Agenda
Overview of Process Discussion of Caster in detail
Defects and preventative measures
Discussion of inspection procedures
UT ASTM A578
Questions
Steelmaking Process
Melt Shop: Scrap
Melt Shop: EAF
Tapping EAF
Melt Shop: Twin LMF
Melt Shop: LMF
Meltshop: Casting
Casting Liquid into a Slab
Slab
Roll Mill: Reheat Furnace
Roll Mill: Rolling Mill
Roll Mill: Hot Shear
Roll Mill: Leveler
Cooling Bed
Roll Mill: Cold Shear
Mechanical Testing Lab
Impact Testing Tensile Testing
Product Traceability
Die Stamping Paint Marking
On-Site Metallurgical Facilities
Scanning Electron Microscope Electrolytic Macro-etch
Shipping
Discussion of Internal imperfections
Segregation Voids Streaks Laminations
Slab Defects
Segregation
Solidification
Solidification
Grain Structure
Ways to minimize segregation
Lower carbon Control superheat Control bulging Lower cast speed to be able to do more soft reduction Lower Hydrogen Minimize Chemistry Higher reduction ratios
What is Soft Reduction?
Squeeze at final point of solidification
Localized
Final point of solidification moves down with increasing casting speed
Linear
Superheat Monitoring
Voids and Laminations
Caused by similar factors as segregation
Superheat Dissolved gases Misalignment in machine Steel shrinks as it solidifies.
Voids considered normal Laminations not considered normal.
Radial Streaks
Ways to minimize streaking
Excellent roll alignment Control bulging Lower Hydrogen Minimize Chemistry Higher reduction ratios to heal any streaks Uniform cooling
Rolling process
Rolling Direction
Equiaxed Grains
Elongated Grains Very high strength and low ductility
Nucor In-House Quality Checks
Nucor-Hertford Inspection of Bridge Grades
All weathering grades > 1.25, each end for 24 All grade 50 > 1.50, each end for 24 All grade 36 > 1.50, each end for 24
Nucor vs Industry Standard for Internal Soundness
Industry Standard
ASTM A578 or A435, only when ordered
Flaw size permitted, up to 3 diameter with total loss of back reflection
Nucor Standard
Rejection criteria is more stringent than ASTM
Nucor-Hertford UT Acceptance Criteria
Level
Criteria
Bridge
Other Structural
Level 1
Less than 10% Screen Height
Pass
Pass
Level 2
10%-30% Screen Height
Pass
Pass
Level 3
30%-50% Screen Height
Pass
Pass
Level 4
50% Screen Height Indication Less than 1
Fail
Pass
Level 5
50% Screen Height Indication Greater than 1
Fail
Fail
Typical UT Indication on a 2 plate
100
80
Screen Height (%)
60
40
20
0.5
1
Distance (in.)
1.5
ASTM UT Reject at Mid-Thickness of 2 Plate
100
80
Screen Height (%)
60
40
20
0.5
1
Distance (in.)
1.5
Nucor Hertford UT Rejection
100
80
Screen Height (%)
60
40
20
0
0 0.5 1
Distance (in.)
1.5
Mannesman Class 1
Class 2
Class 5
Short and Long term plans
Short term
Machine alignment Increased inspection when a problem is found Reduced cast speed Degassing
Speed Restrictions
Since 2008, Nucor has 62 grades that have speed restrictions to help with centerline and porosity(35% of our grades and mix).
Speed restriction cause solidification higher in the machine and allows for more time to perform soft reduction 60% of all greater than 1 material has speed restrictions. 95% of all greater than 2 material has speed restrictions.
Work done on improving surface quality
2010 revised our soft reduction tables 2011 set up routine macro sampling Added personnel to do this Helps identify problems in machine sooner 2011 Improved superheat control 2012 Installed Degasser Started up July of 2012 Now degassing 20-25% of our product
Results of Quality Improvements
Year
2008 2009 2010 2011 2012 Internal Soundness 0.21% 0.31% 0.42% 0.24% 0.17%
Porosity
0.04% 0.01% 0.12% 0.04% 0.02%
Total
0.25% 0.32% 0.55% 0.28% 0.18%
* Results are summary across all gauges/grades and include non degassed material.
Long term plans
Long term
Replace segments to improve cooling patterns
Current segments leave non-uniform soldification patterns
Danieli new anti-bulging program Investigating on-line UT
