ingot cleanliness improvements using sprue extensions
TRANSCRIPT
![Page 1: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/1.jpg)
Ingot Cleanliness Improvements Using SprueExtensions Beyond The Mold Outlet
Ryan VanderMeulen
ArcelorMittal Coatesville
April 11, 2012
![Page 2: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/2.jpg)
2
Steelton
Coatesville
Conshohocken
Burns Harbor Cleveland
Lackawanna
Hennepin
Columbus Coatings
Riverdale
Indiana Harbor
Steelmaking and processing facilities
Processing facilities
Research center
Research Center
Weirton
Georgetown
ArcelorMittal USA Locations
Newton
![Page 3: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/3.jpg)
3
ArcelorMittal USAPlate Production Locations
Steelmaking, Rolling, Heat Treating:Burns Harbor, Coatesville
Rolling & Heat Treating:Conshohocken, Gary
Steelmaking:Indiana Harbor,Cleveland, Riverdale
CoatesvilleConshohocken
BurnsHarbor,Gary
ClevelandIndiana Harbor
Riverdale
![Page 4: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/4.jpg)
4
Plate Mills Production Focus
• Burns Harbor– 160” – larger, TMCP, Q&T, precise weight
– 110” – commodity to 1”
– 160” @ Gary – commodity to 1.5”, Q&T
• Conshohocken– 110” - commodity, thin, Q&T
• Coatesville –– 140” - heavy, varied chemistries, Q&T
– 206” - very wide and heavy, Q&T
![Page 5: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/5.jpg)
5
Production Focus
• EastClad, Flamecut, ConversionMost alloy and Q&TVery clean steelVery wide or heavy plateLight thickness plateSmall special orders
• WestControl rolledPrecise weightSpecial surface requirementsVery large ordersHeat Treated Commodity
![Page 6: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/6.jpg)
6
ArcelorMittal USA OperationsCoatesville Steelmaking Process Plan
Ladle
Argon Stirring
Electrodes
Wire Feed
Argon Stirring
AutomaticAlloys
Ladle Furnace
Electric Arc Furnace
ContinuousCast Slabs
Ladle Degasser
BottomPoured Ingots
AutomaticAlloys
![Page 7: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/7.jpg)
7
Ingot CastingCoatesville
• Bottom pouring
• Hot topping
• Argon shrouding
• Maximum sizeplate 50 tons (45 Mt)
![Page 8: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/8.jpg)
8
Bottom Poured, Ingot Casting
Ladle
ArgonShroud
Argon Inlet
CenterRunner
RunnerBrick
MoltenSteel
Mold
CastingPowder
Hot Top
![Page 9: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/9.jpg)
9
Products Produced From Ingots
• Thick plates, 3/1 reduction for PVQ; structural grades2/1; military 4/1
• Heavy plates over ~13.5 sTon
• Difficult chemistries– High sulfur free machining grades
– Tool steels
– Certain military grades
– Some unique customer requirements (prequalification)
• Grades covering wide thickness range with limitedproduction
![Page 10: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/10.jpg)
10
High Strength Q&T Steels
• A514 family and T-1®
Steels, Hardwear®
• High strength orabrasion resistance
• Flatness requirements
1/2 commercial
• Fabrication guidelines
![Page 11: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/11.jpg)
11
A514 Steels
• A514A - to 1-1/4” N-A-Xtra,National
• A514B * T-1A® to 1-1/4”
• A514E - to 6” ex-Armco
• A514F* T-1® to 2-1/2”
• A514H* T-1B® to 2”
• A514Q* T-1C® to 6” basis for gearrack grades
* PWHT cracking concerns
![Page 12: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/12.jpg)
12
API Offshore Steels
• 2H42 and 50 (N)
• 2Y50 and 50T (QT)
• 2MT1 (CR, AC)
• 2Y60 (QT)
• Burns Harbor
– AC, N, QT
• Coatesville
– N, QT
– Special Chemistry (Pcm)
– Heavy plate, ingot
– RP 2Z prequalified Ingot to 3”
![Page 13: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/13.jpg)
13
Pressure Vessel Steels
• Shipped to ASTM A20requirements
• Fabricators export theirvessels
• Plate export opportunities
• Most popular grades A516,A387 - 11/22, A353/553, Clad,A203E, A537, A299
![Page 14: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/14.jpg)
14
A516
• C-Mn steels to 15” (380 mm) thick and 100,000pounds (45,000 kg) weight
• -50oC to +300oC temperature pressure vesselapplications, Grades 55, 60, 65 and 70
• Carbon equivalent controls and HIC - testing
• Available normalized or Q&T
• Similar behavior of A299 steels
![Page 15: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/15.jpg)
15
A387
• Cr-Mo steels to 12” (305 mm) thick and 100,000pounds (45,000 kg) weight
• Grades 11 (1-1/4 Cr - 1/2 Mo) and 22 (2-1/4 Cr - 1Mo) most popular; other grades to 9% Cr
• Elevated temperature pressure vessel applications
• Temper embrittlement resistance
• Post weld heat treatment (stress relief)
• Available N&T or Q&T
![Page 16: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/16.jpg)
16
Roll-Bonded Clad
• Composite of economical “Backing Steel” and high performancealloy
– examples: A516/304L, A387/410S, A36/C276
• Assembly of a “Clad Pack”
• Cost advantages
• Fabrication procedures - forming and welding
• Pressure vessels, FGD systems, pulp and paper equipmentSpacer bars
Nickel LayerBacking Steel
Alloy Inserts Parting Compound
![Page 17: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/17.jpg)
17
Military Armor
• Navy Armor Steels - HY-80 & 100,HSLA-80 & 100 - surface shipsand submarines
• Army Armor Steels - moderateand high hardness grades - M-1tanks, other vehicles
• Require Q&T and Fineline®
• Special testing - first article,ballistic
• Plates from ingots usedparticularly in Carriers
![Page 18: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/18.jpg)
18
AISI Alloy and Mold Steels
• Chemistry only grades
• Most popular 4140, 4142, 4130,
8620, 4340
• All vacuum degassed, some may
be Clean-Cut or Fineline
• Thermal cutting and quench
cracking concerns
• Used in variety of tooling
applications, including MTD steels
![Page 19: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/19.jpg)
19
MTD® Steels
• Mold, tool and die pre-hardened steels for plasticinjection molds and holder blocks, 262-321HB*
• MTD #1 - N&T 4142 used to 6-1/2” thick
• MTD #2 - Q&T 4130 used to 12” thick
• MTD #3 - Q&T .30% carbon, Fineline quality to12” thick; ingot only for internal quality, BEUwhere possible
• MTD #4 - N&T 4150 used to 6-1/2” thick
• MTD #1, #2, #4 may be Clean-Cut quality
* MTD #1 and #4, to 3”: 241-320 over 3 - 6-1/2”
![Page 20: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/20.jpg)
20
Free Machining Grades
• Higher sulfur levels for improved machinability
• Clean-Cut® 20 and 45, .06/.12 sulfur, twocarbon levels, calcium treated to 15” thick
• C1119 mod. and C1144 mod., .24/.33 and.20/.33 sulfur levels always ingot
• Clean-Cut® Alloy Steels, .02/.04 sulfur, calciumtreatment available in 4140, 4142, 4150, 8620,MTD #1, #2 and #4
![Page 21: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/21.jpg)
21
Tool Steels
• Cold work tool steels - A2, 01, S7, S5, D2, A8 mod.
• Mostly ingot produced at Coatesville, some meltedoff-site– D2 ingot from outside source
– S5 can be strand cast
• Long processing cycles
• Produce full sized plates that customers can cut intobars
• Flatness tolerances are critical for cutting andmachining
![Page 22: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/22.jpg)
22
Bridge Steels
• Industry push to use ASTMA709
• Grades 36 through 100 ksiyield
• Three zones for determiningCVN impact requirements,also fracture-critical membercriteria
• New HPS 50W/70W/100W
• Ingots used in thick, wide&/or long plates
![Page 23: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/23.jpg)
23
Flame-Cut Products
• Oxygen-fuel or plasma cuttingof all grades, thicknesses andweights of plate we can roll
• Beveling of edge detail/weldpreparation to drawingspecifications
• Plates/parts can be pressflattened to meet tolerances
• Finished pieces used instructural and sub-assembly,forming, fabrication andmachining applications
![Page 24: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/24.jpg)
24
Common Ingot Quality Issues
• Cracks
– Rate of Rise
– Mold Centering
• Hot Top Fins
– Board Fit in Molds
• End/Side Laminations
– Solidification
– Rolling
• Pipe/Burst/UT Failure
– Solidification
– Cooling
– Trapped Junk
![Page 25: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/25.jpg)
25
Potential Sources of Trapped Junk
• Foreign debris including cardboard
• Damaged Refractory Brick
• Nalcosil
• Runner Sand
• Fluxes/Powders – most common HT2
![Page 26: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/26.jpg)
26
Ladle Sand
• Prevents steel from escaping through the outlet
• Protects opening of ladle from damage
• Allows for better flow of steel
![Page 27: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/27.jpg)
27
Refractory Brick
• Can be easily fractured or crack
• Uneven plates cause bricks to be misaligned
![Page 28: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/28.jpg)
28
The‘Trap’
![Page 29: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/29.jpg)
29
The ‘Trap’
Sprue Cap
14” Double MaleStraights
9” Slotted Outlet
![Page 30: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/30.jpg)
30
Picture of Sprue
![Page 31: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/31.jpg)
31
End of Sprue
![Page 32: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/32.jpg)
32
Diagram of Sprue
Note: A, B, C, D, E are all ½”
13”
OUTLET
.5”0 2”1” 2.5” 6.5” 7” 13.5”
END A B C D E
Distance from the End to Outlet
1” 4” 6”
![Page 33: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/33.jpg)
33
End Pieces
• Where most junk was found
• Not fully circular
C0082 C0086Melt No.-Position C0192-1 C0192-3
![Page 34: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/34.jpg)
34
Definition of Junk
• All non-metallics
• Material on edge of piece extending deep into the surface
• For air bubbles, only parts that appeared to have been non-steel material
![Page 35: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/35.jpg)
35
0.0%
0.5%
1.0%
1.5%
2.0%
2.5%
3.0%
3.5%
4.0%
0 2 4 6 8 10 12 14
Distance from End to Outlet (inches)
Per
cen
tIn
clu
sio
n
C0082
C0086
Trapped Inclusions for C0082/C0086
![Page 36: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/36.jpg)
36
0%
2%
4%
6%
8%
10%
12%
14%
16%
18%
0 2 4 6 8 10 12 14
Distance from End to Outlet (inches)
Per
cen
tIn
clu
sio
n
C0192-1
C0192-3
Trapped Inclusions for C0192
![Page 37: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/37.jpg)
37
Percent Inclusion by Piece
Piece C0082 C0086 C0192-1 C0192-3
A 3.8% 3.6% 13.3% 15.8%
B 1.2% 0.59% 9.8% 6.5%
C 0.17% 0.08% 3.9% 6.0%
D 0.17% 0% 2.8% 7.6%
E 0.12% 0% 0%
Total % Inclusion 0.42% 0.25% 3.3% 5.5%
![Page 38: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/38.jpg)
38
Indication of Swirling Motion
C0086A
C0086B
C0192-1D
C0192-3D
![Page 39: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/39.jpg)
39
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Middle % 6.7% 2.2% 27.3% 25.1%
Outer % 93.3% 97.8% 72.7% 74.9%
C0082 C0086 C0192-1 C0192-3
Location of JunkOutside
Middle
1.5”
1.06”50% ofArea
![Page 40: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/40.jpg)
40
Flow Model
CenterRunner
Mold
Sprue
‘Trap’
![Page 41: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/41.jpg)
41
Flow Video
![Page 42: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/42.jpg)
42
Cost
• Refractory cost increase per ingot of ~3%.
• Worst-case yield loss of ~0.1%.
• Total cost increase under $1.00/ton.
• One trapped junk rejection = $5,000+ depending on size andgrade. Can be over $20,000 for large armor ingots.
![Page 43: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/43.jpg)
43
Follow-Up Work
• Work with vendor to develop a standard “trap brick”
• Integrate trap usage into all special heats to start
• Make traps standard for all heats
![Page 44: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/44.jpg)
44
Conclusion
• Demonstrated ‘Trap’ is capable of catching junk
• Minimal cost and yield loss
• Potential to produce cleaner ingots and reduce the number ofrejections
![Page 45: Ingot Cleanliness Improvements Using Sprue Extensions](https://reader031.vdocument.in/reader031/viewer/2022020622/61ed196525519d2274376897/html5/thumbnails/45.jpg)
45
Questions?