US3875990A - Methods of producing large steel ingots - Google Patents

Methods of producing large steel ingots Download PDF

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Publication number
US3875990A
US3875990A US404245A US40424573A US3875990A US 3875990 A US3875990 A US 3875990A US 404245 A US404245 A US 404245A US 40424573 A US40424573 A US 40424573A US 3875990 A US3875990 A US 3875990A
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United States
Prior art keywords
ingot
steel
electrode
wall
melted
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Expired - Lifetime
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US404245A
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English (en)
Inventor
Lloyd R Cooper
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Heppenstall Co
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Heppenstall Co
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Filing date
Publication date
Application filed by Heppenstall Co filed Critical Heppenstall Co
Priority to US404245A priority Critical patent/US3875990A/en
Priority to AU65510/74A priority patent/AU476394B2/en
Priority to CA192,764A priority patent/CA1015130A/en
Priority to FR7405577A priority patent/FR2246339B1/fr
Priority to IT48570/74A priority patent/IT1008912B/it
Priority to GB1218574A priority patent/GB1458743A/en
Priority to AT365974A priority patent/AT349665B/de
Priority to JP49059837A priority patent/JPS5123455B2/ja
Application granted granted Critical
Publication of US3875990A publication Critical patent/US3875990A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
    • B22D23/06—Melting-down metal, e.g. metal particles, in the mould
    • B22D23/10—Electroslag casting

Definitions

  • ABSTRACT A method for producing large steel ingots with increased yields by casting a steel ingot to the desired final size, removing metal to form an axial central cavity, melting a steel electrode under a fused slag in the axial cavity while simultaneously remelting and refining a proportionate controlled portion of the ingot wall surrounding the central cavity by action of the fused slag and solidifying the combined melted electrode and melted metal from the ingot wall integral with the remaining ingot shell to form a composite solid ingot mass.
  • the present invention is an improvement on that patent wherein the process of electroslag remelting within the central cavity of an ingot is controlled, by an improved method, so that a determined amount of ingot metal from the internal zone around the central cavity is remelted at the same time as the metal is remelted from the electrode. In this manner, the total amount of metal that is remelted, refined and resolidified in the internal portion of the initial ingot is controlled according to the intended use for the ingot, and the desired physical, chemical and mechanical characteristics in the interior of the ingot and its end use product.
  • the method of this invention coordinates (l) the electrical energy applied to the electrically conductive slag through the electrode, (2) the thermal energy in the ingot surrounding the central cavity and (3) the amounts of metal melted from the electrode and from the ingot wall.
  • FIG. I is a fragmentary section of ingot and electrode showing their relationship to the liquid metal pool
  • FIG. 2 is a graph of electrode melt rate to radius at different ingot temperatures
  • FIG. 3 is'a graph of electrode melt rate to radius at different ingot temperatures.
  • FIG. 4 is a graph of electrode melt rate to radius at different ingot temperatures.
  • This figure shows the profile through the ingot during the course of remelting, refining and resolidifying the central zone, with the layer of liquid, electrically conductive slag on top of the liquid metal pool.
  • the metal in the liquid metal pool is made up of remelted metal from the electrode and remelted metal from the adjacent ingot wall.
  • the proportionate amount of metal remelted from the ingot wall is determined by the extent to which the layer of liquid slag penetrates into the ingot wall.
  • the central axial hole, of diameter D" (or radius r")is formed in the previously teemed and solidified ingot.
  • the electrode makes electrical contact with the liquid slag and provides the electrical energy for heating the slag and melting the metal in contact with the liquid slag.
  • the slag of volume V" has a thickness 1" and a diameter
  • the radius of the slag layer extends from radius r at its top surface, to radius p where it rests on top of the liquid metal pool.
  • the amount of electrical energy required to melt iron can be determined from calculations for the increase in the heat content from a starting temperature (e.g., am-
  • the electrical energy serves to melt some of the steel from the ingot wall as well as steel from the electrode according to the energy balance (electrical and thermal energy) as shown here.
  • the relationship of the amount of ingot versus electrode melted can be controlled by controlling the temperature of the ingot. A major amount of the ingot is melted if the ingot is preheated whereas a lesser or minor amount is melted if the temperature of the ingot is limited or if the ingot is cooled.
  • FlG. II shows graphically the relationship, for a given power input of 1560 kw, between the steel melted from the electrode and the steel melted from the ingot body according to the representative energy requirement of 1200 kWh/metric ton.
  • the ingot has an outside diameter of 2000 mm (78.7 inches) and an inside diameter of 600 mm (23.6 inches).
  • the electrode diameter is 410 mm ⁇ 16.l inches).
  • the electrode will melt at the rate of 1300 Heat No. 413822 kg/hour, or a length of 1262 mm/hour. If the ingot is at the same ambient temperature of 25C., and the electrode melts at a slower rate, the remaining electrical energy will melt a determined amount of the ingot wall. At the indicated electrode melt rate of 450 mm/hour,
  • the remaining electrical energy (after melting the 463 kg/hour from the electrode) will melt more of the ingot wall: 1 122 kg/hour and the melted central zone will be 1 100 mm in diameter (Point B).
  • the family of curves showing the effect of ingot temperature are transferred to a clear plastic slide which can then be positioned on the logarithmic curve according to the electrical power input and the electrical energy requirement of the specific facility.
  • the ingot blank is heated to the temperature range that corresponds to the size of central melted zone that is desired, with the power input and the electrode melt rate.
  • the factors of power input volts, amperes
  • electrode melt rate the temperature of the ingot.
  • EXAMPLE I A 50-ton (metric) ingot measuring 2130 mm (83.9 inches) diameter X 2370 mm (93.3 inches) high with a 700 mm (27.6 inches) diameter axial hole, was processed according to this invention, using an electrode whose diameter was 430 mm (16.9 inches).
  • the ingot and electrode were of the same compositron:
  • slag composed of calcium oxide, alumina, and calcium fluoride
  • the power applied to the electrode was adjusted to 64 volts at 15,000 amperes, or 960 kw, and the rate at which the electrode was melted averaged 478 mm (18.8 inches) per hour, correspond- 5 ing to 544 kg per hour (or 1200 lbs. per hour) from the electrode.
  • the control for this example is shown in FIG. 111, with the penetration into the ingot wall providing a melt zone of 444 mm radius, or 888 mm (35.0 inches) diameter (Point D on graph).
  • the total zone melted corresponds to an overall melt rate of 869 kg per hour (or 1915 lbs. per hour).
  • the ingot blank was preheated to 600C. (1112F.) before starting the process.
  • the power applied to the electrode was adjusted to 72 volts at 15,000 amperes, or 1080 kw, with the electrode melting at a steady rate of 262 mm (10.3 inches) per hour, corresponding to 271 kg per hour (or 598 lbs. per hour) from the electrode.
  • FIG. 1V shows the penetration of the melt zone into the ingot wall (Point E") equal to 610 mm radius. or 1220 mm (48.0 inches) diameter.
  • the 262 mm per hour melting rate of the 410 mm diameter electrode corresponds to a 122 mm (4.8 inches) per hour rate of rise within the 600 mm diameter axial hole.
  • the total melt zone of 1220 mm (48.0 inches) diameter rising at the same rate corresponds to an overall melt rate, in the system, of 1118 kg per hour (or 2465 lbs. per hour). This is a melt rate 28.7% greater than that of Example 1. although the kw power input was only 12.5% higher.
  • Example 11 Examination of the cross section through forged blooms of Example 11 confirmed the size of the melt zone to be 1200 mm (47.25 inches) diameter as compared with the 1220 mm (48.0 inches) indicated by the control diagram of FIG. Ill.
  • the chemical analysis through the section showed a uniform lower carbon content of 0.66 0.70% in the central melt zone as compared with the 0.85% carbon content in the outside shell of the ingot body. indicating the diluting effect of melting the 0.10% carbon steel electrode within the high carbon steel ingot body to produce the lower carbon steel core of the composite ingot.
  • the rate of melting the electrode can be adjusted to provide a greater or lesser difference in chemical composition between the ingot wall and the ingot central zone, according the desired characteristics of the composite final ingot.
  • the improved process of producing large steel ingots with increased yield from poured weight to weight of wrought product comprising the steps of a. Casting a steel ingot to the final desired size, pref erably with all of the cast steel weight in the ingot body, with no sinkhead on top of the ingot body.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacture And Refinement Of Metals (AREA)
US404245A 1973-10-09 1973-10-09 Methods of producing large steel ingots Expired - Lifetime US3875990A (en)

Priority Applications (8)

Application Number Priority Date Filing Date Title
US404245A US3875990A (en) 1973-10-09 1973-10-09 Methods of producing large steel ingots
AU65510/74A AU476394B2 (en) 1973-10-09 1974-02-12 Methods of producing large steel ingots
CA192,764A CA1015130A (en) 1973-10-09 1974-02-18 Methods of producing large steel ingots
FR7405577A FR2246339B1 (de) 1973-10-09 1974-02-19
IT48570/74A IT1008912B (it) 1973-10-09 1974-02-20 Perfezionamento nei procedimenti per la produzione di lingotti di acciaio di grandi dimensioni
GB1218574A GB1458743A (en) 1973-10-09 1974-03-19 Methods of producing steel ingots
AT365974A AT349665B (de) 1973-10-09 1974-05-03 Verfahren zum herstellen von grossen stahl- bloecken
JP49059837A JPS5123455B2 (de) 1973-10-09 1974-05-29

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US404245A US3875990A (en) 1973-10-09 1973-10-09 Methods of producing large steel ingots

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US3875990A true US3875990A (en) 1975-04-08

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US404245A Expired - Lifetime US3875990A (en) 1973-10-09 1973-10-09 Methods of producing large steel ingots

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US (1) US3875990A (de)
JP (1) JPS5123455B2 (de)
AT (1) AT349665B (de)
AU (1) AU476394B2 (de)
CA (1) CA1015130A (de)
FR (1) FR2246339B1 (de)
GB (1) GB1458743A (de)
IT (1) IT1008912B (de)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4036278A (en) * 1974-11-11 1977-07-19 Centro Sperimentale Metallurgico S.P.A. Process for the production of large steel ingots
EP0094820A3 (en) * 1982-05-14 1984-02-15 Hitachi, Ltd. Method and apparatus for manufacturing a composite steel ingot
US4729421A (en) * 1983-10-28 1988-03-08 Werner Schatz Method and device for the production of metal blocks, castings or profile material with enclosed hard metal grains
CN102978413A (zh) * 2012-12-14 2013-03-20 烟台台海玛努尔核电设备股份有限公司 一种百吨级大型三相电渣炉补缩工艺
CN110586903A (zh) * 2019-10-29 2019-12-20 沈阳铸造研究所有限公司 一种电渣重熔中心补缩方法

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3603374A (en) * 1969-02-10 1971-09-07 Heppenstall Co Methods of producing large steel ingots

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3603374A (en) * 1969-02-10 1971-09-07 Heppenstall Co Methods of producing large steel ingots

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4036278A (en) * 1974-11-11 1977-07-19 Centro Sperimentale Metallurgico S.P.A. Process for the production of large steel ingots
EP0094820A3 (en) * 1982-05-14 1984-02-15 Hitachi, Ltd. Method and apparatus for manufacturing a composite steel ingot
US4729421A (en) * 1983-10-28 1988-03-08 Werner Schatz Method and device for the production of metal blocks, castings or profile material with enclosed hard metal grains
CN102978413A (zh) * 2012-12-14 2013-03-20 烟台台海玛努尔核电设备股份有限公司 一种百吨级大型三相电渣炉补缩工艺
CN102978413B (zh) * 2012-12-14 2013-11-20 烟台台海玛努尔核电设备股份有限公司 一种百吨级大型三相电渣炉补缩工艺
CN110586903A (zh) * 2019-10-29 2019-12-20 沈阳铸造研究所有限公司 一种电渣重熔中心补缩方法

Also Published As

Publication number Publication date
AT349665B (de) 1979-04-25
AU476394B2 (en) 1976-09-16
JPS5065419A (de) 1975-06-03
FR2246339B1 (de) 1980-06-20
CA1015130A (en) 1977-08-09
FR2246339A1 (de) 1975-05-02
JPS5123455B2 (de) 1976-07-16
AU6551074A (en) 1975-08-14
ATA365974A (de) 1977-09-15
IT1008912B (it) 1976-11-30
GB1458743A (en) 1976-12-15

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