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    DH Heavy Plates With Special Process

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    vignesh558855
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    HEAVY PLATES WITH SPECIAL PROCESS DESIGN TO MEET EX- TREME CUSTOMER REQUIRE- MENTS Werner Oswald, Alois Streisselberger, Robert Thul, Hans-Jirgen Nehrenberg, Jurgen Kirsch AG der Dillinger Hottenwerke, Dillingen/Saar Summary Some aspects of the development of tne production program of Dillinger Hutlenwerko {DH) during the last 10 years are illustrated. The two main groups have boon TM line pipe Plates and customer plates for a wide range of sizes and applications. ‘The driving forces for the entering into new markets especially with extreme specifica- tions have been on the one hand a systematic extension of equipment and facilities on the other hand the gaining of know how in the fieids of process control and metallurgical product development. The presentation addresses the possibilities resulting from the installation of further reheating facilities, the powerful §.5m-4-high stand with its process control devices, the MULPIC-accelerated cooling equipment and the exploitation of this combined technology based on specific strategies to fulfill unique combinations of specification requirements or to assure a safe fabrication route or application service at the customer side ‘The banetits of such progress are to be seen In the more sophisticated products which are contributing to more satisfying steel steuc- tures. 1400 fmt Toa proaucton| EM prdvetion g ‘veraging over year a Quanto plate grecucton peryeae, 10 o § 8 8 8 t | | iy | | aerosol TSieTI7o lesueaea —Is6NaTIES Tee a8 Figure 1: Plate production - Development of tonnage per year As an example for such tallor-made plates the longitudinally tapered plates should be mentioned. It has to be emphasized that quality assurance systems and the feed-back from the fabricator or user side to the plate producer are key points for the well- controlled development of process and product, 1. INTRODUCTION Dillinger Hittenwerke (DH) is operating a Plate mit with 2 powerful four-high stands using slabs and ingots from their own steel shop. Together with all the other equipment which has been installed during the ast two decades in the plate mill, the application of @ great variety of processing routes has been enabled. As an important supplier of several large~ diameter-pipe mills all over the world, DH entered into the production of TMCP materials already mors than 15 years ago, in parallel to the production of heavy plates for 2 wide range of applications made by various rolling and heat treatment variants. Figure 1 gives an illustration of the devetop- Ment of production tonnage during this recent history. Whereas the importance of TM-rolling especially togothar with ACC has been highlighted in other papers 1.2) this presen- tation will fecusize on those processing variants which allow to meet special combi- nations of customer's product requirements both In terms of geometry and physical properties, These product groups will bs according to Table 4 Table 1: Special product and process variants Product Process Plates with extreme size “| cimensions of equipment; lab oF Ingot size Hs-rolling (high shape factor) LP-roiting thickness, (LP. longitudinally proftes) Plates with unusual heat Tweatment ELO + MULPIC (austenitzingewater cooling, ‘Acc, Na/DA, a81) W-rolting (%..normalizing) N-heat-trestment * plates with extreme size * plates with extreme thicknoss * plates with variable thickness plates with unusual combination of heat treatment cycles or substitution of heat treatment by rolling schedule design + and finally the possibilities of combining these features. Fig. 2 gives an illustration of the various process stages which contribute more or less to the geometrical and physical product properties. Process Somat Casing Hot Rtng Cosine Heavier _ wag Fein Geometry. T ‘Mech. Properties Product Figure 2: Contribution of process steps to product properties 2. PLATE MILL LAYOUT AND EQUIPMENT The layout of the plate mill (Fig__3) is Setermined by the following design features: + sufficient and flexible reheating facilities: 3 pusher type furnaces, i.e. up to 7 slab rows can be chargod in parallel, Bbogie hearth furnaces, asp. for ingots or smali size siabs or non-ferrous mate rlals + high pressure descaling unit (186 bar) ia front of the stands + 2 powerful 4-high reversing stands (Fig. 4) first: 5.5 m barrel length, mainly for pre rolling including broadside rolling second: 4.8 m barrel length, tor finish rolling both: automatic gauge control for thick ness control and roll bending devices for flatness control process control: PLATE model for pass schedule calculation space between stands: 105 m + MULPIC-ACC-equipment: 30 m long water illow system for accelerated cooling or direct quenching (More details cn the MULPIC process conirel aze given in chapter 3.4.) + 5.2 m hot leveller = heat treatment facilities for normalizing, quenching and tempering + cooling beds and inspection bad (for 50 m. rolled length) + in-iine automatic US-tasting (100 % body testing) + 2 shearing lines (up to 52 mm thick plates) « torch-cutting (for heavy thickness range) cold levellers shot-biasting (+ painting) The principal material flow during plate production occurs along 1 hatl of 1.2 km length. stan posner | stab yara furnaces 1 ‘5m-4-high stand 44.00 -4- igh stand igure 3. Plate Mill - Layout Ace veqipnent | (Roliing part) ‘ACC - equipment "55 med high stand “igh wae Sage aid features - = aim sem 1968 os) 1971 (Geom) wore max ooweo1 | mx sooth | gy _fOR® rman 2x 500 en | me 2xczn0 wn | SURES ‘ne nae oe ‘Soe (PUTE ‘cone Sun eure) Figure 4: Construction dala of the 4-high stands The heart of the plate mill is the rolting part with its two 4-high-reversing stands. Their general performance has been described elsowhere 2), The attention should be drawn to those aspects having relevancy tor the topic of this paper. Especiatly during the design of the 5.5 m-roughing stand the base for the future production and delivery program has been laid. This high barrel length allows the use of longer and heavier concest slabs, especially during broadside roiling. Thereby _ the Program was net only extended to heavier, thicker and wider plates but also an increase in the mean value of slab weight has been achioved which moans a higher production elficiancy. When the 8.5 m-stand is used as a finishing stand, plates up to approximately 5.2 m width can be delivered. For large diameter pipe mifis the production of 64 inch- pipes has been onabled with plates trom Dillingen, and for general structures of large vessels such wide plates allow to spare welding work. During specifying the technical features of the stand a lol of very different application cases had to be regarded. The most important of them are illustrated in Fig. § in torms of rolling force and torque situation. This covers normal hot rolling of plain carbon manganese steel plates which get their final properlies by additional heat treatment, ‘Thickness reduction ger pass Is in the range of 30 to 40 mm due to relatively high rolling temperatures; only for extreme cases, 6.9. low total reduction from siab to plate the single reductions ate increased up to 66 mm. The purpose of such rolling technique will ba expiained iater in this papor (chapter 3.2). In the caso of TM-rolling the ing passes ara applied in the range of Ars or even at lower temperatures, |.e. without softening in the interpass times by recrystallization dua to microalloying of high strength stools. As 2 consequence, even with reductions as low as 10 mm, the ‘rolling loads are considerably greater than those dering normal rolling The torques become high even with moderate forces when they are combined with high thickness reduction. That is why the 4.8 m-stand and its motor were prepared for max. torques of 3200 kNm per roll ane the 5.5 m-stand even up to 4500 kNm per roll based on a synchronous type of drive motor. Further user orientated application examples of the equipment are presented in the subsequent chapters, As shown in Table 1 each special product group has been based on a process design oxplciting the possi- ies of the installed equisment. Figure 5: Galoulation examples of rolling force and torque for the 4-high stands 3, SPECIAL PROCESS AND PRODUCT VARIANTS 3.1 Plates with extreme size ‘One prerequisite for the production of ptates with extreme weight and size is the design of the rolling equipment as described above, The second base for such products is the available matorial to be put into the reheating and rolling process. Table 2 presents a list of slab and ingot Sizes coming from the steelmaking plant at Dilingen which fs located at a distance of Jess than 1 km from the plate mill. The gap between the both is used for the slab finishing and storage, i.e. siab yard, These circumstances are also favourable tor werm or hot charging of CC-material. As each plate is rolled due to ordered dimensions which can vary extremely, @ large variety of slab and ingot sizes is necessary to assure in all Processing stages a sale and reproducible handling. Table 2: Slab and ingot sizes tor plate ta wich, aeegal SEASESRETaR es pate Piensa nom cece eam ema Elgure 6: Plate delivery program for various processing conditions appropriate transport facilities’ both in the mill which include cranes, rotter tables, trucks and railway systems and also for the transport to the customer which include special trucks or waggons for inclined transport of large width plates and ship transport trom Dillingen's harbour. As an additional service lo the customer plates can be delivered shot-blasted and painted and even with edge preparation or reforming by the DH fabrication shop. 9.2 Plates with extreme thickness production Slabringet | section] _ Spee. |max. wolgnt "| welghtim mmx mm t 1 Céata A | 2200x300 | 5.0 a +B | zevox250 | 4a 23 + ¢ | 2200x200 | 34 18 +p | tssoxas0 | 30 16 + | tssox200 | 24 19 ingot 1 | 2510x010 56 + on | 2125x878 - 40 : 1090 x710 : a st engi range for pubes type tern ™ Due to the ordered delivery condition, e.9. as rolled, normalized, quenched and tempered, ‘TM-processed, ..., a range of available plate sizes can te defined and collected in the delivery program (Fic, 6). As a result the atmost limits of the production program cover thickness {rom 5 to 420 mm, width from narrow lamella 10 5.2 m, length rolled up to 48 m, delivered up to 36 m and 28 m for heat-treated piates, and all this in a large variety of steel compositions and grades which are not dealt with hore in more detail. It should be mentioned that extreme plate sizes and weights require the For almost three decades the advantages of continuous casting have been already exploited to produce heavy plates with an optimized level of homoganoity both over thickness and length of the product. By using CC-slabs also bottlenecks in steel and plate Production coming from the complications with ingots could be avoided and the yield of the whole process has been brought to @ considerably higher tevel. The use of CC-slabs is restricted to a certain maximum plate thickness. A defined total reduction ratio, that means stab to plate thickness, Is necessary in order to moot the property requirements on plate. The required total reduction ratic depends on the level of properties that has tc De mel, the features of the starting material (slab) and on the rolling process itself. A sophisticated and “sata” production route Is required tor production of thick plates, e.g. 125 mm starting from CC-stabs | with thickness 300 mm, which corresponds to a total reduction of 2.4 times, "Safe" means plates with satisfactory internal quality both in terms of soundness (no harmful porosity) and of properties even in the core (especially of toughness and through-thickness-proper- ties) To achieve this goal, it is necessary to apply a rolling process which ensures to get also in the core of the material a local deformation comparable to the nominal deformation. The essential parameter of the rolfing pass describing its efficiency in penetration of deformation into the core is its shape factor m (Eigure 7, tng Shape cr = at =anl His sna (seen ata) ost rt eon Ge tomcuw = e108) ‘ye, 4718014 2 pane 0) 4, = 171 50+ A) / 3 pea | Figuie 7; High shape factor rolling The shape factor depends on the reduction per pass and the work roll radius and ‘expresses the size of the compressive stress zone in the material between the rolls. Tae higher the shape factor the higher the efficiency in reducing porosity. And in order to improve properties in mid-thickness, the rolling has to be performed with an as low as, possible number of passes respectively an as, high as possible reduction per pass, that means high shape factor. One prerequisite to perform rolting with high shape factor (abbreviated: HS-relling) is a powerful rolling stand. For example, at the 5.5 m - 4-high stand of Dillinger Hutte which enables rolling up to a maximum force of 108000 KN and torques up to 4500 kNm 2 reduction per pass of up to 60 mm can be performed. Tho efficiency of HS-roliing can be incroased by [ow speed rolling, which is only possible with suitable roll bearing systems. Figure 8 demonstrates the effect of the HS- rolling on the reduction of area values in through-thickness direction. ‘It clearly ap- pears, that by using HS-rolling instead of normal rolling, that means low shape factor roiling (LS), the reduction of area can be considerably improved for a given. totat reduction ratio and fer a dafined steel type and cleanliness level. As the H&-rolling is applied to use CG-siabs in competition to ingots for a certain thickness range, it also allows to extend the possible plate thickness range for a given ingot thickness (¢.g. 809 mm). and defined plate requirements to higher values. Ancthas application example can be seen in the first rolling stage of TM schedules where the HS-rolling “assures a complete rectystallization of austenite in the core of the material 4). This is an important contribution to the grain refinement and thereby to a high level of strength and toughness. 3.3 Longitudinally tapered plates Gne feature of performance of a plate mill has to be seen in the accuracy and homogeneity of thickness over the whole length of each plate. To avold thickness deviations along the plate, sophisticated © = rsa 3 © thickness oon = : 2 7 [a=s[_ ee [ian] * »|—s $3] | am ee ee ee 20. + TCR * | 02 | Effect of HS on R.A. values TRewet| sn | sesace| toe | ‘ total reduction fe = 1/4) control mechanisms and their technical realization have been implemented. They are well-known as AGG (automatic gauge con- trol) systems with various modas of appli- cation (relative, adsolute, feod forward, ...) Based on this technique of contro! of detined constant thickness over plate length, another exploitation of the system was created by using it for the production of variable plate thickness over length From the construction point of view a lot of structural components like beams, box girders or similar parts, o.g. in bridges have to bear load distributions which ara changing over length The answor of the plats producer are LP- piates, i.e. tongitudinally tapered plates 5, 6). Thay allow to reduce costs by decreasing the weight of the whole construction or the number and extent of weld seams and machining of transition parts. These avdantages compared to the conventional construction case are illustrated in Fic, 9. Gonvoniona racine enventonal Figure 9: Advantages of LP-plates The maximum values for thickness change and gradient bave been recently incroased to 55 mm and 8 mm/m respectively. From the process point of view, Eig. 10 desired profile is fed into the process computer. The rolling is performed in a reversing mode by increasing the defined deviation from parallel faces pass by pass. The thickness deviation for each longitudinal position is applied via the AGC-positioning system, i.e. a hydraulic oil/grease system, the cata of which are desoribed in Table 3 Table 3 Data of AGC (automatic gauge control) on §.5 m-4-high stand Hydraulle roll positioning system (AGC) |. type Mos-SERMES: (oligreats eysiem) |. ate plato stam 1210 mm |. ain piston stroke

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