Development of China's steel industry strongly support the rapid rise of the national economy,but with the resources,the environment and the transformation of economic development model is facing from quantitative to qualitative change of great challenges.Wherein the large cross section of high-quality special steel products have long been used ingot plus forging process,longs low processing costs and high energy consumption,low production capacity and that this process can not meet the needs of the development of related industries,which restricts clean energy,development of nuclear power,marine engineering as well as high-speed railways and other high-end manufacturing.The level of development of high-quality steel obedience"multiplication rule",in which metallurgical equipment technology and production technology is the biggest factor in weight.
Special steel casting and solidification characteristics of complex and large cross section of high-quality special steel production equipment and processes for Advancement and integration requirements are higher,it is considered to be in urgent need of modern metallurgical industry joint breakthrough core technology.
The start of the project,to meet the large-scale clean energy equipment needed for wind power and other large marine section of special steel casting products abroad without precedent.Molded timber traditional mode of production is low,long process,low efficiency,poor stability and quality of the process,can not meet the specifications of high-end equipment manufacturing larger,higher quality,more reliable quality special steel material requirements,such as the global mining machine industry leading enterprises,large excavators US Caterpillar gear steel,requiring oxygen content of less than 12ppm,in order to ensure its fatigue life,and traditional molding process is difficult to control the oxygen content stabilize at 20ppm or less.Whole arc casting is a modern low-cost,efficient production processes,such as production process can overcome the technical problems will be the production of high-quality special steel products large cross section of the preferred process.Special steel round billet continuous casting maximum section was put into operation at home and abroad can do 500mm or less,greater cross-section continuous casting equipment and application in the world is still in the development stage.Large section of special steel casting bottleneck in the presence of a series of technical quality assurance,technology and complete sets of equipment development,mainly in special steel casting solidification phase two mayor,feeding difficulties,it is prone to osteoporosis center,center segregation and various crack;large section of slab weight up to more than 100 tons,down force,the overall stiffness of the continuous casting equipment and process control requirements extremely high;in addition,the larger cross-section,the higher the degree of difficulty casting quality control,800mm or more large cross section continuous casting technology,there is no precedent in the world,it is considered the modern domestic and foreign counterparts to further replace the traditional casting and production patterns molded fortress!
Based on national strategies and market-driven demand,MCC Capital Engineering Technology Co.,Ltd.jointly Jiangyin Xingcheng Special Steel Co.,Ltd.,China Metallurgical Continuous Casting Technology Engineering Co.,Ltd.,Hubei Xinye Steel Co.,Ltd.and Beijing University of Science and lasted nearly a decade multi-disciplinary research,based on independent development,to create a large cross section of the special steel moment round billet continuous casting production of new models.Broke through the continuous casting production quality assurance,technology and research outfits in the series of technical bottlenecks,straightening overcome resistance,the internal and surface quality is difficult to control key casting technology,innovation developed the world's largest size round billet(1000mm)and the largest size rectangular billet(410mm×530mm)special steel casting machine.To achieve a high-quality special steel section of large-scale products,clean production and application of continuous casting.The main innovations are as follows:
1.For large sections of special steel casting loose internal controls and segregation problems,propose innovative and solidification of molten steel injection flows superheat strengthen dissipation theory,developed a constant temperature and casting speed cyclone casting technology;the establishment of a continuous casting electromagnetic fluid-heat-coupling solute transport model,reveals the continuous casting process of the formation and distribution of macro segregation,laid the theoretical foundation for large cross section casting process and product homogeneity internal control.
2.When the surface crack problem for the special steel casting large deformation resistance and easily,based on a special steel cast high temperature thermal physics,thermoplastic and their organizations in-depth study of the correlation,the development of large cross section of small curvature,ultra-low temperature and weak cold strain continuous straightening technology,as well as online insulation,warming and other equipment under the wire sets of advanced technology for the elimination of special steel casting large cross section and surface cracking during thermal loading provides a reliable technical support.
3.For large sections of special steel casting equipment vacancy and design problems,developed a unique large cross section mold,imitation arc hydraulic vibration unit,straightening and soft reduction units and other key equipment under the innovative design of large cross-section roll caster column,technology and dynamic secondary cooling control system,pioneered the world's largest special steel specifications arc continuous casting machine,and the establishment of a new system design and technical specification is based on CAE analysis caster.In order to break the traditional mode of production molding,to achieve a large section of the Special Steel Casting provides advanced and efficient production equipment support.
4.In response to the shortage of high-end manufacturing all kinds of large cross section of high-quality special steel products,covering the development of steel refining,protective casting and multi-casting furnace continuous casting and other production techniques,the first series of steel sections and different specifications of the continuous casting production core technology and proprietary technology,development and application of judgment and slab quality diagnostic systems(QES),for the continuous casting process of large-scale production of high-quality special steel products to provide a reliable production process guarantee.
The project created a large cross section of special steel casting production systems and new norms of the industry chain,to cultivate a large section of the international special steel casting products from scratch in the market.Formed Xingcheng Special Steel,the new Steel,Dongbei Special Steel and other six production bases.The development of large diameter thick ultra supercritical pressure boiler tubes,ultra-low temperature clean energy and marine engineering steel,more than 200 domestic and international market shortage of high-quality special steel products,has made the top eight major international classification societies certified,has been nearly three years generate direct economic benefits more than 19 billion yuan.
Project authorized 11 patents and software copyrights four,published 23 papers,chaired or participated in the drafting of casting engineering design specifications,three special steel product standards and regulations.Results by industry and provincial Grand Prize 1,first prize three.Large sections of special steel round billet continuous casting technology has reached the international advanced,and was listed as one of the key technology development Twelfth Five-Year"development plan","iron and steel industry."The results of the project a strong impetus to the special steel metallurgy equipment,production technology and the overall progress of the subsequent high-end manufacturing.