Recent Progress in Non-Circular Ingot Continuous Casting Technology
Abstract Demonstration of non-circular steel ingot production by continuous casting process in various industrial scale trials has long been a research target. This paper summarizes the latest developments in non-circular continuous casting technology, including process design, operational equipment, forming apparatus and pre-equipment process flow. The advantages and disadvantages of each approach are discussed in detail. The expected future development and possible opportunities of this technology are also discussed.
Key Words Non-circular steel ingot; continuous casting; process design; forming apparatus
1 Introduction
Continuous casting is a widely used technology that simplifies the steelmaking process by casting molten steel in a continuous process, bypassing the time-consuming steps of ingot formation and hot-rolling. This technology has enabled much more efficient and consistent steel production, resulting in higher yield and quality. However, the traditional round shape of the ingot limits its potential for further improvements. Non-circular steel ingots, including oval, rectangular and other shapes, can offer advantages in certain production processes such as forging and heat-treatment. If the non-circular shape of steel ingots can be replicated in the continuous casting process, this technology can be significantly improved.
2 Recent Developments
The development of non-circular continuous casting technology is undergoing rapid advances. In recent years, various industrial-scale trials have demonstrated non-circular steel ingot production by continuous casting process. In such trials, process design, forming apparatus and pre-equipment process flow are typically improved in order to produce the desired shapes of ingots.
2.1 Process Design
Process design is one of the key factors that affects the successful application of non-circular continuous casting technology. In particular, the design of the metallic mold which is in contact with the molten metal during the casting process must be given extra attention. Generally speaking, the metallic mold must be designed to match the desired ingot shape, ensuring a proper geometry and balance between the molten steel flow and die temperature. Furthermore, different mold coatings can be employed in order to reduce friction forces between the steel and the die.
2.2 Forming Apparatus
A number of forming apparatus have been developed to shape the molten steel during the continuous casting process. Examples of such apparatus include vacuum deformers, hydraulic die drawing devices, and movable steel plates. In order to successfully produce the desired shape of ingots, the forming apparatus must be carefully calibrated, ensuring that the molten steel is evenly distributed around the metallic mold.
2.3 Pre-Equipment Process Flow
In order to ensure a successful continuous casting process, the pre-equipment process flow must be carefully considered. Factors such as the casting speed and temperature, as well as the size and shape of the metallic mold and the forming apparatus, must all be taken into account when calculating the pre-equipment process flow. This is necessary in order to ensure the proper distribution of the molten steel in the mold and ensure the desired shape of the ingots.
3 Advantages and Disadvantages
The application of non-circular continuous casting technology has a number of advantages over the traditional circular casting process. Firstly, non-circular ingots can offer more efficient forging and heat-treatment operations as the shape of the ingots is more suitable for these operations. Secondly, non-circular ingots can reduce weight and costs, as less steel is required to produce the desired shape. Lastly, the use of non-circular ingots can help to reduce wastage as the ingots can be tailored to the exact specifications of the required components.
At the same time, there are some disadvantages associated with the use of non-circular continuous casting technology. Firstly, the process can be more complicated and expensive, as more sophisticated process design and equipment are required. Furthermore, the process can be vulnerable to operational errors, as the molten steel must be evenly distributed around the metallic mold in order to achieve the desired shape of the ingots. Finally, the process is generally not suitable for large-scale production, as it is difficult to keep the forming apparatus accurately calibrated for an extended period of time.
4 Future Development and Opportunities
Non-circular continuous casting technology is rapidly developing. In the near future, it is expected that the introduction of advanced control systems and robots will enable the consistent production of non-circular ingots with higher precision. Furthermore, advanced mathematical modelling and simulations may enable better process control, allowing the molten steel to be distributed with higher accuracy.
There are a number of opportunities associated with the development of this technology. Firstly, it could be used as an alternative to traditional circular continuous casting, providing a more efficient and consistent process for producing ingots with precise shapes. Secondly, it could be used to create ingots of unique shapes, such as I-beams and hollow sections, further increasing efficiency and reducing costs. Finally, the introduction of precise control systems would allow manufacturers to produce ingots with very specific properties, providing a wide range of potential applications.
In conclusion, non-circular continuous casting technology is rapidly developing and holds promising potential for future improvement. This technology can offer advantages over traditional circular casting, including reduced costs and improved efficiency. Furthermore, the introduction of advanced control systems and robots could revolutionize the process, allowing for precise and consistent production of non-circular steel ingots.
