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By Gabriel Andrade Medeiros, Christian Brugger, Paul Pennerstorfer, Daniel Fuchshuber, Reinhold Leitnerl

State-of-the-art automation technology enables digitalization of the continuous casting process that goes far beyond conventional automation of industrial production. Primetals Technologies provides a digital twin that combines an intelligent digital representation of a casting machine as well as the casting process and the slabs, blooms or billets that are produced. It allows metallurgists and process engineers to predict the behavior of the involved complex production process and optimize parameters before using them in real production. New steel grades or production processes can be evaluated off-line without any risks to process stability and product quality. Primetals Technologies installs the digital twin with every new installation of a continuous caster optimization system. This paper describes how the setup and simulation possibilities of the digital twin provide numerous benefits by modelling and simulating the casting process. It allows for example the calculation of material properties according to the actual composition, strand surface temperature profiles and dynamic soft reduction before the final point of solidification. An outstanding feature of the digital twin is the replay functionality provided for various models to analyze and further optimize real production situations. The paper also gives an example how usage of the digital twin optimized production at a customer.

Oct 1, 2019

By Frank Schrama

The Steel Plant Model (SPM) is an advanced logistic simulation model for steel plants. With the SPM, bottlenecks can be solved and logistics can be optimized. Both existing plants and greenfield designs can be simulated. All movements and actions simulated, from hot metal to cast products. Not only all major equipment and their relevant components (like a sublance) are simulated, but also ladles, scrap boxes, transfer cars and cranes. The whole plant is simulated in 3D and actual distances and speeds determine transport times. The SPM includes process time deviations and equipment downtimes for maintenance or unexpected breakdowns. This ensures more realistic and reliable results. Logistic optimization is based on comparison of different scenarios. For a new scenario, equipment and practices, etc. can easily be modified, added or removed. At the same time the SPM produces all relevant data for every new scenario, which can be presented conveniently. This makes the SPM the ultimate tool to find bottlenecks or optimize plant logistics. The SPM is validated for several plants world-wide, with different characteristics and layouts. The SPM not only realistically simulates existing plants with all utilizations, crane movements and waiting times, but also to accurately predicts the influence of plant modifications or unexpected events like breakdowns. Given the flexibility of the SPM, any (new) steel plant can be simulated quickly when a layout and the requested data are provided.

Aug 16, 2017

By Daniel Antonio Kapper Fabricio

Laboratórios de ensaios têm buscado implementar Sistemas de Gestão da Qualidade baseados na norma ABNT NBR ISO/IEC 17025 e procurado a acreditação de seus ensaios. A norma ASTM E517 estabelece um método de ensaio para a determinação do índice de anisotropia plástica de metais laminados, um importante parâmetro em processos de conformação mecânica por estampagem. Atualmente nenhum laboratório é acreditado pelo Inmetro na realização desse ensaio. Assim, o Laboratório de Metalurgia Física (LAMEF) da UFRGS optou por aumentar seu escopo de acreditação para abranger esse ensaio. O objetivo do trabalho é apresentar as adequações gerenciais e técnicas ao Sistema da Qualidade existente para a extensão de escopo, assim como as não conformidades encontradas e os pontos fortes para obtenção da acreditação junto ao Inmetro.

Aug 7, 2018

By Willy Ank de Morais

Este trabalho teve como objetivo analisar, através da fractografia, o desempenho de aços inoxidáveis Duplex 2205 soldados por três processos diferentes: FCAW - Flux-Cored Arc Welding (Arame Tubular), o GTAW - Gas Tungsten Arc Welding (TIG), e o SMAW - Shielded Metal Arc Welding (Eletrodo Revestido). A superfície de fratura das amostras foi obtida através de ensaios de tração, nos quais foram registradas as respectivas curvas tensão-deformação completas, que também foram analisadas. Os resultados mostraram que o tipo de influência da solda nas propriedades mecânicas analisadas.

Oct 30, 2017

By Diego Pacheco Wermuth

Micrometric surgical components typically have high geometric complexity and stringent regulatory specifications. These components need to have excellent mechanical properties and a high demand of products. Besides these factors, it is necessary to maintain a low manufacturing cost, performing essential research on new manufacturing technologies. Metal Injection Molding (MIM) is a process that has been explored , providing an interesting alternative for making medical devices. The research in the production of microcomponents obtained for MIM is gaining momentum and prominence, due to low cost and high productivity of this process. This paper is a study and development of feedstocks with AISI 316L alloy , which is known for its biocompatibility. Four feedstocks with 61%vol. of metal powder were analyzed by capillary rheometry and DSC/TGA.

Aug 16, 2017

By Thomas Schanz

Current steel market conditions require small investments only to lower operational cost. SMS Concast has developed new products which optimize continuous casting process cost for long product steel production. This paper describes a selection of three products. All three systems are patented (patent pending for CONDRIVE). CONSAFE, a non-radioactive mould level measurement system for reliable mould level measuring on open stream casting CCM’s; CONSTIR-MWS, an improved control software for electromagnetic stirrers which lowers energy cost by 35%; CONDRIVE, a brand new oscillation drive system which provides the features of a hydraulic oscillator, however with a cost efficient electric drive.

Aug 17, 2017

By Bruno Kneipel Neto, Mylena Inaiê Correia, Fabricio Cerqueira, José Francisco da Silva Filho

The automotive industry, when aiming to increase the resistance to corrosion, uses in the Body in White (BIW) concept the galvanized steels. The hot-dip galvanized steels that stand out most are known as GI steels. They are formed by the zinc element and by phases of intermetallic intermediate iron-aluminum-zinc compounds. The characteristic properties of the GI coating are directly related to the formation of the intermetallic layer, which is responsible for providing the connection between the metal substrate and the coating layer. In this context, two different types of steel (SAE1005 and TRIP780 steel) were used for laboratory characterization of their intermetallic layers through metallographic techniques. The results of the tests showed that the inclined section metallographic inlay technique allows obtaining a larger region of analysis of the intermetallic layer. For the surface analysis, it was observed that the chemical solution used in the preparation of the samples was effective, making possible an analysis more specific about the intermetallic layer formation, distribution and morphology.

Oct 12, 2019

By Laurent Dorel

Surface quality monitoring is primarily implemented in the last steps of steel manufacturing before shipment to the end user. However, an increasing trend for also addressing this topic in the upstream stages, such as hot rolling plant, is tackled by Primetals Technologies to give steel producers the key to a global optimized yield management, and efficient “lessons learned” processes. After the last developments of SIAS Next Gen platform, including High Resolution and Near Infra-Red, some site results will be exposed on the very specific high constraints lines such as ESP Endless Strip Production and Plate Mills, and highlights the related most interesting aspects for our customers.

Aug 17, 2017

By Alessandro Pigani

Over the last 25 years the thin slab casting and rolling process has been gaining a major market share in the production of hot rolled strip, progressively eroding the areas previously of exclusive domain of conventional mills. This is mainly thanks to the competitiveness of the process over conventional ones, and to the growing ability of this technology to cover the majority of market niches, well beyond the boundaries of the commodity market. After having significantly contributed to the continuous expansion of this production mode and after an extensive campaign of theoretical research and physical testing in reference plants, Danieli has progressively developed over the years a new generation of thin slab casting and rolling layout, marking a new phase in the evolution of this process. The new step-ahead is epitomized by the name QSP-DUE. This configuration belongs to the Quality Strip Production (QSP) family, which is Danieli’s strip-quality-oriented thin slab based plants. The innovative features of the process are embodied in the acronym DUE, which stands for Danieli Universal Endless (Danieli patented technology – US patent n. 8087449, January 3rd, 2012). What makes this new concept different is the ability of “universal” rolling modes thanks to the fact that, now, within one single plant it is possible to perform coil-to-coil, semi-endless and endless rolling modes, making this plant a major technology innovation compared to the previous generation.

Aug 16, 2017

By Laurent Dorel, Sebastien Maillard, Afchine Nasserian, Jean-Paul Faure

Surface quality monitoring is primarily implemented in the last steps of steel manufacturing before shipment to the end user. However, an increasing trend for also addressing this topic in the upstream stages, such as hot rolling plant, is tackled by Primetals Technologies to give steel producers the key to a global optimized yield management, and efficient “lessons learned” processes. After the last developments of SIAS Next Gen platform, including High Resolution and Near Infra-Red, some site results will be exposed on the very specific high constraints lines such as ESP Endless Strip Production and Plate Mills, and highlights the related most interesting aspects for our customers.

Oct 1, 2019

By Paul Riches

LR Process Expert is a cost-efficient process automation system for all types of long rolling mills, including, rod, bar, section, rail, reversing mills, and flat blocks. The system performs a wide range of tasks for optimized operation – from suggesting pass schedules to calculating and downloading optimized mill settings according to the availability of rolls. LR Process Expert also monitors and collects data from the raw material stage through to the finished product. It delivers valuable mill reports to the operator staff and management so they can easily assess a plant’s performance and optimize production. Defined Key Performance Indicators (KPIs) help to assess a plant’s performance; this system is not limited to one plant but can enable plant-toplant performance at corporate level.

Aug 16, 2017

By Rafael Humberto Mota de Siqueira

O objetivo da presente contribuição é discutir o aparecimento das trincas a quente em três ligas de alumínio, AA2024, AA6063 e AA6013, soldadas a laser. Para tanto um laser do tipo Yb:fibra foi usado em condições de aportes térmicos diferentes. Os resultados indicam uma tendência ao trincamento em várias condições experimentais. No entanto, para os parâmetros de processo utilizados e para as ligas estudadas, observa-se que quando a liga possui entre 0,6% e 1% de silício a sensibilidade ao trincamento diminui.

Oct 30, 2017

By Eddy Dierckx

Modernization of flat rolling plants is essential to sustainably fulfill increasing market demands and to improve competitiveness. Intelligent modernizations ensure getting maximum prime yield of existing mills, even if they have gone through half a century of operation. Existing mills were designed based on former production, consumption and quality targets. Ever increasing requirements such as increase of productivity, change of product mix (e.g. new steel grades), reduction of energy consumption and improvement of product quality lead to the necessity to adapt the existing equipment to the new target. SMS group provides, besides the reliable equipment and automation solutions to successful upgrades of existing mills, also a systematic approach to develop technical and economical solutions together with our customers (conceptual engineering). This paper describes the SMS group approach to modernizations / upgrades, introduces powerful performance modules and provides a number of successful examples that have been implemented recently.

Aug 17, 2017

By Francisco Morganti

The market requirements which strip processing lines have to deal with have altered significantly within the last decades. Particularly, the production has to be economical and ecological efficient and processing lines have to cover a broad product portfolio. Already existing plants either directly or indirectly are competing with new plants, which are equipped with the latest technologies. The “Special Strip Processing Equipment” is designed to be integrated easily and within small downtime phases in existing lines. All single machines can be delivered in short time “ready-to-perform” with a tested and proved automation system. Thus, the competitiveness of existing lines can be increased immediately with less effort. To find out which machines can be reasonably implemented SMS group offers an “Efficiency Check”. A special proceeding is used by experts to find out quickly which machines will have the largest effect on the efficiency of the line while demanding at the same time the smallest expense.

Aug 17, 2017

By Constantino Capurro

For certain applications, coarse titanium nitride (TiN) precipitates can be deleterious for the final properties of the material. Hence, in order to better understand the mechanisms involved in the generation of these precipitates, a thorough characterization of the particles observed in steels with different titanium and nitrogen content was carried out. Samples from liquid steel (tundish), continuous casting billets and final product were evaluated using an Automatic Particle Analyzer (APA) coupled to a Scanning Electronic Microscope (SEM). The location, frequency, size distribution and composition of the different particles observed were assessed. While only few TiN precipitates were observed in liquid steel samples, the density of this type of particle significantly increased in the continuous casting billets samples. Particles ranging from 1 to 10 µm were mainly found in the interdendritic zones of the as-cast structure. The density of TiN particles observed in these samples did not change after re-heating and rolling operations. A model to predict TiN precipitation during solidification was developed. A reasonable agreement was found between model results and measured data. Results of this analysis confirmed that the precipitated fraction of TiN increases as the product of steel Ti and N contents rises.

Oct 30, 2017

By Diego Moisés Maciel Vieira

Aços resistentes à abrasão possuem alta dureza, sendo largamente utilizados em aplicações nas quais o componente é submetido a situações em que é exigida alta resistência mecânica e resistência ao desgaste. Podem ser empregados para fabricação de implementos rodoviários, implementos agrícolas e na indústria de mineração. O presente trabalho visa analisar a influência da espessura dos corpos de prova de Charpy-V na energia de impacto absorvido em amostras de aço resistente à abrasão da série 450HB. Os corpos de prova foram usinados com as dimensões padronizadas pela norma ASTM E23 [1]. Os resultados obtidos demonstram uma redução nos valores de tenacidade ao impacto com a redução da espessura, explicitando a importância do método da energia relativa absorvida para análise dos resultados dos ensaios que abordam variação de espessura.

Aug 16, 2017

By Patrick E. Connell

During the ABM Conference of 2015 the latest design and process features of the new 3-roll RSB® generation were presented together with a unique Size Control System SCS® for a real time closed loop control to produce an extraordinary quality SBQ – day in, day out. In the past two years, Kocks has focused on improving the repeatability of the rolling process and developed technology to enhance the performance of its equipment. These developments include Fast Remote Control (FRC), Stands Adjustable Under Load (AUL) implementation of closed loop Size Control System (SCS), and finally a state of the art laser Gauge (4D Eagle) that pulls all of these developments into a complete package of quality. Gauges used in the past generally operated with the “shadow” measuring system. The latest gauge developments are based on the “light section” method. This method is more suitable to provide real time measurement parameters of the rolled bar. Placed close to the last rolling stand, the “light section” gauge is capable of measuring around the complete diameter with a clear definition of the bar stage in relation to the axes of the rolls. It is also capable of making these measurements using a very high measurement frequency. Following requirements of the market, requiring the highest gauge measuring frequencies which display the bar in the most accurate way even at the highest rolling speeds, the “4D Eagle” gauge was developed. This paper describes all the process features and parameters of this impressive and unique newly developed gauge as well as the other described technical improvements.

Oct 30, 2017

By Douglas Glenn Stalheim

Hot strip structural steel coil used in construction, engineering, transport, structural applications and other applications are widely used in yield strengths from 300 – 700 MPa. However, structural design engineers are now not only requiring various strength levels but also other mechanical properties, primarily good formability, toughness and weldability. To produce a balanced approach to a cost effective structural steel, hot strip coil requires an understanding of utilization of an optimized alloy composition designed for the layout/equipment capabilities of a given hot strip mill to produce the desired metallurgy for optimum mechanical property performance. The term “cost effective” does not just focus on alloy design, but also ease of overall processing from steelmaking, casting, rolling and cooling, stable mechanical properties with a statistically normal distribution, no downgrades/rejections and a product that the end user recognizes as being superior to others. The desired metallurgy is simply understanding what will be the optimum microstructure and cross sectional grain size/distribution needed to meet the mechanical property requirements. This paper is a follow up paper that previously described optimum base alloy designs along with steelmaking/casting processing considerations and will focus on proper reheating, rolling and cooling metallurgy/processing strategies to produce quality cost effective hot strip structural steel coil.

Aug 17, 2017

By Konrad Krimpelstätter

The need for more effective and flexible roll-gap lubrication technologies in hot and cold rolling mills is steadily increasing due to ever-greater requirements placed on the rolling process and the final products. In particular, the rolling of high-strength steels poses enormous demands for both the rolling mill and the coolant/lubricant to be used. The presented paper focuses on two innovative technologies for highly efficient roll-gap lubrication for hot and cold rolling, which were developed utilizing extensive knowledge and expertise about the tribological interactions in the roll-gap. The advanced work-roll lubrication package (A-WRL) for hot rolling and ESP mills is using specially designed mixer-nozzle units to mix the water/oil emulsion very close to the nozzles to minimize the risk for contamination and clogging. The nozzles are quickly exchangeable and are optimized to ensure uniform lubricant distribution, high plateout efficiency and minimum oil consumption. This eco-friendly solution does not require any chemical additives or cleaning agents and significantly reduces electrical energy consumption and work-roll wear. The roll cooling system on mill entry and exit side remains switched-on, which is of vital importance especially for highperformance hot strip mills. Minimum Quantity Lubrication MQL® represents a new generation of roll-gap lubrication technologies for cold rolling, which applies minimum amounts of pure rolling oil finely atomized with pressurized air directly onto the work roll surface. This allows controlling the oil film thickness depending on actual process and product parameters, providing increased lubrication flexibility, significant improvement of strip surface cleanliness through reduction of strip wear. MQL® was successfully installed and tested on two industrial tandem cold rolling mills in Europe. Advanced WRL and MQL® represent Primetals’ latest technologies that feature a robust and reliable system comprising standardized interfaces and flexible communication options. Both packages can easily be integrated into existing or new hot strip mills, ESP lines or cold mills.

Aug 17, 2017

By Rudi César Comiotto Modena, Gabriel de Castro Moreira, Diego Machado Marques

The definition of geological/geostatistical domains is the first step in building a mineral resource model. A suitable division for these domains requires some prior knowledge about the deposit geology and can be supported by a careful statistical analysis. It is crucial that data with similar characteristics are grouped together, to avoid the mixing of statistical populations, defining the so-called stationary domains. In order to assist in this definition, two unsupervised clustering algorithms were applied: Otsu and K-means. The first one is widely used in image segmentation and it is based on the exhaustive search of the data to determine the best threshold for separating them. K-means is one of the most used techniques in machine learning, and it is based on the iterative analysis of the statistical distribution. Clustering algorithms may present some shortcomings when applied to geological data, since they are based on pure statistical analysis, not considering spatial distribution or data location. Choosing the most appropriate number of domains can also be challenging. Some methods for defining the best number of groups are presented, based on the analysis of variances between/inside groups, supported by indicators variography in order to verify this definition.

Oct 3, 2019