial tests.
mass balance, can be estimated using the following equation (taking Almost complete prevention of longitudinal cracks on slabs of
into account assumptions about the almost complete removal of peritectic steels and significant reduction of surface scarfing was
overheating in the mold): achieved when the Mn to S and Ca to S ratios were above about 150
and 0.3, respectively.
2ℎ𝑎 𝑅
w = 𝑞� ∙ ∙ (1 + ), (3) The optimal values of the ferritic potential when casting
𝜌(𝑅𝑐∆𝑇+2𝑥𝐿) 𝑏
peritectic steels with various carbon contents were determined. For
where q is the mean heat flow extracted from the slab surface in steel without niobium the ferritic potential should be less than 0.88,
the mold; ha is the height of the mold; b & R are the width and the whereas the steel containing 0.12-0.16% C, 0.08-0.12 and 0.10-0.14%
thickness of the slab; c is specific heat of the metal; x is the C and 1.35-1.50% Mn - in the range of 0.76 ... 0 80, 0.80 ... 0.84,
thickness of the solid shell and L is the heat of crystallization. 0.86 ... 0.90, respectively.
The Calculation was carried out using a modified dependence
[11], in which the coefficient A is assessed by monitoring the heat
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