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
• • 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
  • C21C7/0056—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00 using cored wires

Definitions

• the invention relates to the technical field of tubular casings containing compacted powdered or granular materials, these core casings being used for the treatment of liquid metals, in particular steels, and conventionally being referred to as "filled cores".
• filled cores The introduction into the liquid metal baths of these cored wires allows the refining, deoxidation, degassing, calming and / or modification of the composition of these baths.
• filled son containing Mg and C 2 Ca or else Na 2 CO 3 , CaCO 3 , CaO, MgO.
• Flux-cored wires are typically used in secondary metallurgy of steels, among other means such as pocket stirring, powder injection, CAS (Composition Adjustment Sealed), arc pocket furnace, RH (Ruhrstahl Heraeus), tank vacuum.
• the cored wires are used for the desulphurization of cast irons, for the production of GS cast irons, the inoculation of casting cast irons.
• the inoculation of cast irons consists in introducing into the cast irons elements which favor the germination of graphite to the detriment of cementite, these elements being, for example, alkalis, alkaline earths (Ca) or bismuth, alloyed with silicon.
• the primary functions of flux cored wire are, for steels, deoxidation, desulfurization, inclusion control and shading.
• the deoxidation operation consists in combining the dissolved oxygen in the liquid steel from the converter or the electric furnace (content of about 500 ppm or more) with a deoxidizing agent, a part of which will remain dissolved in the metal. liquid.
• the deoxidizing agents contained in the cored wires are ferroalloys, most often (ferrosilicon, ferromanganese, aluminum). They lead to the formation of oxides (silica, manganese oxide, alumina) which, by moderate mixing of the pocket, decant in the slag. Despite all the precautions taken, residual inclusions of alumina can cause the plugging of the casting nozzles or the appearance of defects on the end products of small section such as continuous casting casings in thin slabs. As a result, the cored wires also conventionally contain calcium for aluminum-killed steels. The addition of calcium alloys to a liquid steel killed with aluminum allows a modification of the inclusions of alumina, by partial reduction by calcium.
• Calcium aluminates are liquid at the temperature of liquid steels, close to 1600 ° C., and therefore globular on product when their CaO content is between 40% and 60%.
• the amount of calcium in solution needed to achieve the change in inclusions depends on the aluminum content of the metal bath.
• Most of the calcium introduced by cored wire is therefore in the liquid metal in the form of liquid inclusions of lime aluminates, and does not exceed a few ppm. In practice, it is difficult to avoid the violent bubbling of liquid steel, caused by the sudden volatilization of the calcium contained in the cored wire.
• the vapor pressure of the calcium is indeed about 1.8 atm at 1600 ° C.
• the bubbling if it is too intense, can disturb the penetration conditions of the cored wire in the steel bath and be accompanied pollution of the bath, which oxidizes or rises. At the same time, splashes of liquid steel occur, passing through the slag layer and oxidizing in contact with the air before falling back. In addition, there is a risk of steel projection out of the pocket. This may result in a rise in the levels of O 2 , N 2 and even H 2 of the steel obtained. Boiling is reduced by introducing the calcium, not unalloyed, but as CaSi, with the major drawback of introducing silicon into the liquid steel, which is unfavorable for some steels such as deep drawing.
• the exogenous oxide inclusions resulting from the contact of calcium with the refractories or the powders of the distributor are in fact difficult to eliminate before the solidification of the metal.
• These inclusions of alumina are solid and more harmful than the inclusions of calcium aluminate with regard to the capping of continuous casting nozzles, for example.
• Calcium-cored wire treatment of aluminum-killed liquid steel can also result in the formation of calcium sulphide deposited in continuous casting nozzles for steels with low aluminum content and high sulfur content.
• the control of the inclusional state by the addition of chemical components housed in flux-cored wires mainly concerns oxides and sulphides.
• the addition of sulfur increases the amount of manganese sulphides and the machinability of the steel.
• Incomplete or Irregular Compaction An irregular compaction of the material contained in the envelope results in an irregularity in the quantities of this material introduced, per unit time, in the bath of steel or liquid metal. Insufficient compaction of the material contained in the flux-cored wire thus reduces the amount, per unit of time, of the material that can be introduced into the liquid metal by dipping the flux-cored wire into the liquid metal bath. If compaction is insufficient, the pulverulent material can move inside the cored wire.
• drum here is meant well so called dynamic packaging reels that the walls of so-called static packaging cages.
• EP-B2-0.236.246 discloses a cored wire comprising a metal envelope stapled by a fold connected to the circumference, closed on itself and whose edge is engaged inside the compacted mass forming the core of the cored wire.
• the stapling is carried out along a generatrix of the envelope of the cored wire, possibly reinforced by crimping with transverse indentations over the entire width of the staple band.
• Compaction of the core of the cored wire is obtained by forming an open fold, opposite the staple zone, then closing this fold by radial pressure.
• the casing of the cored wire is made of steel or aluminum and contains, for example, a powdery CaSi alloy containing 30% Ca by mass.
• US-4,163,827 discloses a cored wire comprising a core containing ferrosilicon, containing Ca, Al, powder embedded in a resin or a polymeric binder such as polyurethane, this core being extruded before being wrapped by simple winding or double, helically, a thin strip of metal, plastic or paper, with a thickness of 0.025 mm to 0.15 mm.
• a cored wire has many disadvantages.
• the materials forming the resin are an unacceptable source of pollution for the liquid metal bath.
• the mechanical strength and rigidity of the wire are very insufficient.
• the ferrosilicon powder is practically unprotected with respect to the high temperature of the liquid metal.
• the document EP-0,032,874 describes a flux-cored wire comprising a thin-film metal sheath containing an additive at least partially surrounded by an envelope of organic or metallic synthetic material in the form of a strip of thickness less than 100 microns.
• the wire has a flattened shape.
• the thin strip is made of polyethylene, polyester or polyvinyl chloride and form of sealing, possibly heat shrinkable. No manufacturing process is described for this flattened cored wire, whose design is more of a chimera than an industrial disclosure.
• FR-2,610,331 of the applicant describes a cored wire comprising an axial zone containing a first powdery material or granular, surrounded by an intermediate metal tubular wall, and an annular zone, between this intermediate wall and the envelope of the cored wire, this annular zone containing a second powdery or granular material.
• the axial zone advantageously contains the most reactive materials with respect to the bath to be treated. As long as the outer metal envelope of this cored wire is not destroyed, the material that fills the annular zone acts as lagging that reduces the rise in temperature of the intermediate wall, thus reducing the risk of bending of the wire which would prevent sinking into the bath, the intermediate wall retaining a certain rigidity.
• US-3,921,700 discloses a cored wire to be wrapped in steel, containing an axial magnesium wire and an iron powder, of low thermal conductivity and high heat capacity, thus forming a thermal insulator protecting the magnesium from overheating. fast when the cored wire is immersed in the liquid steel.
• graphite or carbon is mixed with the iron powder.
• the document FR-2.384.029 describes an inoculation wire comprising a steel casing sheathing a powdered ferrosilicon compound packed to more than 65% by weight of silicon.
• the silicon diffuses towards the steel casing of the wire, when it is introduced into the liquid metal, so that: the melting temperature of the inoculant contained in the wire will decrease; the melting temperature of the steel of the wire sheath will drop; the carbon diffusing through the outer surface of the wire sheath.
• a cored wire comprising a mild steel sheath (melting temperature 1538 ° C.) containing a ferrosilicon containing 75% silicon (melting temperature 1300 0 C) will melt towards 1200 0 C when dipped for example in a gray cast iron at 1400 0 C, this fusion from the inner part of the sheath, due to the diffusion of silicon in the sheath that lowers the melting temperature of mild steel.
• Document US Pat. No. 4,174,962 mentions, in addition to this silicon diffusion, a dissolution of the outer wall of the cored wire sheath by erosion and diffusion, even if the melt temperature of the sheath is greater than the temperature of the bath of liquid metal.
• 4,297,133 describes a paper tube wound in layers, this tube being closed by metal lids.
• the burning time of the paper is indicated as being three seconds when the tube is placed in a 1600-1700 liquid steel bath 0 C.
• the Applicant has itself described, in publications FR-2.821.626 and FR-2.810.919 flux-cored wires comprising envelopes which, combustible without leaving any troublesome residues, momentarily retard the propagation of heat towards the heart of the wire, these envelopes being paper said for pyrotechnic application, fuel and thermal insulation.
• the applicant has endeavored to solve this technical problem, by providing, in addition, a cored wire whose life in the liquid metal bath is increased, compared to conventional son, so as to reach a predetermined depth in the bath of liquid metal.
• the applicant after complex and long tests, discovered in particular: 1) that it was important to avoid any combustion of paper windings described in documents FR-2.821.626 and FR-2.810.919, before entering the wire stuffed into the bath of liquid metal (free-flow zone of the cored wire); 2) means to prevent this combustion; 3) that the gain in service life of the cored wire was ensured when the burning of the paper did not intervene before the entry of the cored wire into the bath of liquid metal, the paper not necessarily having to be pyrotechnic, or classified Ml , or resistance to high inflammation, contrary to what is indicated in FR-2.821.626 or FR-2.810.919, the paper not burning in the bath of liquid metal, but pyrolyzing to become a material whose thermophysical properties are currently unknown to the applicant
• the Applicant has thus discovered inexpensive and safe means of increasing the service life of flux-cored wires in liquid metal baths, these means being compatible with all the structures described previously for flux-cored wires, these means thus bringing about a technical effect. further advantageous to each of the individual advantages of the different types of pre-filled wires.
• the invention thus relates, according to a first aspect, to a cored wire, comprising at least one thermal barrier layer, said layer being made of a pyrolyzing material when in contact with a metal bath such as liquid steel.
• the cored wire comprises the following characters, where appropriate combined: it comprises an outer thermal barrier layer, enveloping a metal sheath, said outer thermal barrier layer being made of a pyrolyzing material upon contact with a metal bath liquid;
• the pyrolyzing material is a kraft paper, an aluminized paper or a multilayer comprising at least one strip of kraft paper and at least one layer of aluminized paper;
• the pyrolyzing material is covered with a thin metal sheet;
• the thin metal sheet is made of aluminum or aluminum alloy;
• the pyrolyzing material has a thermal conductivity of between 0.15 and 4 W / m ⁇ K, before pyrolysis;
• the pyrolyzing material has a radial thickness of between 0.025 mm and 0.8 mm, before pyrolysis;
• the pyrolyzing material has a starting temperature of pyrolysis of about 500 0 VS ;
• the pyrolyzing material is loaded with water or with
• FIG. 1 is a representation of the principle of introduction of the cored wire in a bath of liquid steel
• FIGS. 2 to 12 are temperature-dependent time curves derived from digital simulation
• FIGS. 13 to 21 are time-temperature curves derived from test campaigns conducted by the applicant.
• Figure 1 is a representation of the principle of introduction of a cored wire into a ladle of liquid steel.
• the cored wire 1 is extracted from a cage 2 such as, for example, described in document FR-2,703,334 of the applicant, or else extracted from a drum 3, and introduced into an injector 4.
• This injector 4 drives the wire in a bent guide tube 5, the cored wire coming out of this guide tube 5 at a height of the order of one meter to one meter and a half above the surface of the liquid steel bath 6 contained in A pocket 7.
• the cored wire 1 is therefore placed in three thermally very different media: - a first medium in which the cored wire is housed inside the guide tube; a second medium located above the liquid steel bath in which the cored wire is placed in direct contact with the surrounding atmosphere; a third medium which is the bath of steel or liquid metal itself.
• the Applicant wished, at first, to thermally simulate the path of the cored wire in order to limit the number of tests with instrumented cored wire.
• the three-dimensional radiative exchanges between plane, opaque, gray and diffuse surfaces were simulated by calculating shape factors and transfer factors.
• the form factors were calculated by the plane flow method, the transfer factors being calculated by the coating method taking into account diffuse multi-reflections.
• the flux received is supposed to radiate from the tube enveloping the cored wire with a form factor equal to 1.
• the flow is considered radiative but coming from the liquid metal bath 6 and the walls of the pocket 7.
• the transfer is considered as convective with a coefficient of exchange of order 50.000 W / m 2 K, the surface temperature being imposed.
• the total emissivity of the outer surface of the cored wire is considered equal to 0.8, that of the guide tube is equal to 1 while that of the bath is considered equal to 0.8.
• FIG. 2 gives the variation of the transfer factor between the flux-cored wire and the liquid metal bath ( ⁇ ⁇ F) as a function of the distance above this bath of liquid metal, the value zero on the abscissa axis corresponding to the surface of the bath of liquid metal.
• the cored wire is considered to comprise three concentric cylindrical layers, namely a steel sheathed calcium core, this steel sheath being covered with paper.
• the diameter of the core of calcium is 7.8 mm
• the thickness of the steel sheath is 0.6 mm
• the thickness of the paper can be set at different values, example 0.6 mm for eight layers of paper superimposed.
• the cored wire is considered to be formed of a solid core made of interlocked calcium and in contact with the steel sheath which is itself nested and in contact with the paper.
• the bath of liquid metal and the walls of the pocket 7 are represented in the numerical model by a volume of temperature equal to 1600 ° with radiation and convection to the cored wire depending on whether the wire is above the bath 6 or in this bath of liquid metal 6.
• L2 is the distance between the lower end of the guide tube 5 and the surface of the bath of liquid metal 6.
• the speed of travel of the cored wire is equal to 2 m / s, the initial temperature of the cored wire being 50 0 C.
• the free path of the cored wire beyond the guide tube 5 and before introduction into the bath of liquid metal is considered to be 1.4 m in length.
• the yarn is considered destroyed when, by calculation, the surface of the calcium core has a temperature greater than 1400 0 C. As shown in FIG.
• the modeling indicates that, for a reference wire devoid of thermal protection, the surface temperature of the core in calcium increases by 70%. 0 C only during the free run and reaches the threshold of 1400 0 C in 0.15 s or after a run inside the liquid metal bath of only 30 cm for a speed of 2m / s.
• the temperature gradient between the steel sheath and the calcium core does not exceed, by calculation, 65 ° C. So when the temperature of the soul's surface in calcium is 1400 0 C, that of the outer surface of the steel sheath is 1465 0 C, so that the steel sheath does not melt before the destruction of the cored wire, the latent heat of fusion of this steel sheath is therefore not taken into account in the numerical simulation.
• FIG. 4 gives four temperature evolution curves of the surface of the calcium core of a flux-cored wire as a function of time, each of these four curves corresponding to a different thickness of protective paper, namely: 0.025 mm for curve 4a, 0.05 mm for curve 4b, 0.1 mm for curve 4c, 0.6 mm for curve 4d.
• the comparison of FIGS. 3 and 4 shows, by numerical simulation, a protective effect of the paper surrounding the steel sheath, this effect being all the more marked as the thickness of the paper is important.
• the curves shown in FIG. 4 were obtained considering that the layers of paper remain intact, without combustion. According to this hypothesis, an insulation thickness of 0.025 mm would be sufficient to protect the cored wire to the bottom of the bath of liquid metal.
• FIG. 5 shows the evolution of the surface temperatures of the paper as a function of the conductivity of this paper, during the first second of free travel of the cored wire, the thickness of the paper being 0.6 mm, the speed the flux-cored wire is 2m / s.
• Curve 5a corresponds to a conductivity of 0.1 W / K.m
• curve 5b corresponds to a conductivity of 0.15 W / K.m
• curve 5c corresponds to a conductivity of 0.2 W / K.m.
• FIG. 6 represents the evolution of the temperature of the surface of the paper for a thermal conductivity of this paper of 0.15 W / K.m, a injection speed of the cored wire of 2m / s, the paper thickness being in curve 6a of 0.6 mm, in curve 6b of 0.2 mm and in curve 6c of 0.1 mm.
• This figure 6 suggests that by decreasing the thickness of the paper, the surface temperature of this paper decreases and therefore the risk of burning of this paper during the free path of the flux-cored wire above the liquid metal bath.
• FIG. 7 shows that the temperature of the paper covering the cored wire is largely affected by the variation of the temperature of the radiation source.
• the curves 7a, 7b, 7c and 7d respectively correspond to emitting surface temperatures of 1500, 1400, 1300 and 1200 0 C.
• the injection speed of the cored wire was 2 m / s and the thermal conductivity of the paper 0.15 W / K m.
• the Applicant then pursued numerical simulations by considering the paper as a body having two different thermal conductivities according to the temperature: a first conductivity which is that of the original paper (0.15 W / Km), this first conductivity being maintained up to a temperature of about 500 0 Start of pyrolysis; a second conductivity (300W / K.m), supposed to be reached when the temperature of the pyrolysis paper is 600 0 C, the pyrolysis being assumed to be complete when this temperature of 600 0 It is reached. Between 500 and 600 0 C, the change in conductivity from 0.15 W / K.m to 300 W / K.m is assumed to be linear in the simulation as a function of temperature.
• Curve 8 gives the results of the numerical simulation for the surface temperature of the calcium contained in the flux-cored wire, the paper being supposed to be dissolved in the bath of liquid metal, just after its pyrolysis.
• Curve 8a corresponds to the conventional cored wire, without protective paper.
• Curve 8b corresponds to a cored wire provided with a protective paper having a thickness of 0.6 mm.
• Curve 8c corresponds to a cored wire provided with a protective paper to a thickness of 1.2 mm.
• Figure 8 suggests that, if the paper disappears after pyrolysis, it is not possible to protect the cored wire to reach the bottom of the liquid steel bath, even by doubling the thickness of the wire. paper.
• FIG. 10 shows the results of the numerical simulation for the variations of surface temperature of the paper as a function of time, the curves 10a, 10b, 10c, 10d respectively corresponding to a humidity of 0%, 59%, 89% and 118% .
• the injection speed of the cored wire was 2m / s, the thermal conductivity of the paper being 0.15 W / K.m.
• FIG. 11 gives the result of the radiative calculation performed by adding a very thin layer of aluminum coating paper wrapping the steel sheath of the cored wire.
• This figure 11 shows that the radiative transfer factor is reduced by a factor of 8 compared with that of the paper whose emissivity is 0.8.
• FIG. 12 makes it possible to compare the surface temperature changes of the paper as a function of time with and without aluminum coating, the injection speed of the cored wire remaining at 2 m / s and the thermal conductivity of the paper being 0.15 W / Km
• the surface temperature of the paper increases very little, according to this numerical simulation, in the free path of the cored wire, the aluminum providing a very effective thermal protection for the paper of the cored wire.
• the instrumented cored wire is manufactured in three stages: - emptying the cored wire; positioning of thermocouples in contact with the inner steel sheath of the cored wire, opposite the staple zone; filling the flux-cored wire with the powder.
• the electrical connections and connecting wires of the thermo ⁇ couples are protected by steel tube.
• the instrumented wire is introduced into a steel steel ladle and then reassembled after a predetermined downtime. Since the baths are permanently stirred with argon, an inert atmosphere is created in the free path above the surface of the liquid steel bath, which limits the risk of accidental combustion of the paper of the cored wire.
• point I corresponds to the entrance of the cored wire into the liquid steel ladle.
• a reference test was carried out with a non-paper-lined cored wire, the variation of the temperature inside the reference cored wire, as a function of time, being given in FIG.
• the temperature at point D of FIG. 13 is related to the destruction of the thermocouples.
• FIG. 14 compares the results obtained with the reference wire (reference 14a) and a cored wire comprising a layer of Kraft paper placed between the calcium core and the steel sheath (reference 14b).
• the introduction of Kraft paper inside the cored wire can delay the rise in temperature of 0.4 seconds or a total time of 0.7 seconds before destruction.
• FIG. 14a the reference wire comprising a layer of Kraft paper placed between the calcium core and the steel sheath
• FIG. 15 compares the results obtained with the reference wire (curve 15a) and two instrumented wires provided with two outer layers of Kraft paper (curves 15b, 15c).
• the temperature rise delay obtained is 0.8 and 1.2 seconds allowing the cored wire to reach the bottom of the pocket.
• the abrupt rise in temperature of the curves 15b and 15c corresponds to the moment when the Kraft paper is totally degraded, the steel sheath of the cored wire coming into direct contact with the liquid steel bath.
• FIG. 16 compares the results obtained with the reference wire (curve 16a) and a cored wire protected by two layers of Kraft paper and two layers of aluminized paper (two curved tests 16b and 16c). The curves in FIG.
• FIG. 16 show that the presence of two layers of kraft paper and two layers of aluminized paper retard the rise in temperature by about 1 second, compared to a conventional reference wire.
• Figure 17 are presented the results obtained with two samples protected by three layers of kraft paper and two layers of aluminized paper (curve 17b and 17c) to compare with the values of the reference wire (curve 17a).
• FIG. 18 compares the results obtained with six layers of kraft paper and two layers of aluminized paper (curves 18b and 18c), to be compared with the reference wire (curve 18a).
• the rise in temperature is here delayed by more than 1.2 seconds.
• Curve 20b of FIG. 20 gives the result obtained with a cored wire protected by eight layers of kraft paper and an aluminum layer, the delay of the rise in temperature being 0.8 seconds with respect to the reference wire, curved 20a.
• Curve 20c corresponds to a test in which the cored wire dipped laterally in the slag and did not penetrate the molten steel, this test indirectly giving the temperature of the slag, ie 1200 0 C.
• FR-2.810.919 of the applicant describes the establishment of thermal insulation paper between a steel outer casing and a steel sheath containing the powdery or granular additive.
• the outer steel sheath is designed to prevent the paper from being damaged during handling of the cored wire.
• these so-called hybrid wires as described in document FR-2.810.919 only made it possible to obtain a significant delay in temperature rise if the paper is present in the staple or overlap zone so that to avoid any metal / metal contact in the staple zone, the paper being pyrolyzed in the bath of liquid metal.
• the experimental work was carried out with the assistance of Armines, Center of Energetics, autoimmune des Mines de Paris.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Materials Engineering (AREA)
• Metallurgy (AREA)
• Organic Chemistry (AREA)
• Treatment Of Steel In Its Molten State (AREA)
• Insulated Conductors (AREA)
• Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)
• Heat Treatment Of Strip Materials And Filament Materials (AREA)
• Paper (AREA)
• Ropes Or Cables (AREA)

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