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3 Example for longitudinal profiles of contents of carbon, manganese and chromium at strand centre
over, towards the centre, into a void. Finally, in type d and 0?95 m min21) and the structure was either
the porosity forms a broad band. There is also an equiaxed dendritic or globular. The outer part of the
orientation in the form of short V lines at the centre. But void band of this type forms due to the action of the
long pronounced V lines (as in types b and c) are absent. upper stirrer, and the inner part is made by the lower
There is a variety within each main type and transition stirrer. So this structure is in fact an addition of an outer
structures exist between the main types a–c. For void zone (upper stirrer) and an inner void band. The
instance, instead of one large void as shown in Fig. 5a latter would then belong to type b.
there may be a row of several large voids, and then the The internal appearance of several voids was investi-
structures could also be that in Fig. 5b. Within type b gated using a scanning electron microscope (SEM). The
the centre voids may range from rather small ones with surface consists of dendrite groups which are directed
uniform distances between them to voids of larger and with the tips of the individual dendrites towards the
smaller size, and the V lines may be non-uniform to a interior of the void (Fig. 6). In the V channels (Fig. 7),
lower or higher degree. Type b may be taken to be a there are fine dendrites, as shown in Fig. 6, and coarse
transition structure between types a and c. Because of dendrites. The latter makes a comparatively smooth
this ambiguity there is some subjectivity in allocating the channel wall and was formed by melting of dendrite
structures to these types. Type a was formed at all arms during the flow of the melt in the channel or by
casting rates and when an equiaxed dendritic structure ripening of free dendrites after the melt was sucked
existed at the strand centre. Type b was also found at all away.
casting rates (0?50 to 0?95 m min21). But the crystal Figures 8–10 show the results of the quantitative
morphology at the centre was globular in most cases. measurements. In Fig. 8 the void volume per 25 cm long
The term globular is used for compact crystals which disc was plotted against the position in the 2 m long
do not exhibit a clear dendritic morphology. Type c strand section, for a representative strand section. It is
occurred at low casting rates (0?50 to 0?70 m min21) and evident that there can be considerable variation from
when the crystals at the centre were also mainly disc to disc (up to more than a factor of 2). Averaging
globular. Finally, type d was developed when stirring over 1 m (four discs) decreases the difference between
was with two stirrers, the casting velocity was high (0?80 the averages in adjacent 1 m sections, and it is believed
that the average over the 2 m section is a representative Influence of F-EMS on porosity and
average for the particular casting conditions. segregation
Nevertheless, the present data confirm the findings of
The roller plan of the machine is given in Fig. 14. The
previous investigations that the void volume can be rotary electromagnetic stirrers were positioned on
rather non-uniform along the strand length and that strands 2 and 4 in series 1 and 2. The positions are
sufficiently long sections must be investigated to obtain symmetrical so that the lateral cooling is the same at
meaningful average values. The void volume in 2 m long both sides. In series 3 and 4 two stirrers were installed on
strands is between 12 and 22 cm3 for most of the strand 2, at the roll positions 11 and 13, or 9 and 13
strands, or 6 to 11 cm3 m21 (Fig. 9). There seems to be respectively. The stirrer distribution is summarised in
an increase with the casting speed in series 4, but a Table 1. Strand 3 is the investigated non-stirred
decrease in series 3. So, in total, a clear effect of casting reference strand.
speed cannot be deduced from the data. But there is an It is very important that the electromagnetic stirrers
influence of casting speed on the width of the void band. were positioned correctly. If the stirrer is located too low
The width decreases with the casting speed (Fig. 10). in the machine, the mushy interior of the strand may
Increasing the casting speed moves the end of the have a high fraction of solid close to 1 or the strand may
sump downwards in the strand and, consequently, be completely solid already. So the operation of a stirrer
increases the length over which the residual melt has cannot have a metallurgical effect. If the stirrer is at a
to flow downwards for balancing the solidification too high position in the machine where the interior of
shrinkage at the tip of the sump. It may be assumed that the strand is still completely liquid, there may be neither
the resistance to fluid flow increases and that feeding the desired effect. The suitable position of the stirrer
stops earlier when the sump becomes longer. Con- depends on the casting speed and was determined in the
sequently, the void volume should increase with the present work with the help of a mathematical model
casting speed. However, this is not necessarily so. The available at the institute.10 As an example for the
resistance of the fluid flow does not depend solely on computational results, Fig. 15 shows the progress of
the length of the channel over which feeding has to occur, solidification of a 2406200 mm2 strand cast under the
but also or even more on the permeability of this length conditions of the GMH casting machine with a velocity
that is on the crystallisation details in the channel
Table 1 Stirrer distribution
(uniformity, bridging) which change with the casting
speed and channel length. Thus, it cannot be taken to be Experimental series Stirrer at roll position Strand number
clear that void volume should increase with increasing
casting speed. Previously void volumes in round c. c. 1 and 2 13 2 and 4
strands have been measured by Wünnenberg et al.8 using 3 11 and 13 2
4 9 and 13 2
6 or 13 m long segments and applying the buoyancy
of 0?8 m min21. The lowest diagram gives the lines of (series 4). The pronounced stirring band is caused by the
constant solid fraction fs50?03, 0?25, 0?5 and 1?0. The upper stirrer at roll 9. The boundary in the structure
curve fs51?0 is the solidus contour and represents between the stirred material and the non-stirred material
the thickness of the solid shell. Above the curve (stirring mark) exhibits negative segregation (‘white
fs50?03 the interior of the strand is practically liquid. bands’) if the stirring is strong. Figure 17 gives three
The positions of the rolls 9, 11 and 13 at which stirrers transverse carbon profiles from which the effect of
have been installed during the investigation are marked casting speed on the marks is visible. The transverse
by the dashed vertical lines. It is evident that at vc5 sections were cut from the same experimental strand
0?8 m min21 the rolls 9 and 11 are above and the roll 13 which was cast, subsequently, at vc50?65, 0?80 and
is at the position where fs is 0?03 at the centre. 0?95 m min21. The outer carbon minima corresponding
Consequently, stirring at these positions is in the region to the boundary between stirred and unstirred material
where the strand centre is practically completely liquid. in Fig. 16 move outwards with increasing casting speed.
Whether the mushy zone of the strand has been set So, the stirred inner region of the mushy zone becomes
into motion by the stirrer or not is evident from the wider with increasing casting speed corresponding to the
internal structure of the strand. Figure 16 shows the
longitudinal section of a strand cast at vc50?8 m min21
with stirrers operated at the roll positions 9 and 13
9 Effect of casting speed on average void volume in 2 m 11 Comparison of data on void volume obtained in pre-
long pieces of 100Cr6 blooms of 2406200 mm2 sent work and in work of Wünnenberg et al.8
12 Transverse carbon profile together with void contour: casting speed was 0?5 m min21 and F-EMS was at position of
roll 13
strong. It seems to be clear also that the centre porosity superheat (tundish) was always sufficiently low to
decreases if the centre structure changes from columnar produce an equiaxed centre structure although the
to equiaxed. However, the effects of EMS on segrega- structures at the higher superheat (y30 K) were
tion are not so clear. equiaxed dendritic and at the lower superheat (y22 K)
Usually, it is claimed that the globular centre structure globular. Great effort was made to find the proper
obtained by M and S stirring exhibits less segregation stirring location along the strand. It was found that
and improves the quality of product. But this is not under the present conditions, F-EMS was not beneficial
always so. For instance, high carbon wire achieves more with respect to centre segregation in 100Cr6 blooms but
favourable properties with columnar (not stirred) strand made it even worse. It is to be mentioned that in
structure.9 It is particularly unclear whether F stirring, previous investigations usually rather small samples
in combination with M and S stirring, can decrease the were investigated compared to the 2 m long sections
centre segregation. Early papers claimed considerable studied in the present work, and the method to
beneficial effect.1,11–15 But other work followed and determine segregation often was qualitative (sulphur
found little effect or no effect.3,5,16 In a recent investi- prints). It is believed that, due to the non-uniformity of
gation17 supported by the EC, F-EMS improved the the structure in the strand centre, unambiguous data on
centre segregation in 140 and 180 mm formats but not in segregation can be deduced only by using long strand
120 and 140 mm billets. In the present investigation the segments.
Table 2 Computed solid fraction at strand centre fs (centre) and distances of contour x(fs50?25) from 100Cr6 bloom
surface at positions of rolls 9, 11 and 13*
References
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Rundschau, 1987, (2), 364–374.
3. R. Jauch: in ‘Metallurgie des Stranggießens’, (ed.
K. Schwerdtfeger), 472–531; 1992, Düsseldorf, Stahleisen; see
also R. Jauch, W. Courths and D. Prem: ‘Erweiterung des
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1994, VDEh, Vol. 1, 321–328.
20 Ratio of Cmax(8)/Co plotted against casting speed for 5. K. S. Oh and Y. W. Chang: ISIJ Int., 1995, 35, (7), 866–875.
experimental strands stirred with various modes of F- 6. H. Jacobi and K. Wünnenberg: Steel Res., 1997, 68, (6), 258–
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7. O. Bode: ‘Beitrag zum Verständnis und zur Beeinflussbarkeit der
Makroseigerung beim Knüppelstrangguss des Wälzlagerstahles
maxima. The effect of electromagnetic stirring close to 100Cr6 durch den Einsatz von Finalrührern’, Doctor dissertation,
the sump (F-EMS) was explored by using one or two Technische Universität Clausthal, Clausthal-Zellerfeld, Germany,
rotary stirrers installed at certain positions along two 1996.
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Congress 94, Proc. 2nd European Continuous Casting Conf.,
It was confirmed that the shrinkage voids can form
Düsseldorf, Germany, June 1994, VDEh, Vol. 1, 305–315.
with different morphologies and that there is a 9. D. Ameling, H. Litterscheidt, K. Schwerdtfeger and D. Senk: ISS
characteristic distribution of carbon (and other ele- Steelmaking Conf. Proc., 1986, 69, 387–395.
ments) around the void. Nevertheless, the measured 10. K. H. Spitzer, K. Harste, W. Weber, P. Monheim and
values of the void volume scattered between y5 and K. Schwerdtfeger: ISIJ Int., 1992, 32, 848–856.
y10 cm3 m21, and a clear influence of casting para- 11. Y. Katagiri, H. Takagi and T. Ohnishi: ISS Steelmaking Conf.
Proc., 1982, 65, 246–250.
meters (casting speed, superheat, F-EMS) was not 12. K. Ayata, T. Mori, T. Fujimoto, T. Ohnishi and I. Wakasugi:
discernable within the scatter. The segregation expressed Trans. ISIJ, 1984, 24, 931–939.
with the ratio of Cmax(8)/Co (Cmax(8)5average of the 13. K. Suzuki, Y. Shinsho, K. Murata, K. Nakanishi and M. Kodama:
eight highest carbon maxima on the 2 m long centreline, Trans. ISIJ, 1984, 24, 940–949.
Co5melt composition) increased with the casting speed. 14. T. Fujimura, H. Yamasaki, T. Kayano and M. Kawaberi: ISS
Steelmaking Conf. Proc., 1987, 70, 213–216.
Also, there appears to be an increase with the superheat. 15. C. M. Chien, M. C. Huang and J. B. Jaing: Proc. 4th Int. Conf. on
A beneficial effect of F-EMS could not be detected. ‘Continuous casting’, Brussels, Belgium, May 1988, Stahleisen,
The centre segregation of continuously cast ball 223–234, Preprints 1.
bearing steel 100Cr6 is pronounced unfortunately. The 16. S. Kunstreich: La Revue Métallurgie-CIT, Nov. 2003, 1043–
centre contents of carbon (average of the eight highest 1061.
17. V. Ludlow, A. Normanton, A. Anderson, M. Thiele, J. Ciriza,
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chromium as high as 3?3%, at the melt contents of Continuous Casting Conf., Birmingham, UK, October 2002, IOM
nominally 1?0% carbon and 1?5% chromium. Up to now Communications Ltd, 430–442.