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Towards
Improved Usages Of Induction Furnace To Produce Micro Alloyed Steels
S.I. Singh Director (Actg.), N.I.S.S.T., Mandi Gobindgarh, Punjab
R.K. Bagchi Manager (Tech.), N.I.S.S.T., Mandi Gobindgarh, Punjab
Introduction
Induction crucible furnaces differ from arc furnaces in ways, which
are important metallurgically, althrough both types of furnaces are
used for making steel from scrap and alloys. As compared to arc furnaces,
Induction melting furnaces do possess following characteristics:
1. High, relatively narrow melting vessel (low d/h ratio),
2. Low crucible wall thickness,
3. Relatively small area of metal in contact with slag,
4. Low slag temperature,
5. No carburizing during melting down,
6. Powerful bath motion.
Therefore sections such as oxidation, decarburising and dephosphorising
as well as deoxidizing and desulphurizing, which are usually requited
in quality steelmaking, can only we applied to a limited extent in an
induction crucible furnace used for steel production. Those reactions,
which take place inside the metl, oral the metal-lining interface, are
assisted by the powerful path motion. On the other hand, the metal-slag
reaction suffers because of the smaller contact-area and lower slag
temperature. Any attempts at enhancing this reaction, by using sings
that are more reactive and less viscous ore further limited by the requirement
of production of alloy steels by the remelting process where precious
elements are to be recovered. Also dissolution of any alloy addition
is very effective, because the powerful melt motion dissolves alloying
additions quickly. For this reason, even small induction furnaces can
be operated economically.
Possibility
of Melting H.S.L.A. Steels
High strength low alloy steels, known as micro alloyed steels, are basically
low alloy steels, having micro alloy addition (added in small proportions)
of various elements e.g. NB, Ti, Al, B, V, Cb, etc. These elements are
either added alone or in combination of small proportions, so that total
alloy addition becomes less than 0.30% apart from C, Mn, Si, S &
P. Usefulness of micro alloyed steels for engineering applications is
well understood now. Its production applicabililies are to be seriously
considered by the secondary steel sector. As reported in various literatures
by micro alloying, tensile strength values of particular plain carbon
steel can easily be enhanced by 10.15 kg/mm2 without adopting much expensive
cooling cycles like TMT process. For that matter some trails have been
planned to produce H.S.L.S. steel through induction furnace rout.
Selection
of Chemistry of H.S.L.A. Steels
As a base chemistry, composition of rebar steels have been selected
due to fact that these contain around 0.20-0. 25%C which is easily achievable
by melting of mild steel scrap.
Silicon
Major effect of silicon on strength is through substitutional solid
solution hardening. It also increases the ductile to brittle transition
temperature. So, silicon contents of base metal are selected to be in
range of 0.35-50%. This can be obtained by FeSi for SiMn additions.
Manganese
Manganese refines the pearlitic spacing and increases toughness of steels.
It has an extremely potent effect on hardenability and improves weldability.
So, its content has been limited to 1.2 - 1.4% and can be attained by
FeMn & / or SiMn additions.
Vanadium
Vanadium increases the strength of carbon steels through a combination
of precipitation hardening and refinement of the interlameller spacing
of pearlite. As reported ill various literatures, the economic level
of vanadium addition for effective strengthening is about 0.7%, but
the strengthening factor drops above 0.1 1%. Hence, for trials. vanadium
is to be limited from 0.6%-10%.
Nitrogen
Vanadium in steels precipitates in the form of carbonitrides. In presence
of free nitrogen in steels containing vanadium, VN precipitates at austenite
ahead of VC. Precipitation continues and at the austenite-ferrite (Y-cc)
transformation boundary, simultaneous precipitation of VN and VC in
the form of mixed vanadium carbonitrides occurs.
Precipitation
in austenite considerably retards grain growth. This refines the ferritic
grains and thus, favourably effects strengthening. In view of the dissolved
power of C, V & N in austenite?ferrite and their mutual interaction,
nitrogen content is selected to be in the nitrogen of 0.009%-0.016%
i.e. 90-160 ppm. Vanadium and nitrogen could well be added through Nitrovan
alloy, but due to non-availability of this alloy in our country at present,
addition of FeV and purging of nitrogen gas has been planned.
Additionally
a set of trials has been planned with addition of columbium (Cb) in
place of V+N. Cb contents shall be varied between 0.6%-10% to study
the ef'f'ect.
Quality Situation
Steelmakers of present generation are more concerned about quality steel
production. This may be attributed mainly to the growing awareness of
the consumers, resulting in a very tough competition. For quality steelmaking,
steelmakers must have some flexibility of operations. Low alloy, especially
low carbon steels, are considered a problem due to the refining limitations
encountered. That is why coreless inducdon furnaces arc often nicknamed
as very efficient "Dead Melter". Quality alloy steel grades,
fetching handsome premium at the market-place, have drawn attention
of the steel producers. To achieve the quality standards, induction
furnaces may be balanced/coupled with a refining unit to draw benefits
of induction furnace as an economic melting unit and remove the bottleneck,
of lack of refining, hence very limited flexibility.
Maintaining
a good level of 'S' in steels, i.e. upto 0.025% max has been the need
of day particularly in the context of H.S.L.A. steels and other, provides
sufficient challenge to the producers using
Induction furnace. A close control of charge chemistry is believed to
be required.
Often
level of 'S' presents problems as there are sources for 'S' pick up
by the melt. Reduction of 'S' in induction furnace in difficult, as
for disulphurization, a time slag with high basicity of around 2-4 and
very low oxygen potential of the bath required apart from other factors.
Low
sulphur levels are rapidly achieved using silicon carbide (SiC) a, primary
deoxidiser. This practice is well established in EAF industry in spite
of so much flexibility in slag conditioning. SiCcan easily be used in
induction furnaces because of the reaction.
SiC+3(Fe0)
= SiO + 3Fe + CO
2
The products (at RHS) are SiO2 (acidic), Fe (metallic) and CO (gas).
So, there has been no danger of reactions with lining. CO gas provides
additional bubbling, thereby combination of these effects helps to rise
the desulphurization of these effects helps to raise the desulphurization
level. An addition of 50gm SiC granules (about 5mm size) per ton of
molter, metal is recommended.
SiC
also increase the fluidity of metal, helps in removal inclusions thereby
providing a cleaning effect. This enhances the product quality. Thus
it is recommended that for production of quality steels addition of
SiC is to be adopted.
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