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Influence of casting parameters on void

volume and centre segregation in


continuously cast 100Cr6 blooms
O. Bode1, K. Schwerdtfeger*1, H. G. Geck2 and F. Höfer2
Continuously cast ball and roller bearing steel 100Cr6 exhibits comparatively strong segregation
which poses a quality handicap. In the present work which was carried out in the time between
1992 and 1996 the void formation which is related to the centre segregation and the centre
segregation were measured on 2 m long segments of 2406200 mm2 blooms cast at the steel
plant of Georgsmarienhütte GmbH. It was found that the segregation of carbon expressed with
the ratio of Cmax/Co increases with casting speed and superheat. Many experiments were carried
out to elucidate the effect of electromagnetic stirring along the lower part of the metallurgical
length (F-EMS). But, unfortunately, a decrease in segregation could not be achieved by F-EMS.
The only method to decrease the centre segregation in continuously cast blooms of 100Cr6
seems to be casting at low speeds with low superheat.
Keywords: Continuous casting, Ball bearing steel, 100Cr6, Void volume, Macrosegregation, F-EMS

Introduction As already mentioned the investigation was carried


out some time ago.7 Nevertheless, the centre segregation
The ball and roller bearing steel 100Cr6 tends to exhibit in 100Cr6 continues to be a hot subject and the opinions
comparatively strong macrosegregation, due to its long on the usefulness of F-EMS with respect to segregation
freezing interval and the carbon–chromium interaction. and porosity in high carbon steels are not the same
This is the reason for the late application of the everywhere. Although it has been found in several
continuous casting process to the grade. Still today steelworks that F-EMS did not cause much improve-
100Cr6 steel for high quality balls is made only by ingot ment of the centre structure of blooms, there are other
casting, as far as we know. Owing to the segregation, places where this is not known and an expensive stirring
primary carbides (Fe,Cr)3C can precipitate from the equipment is installed to fight the problem.
residual melt, at the end of solidification. These carbides
elongate during rolling and cause banding in the centre
region of the bar which decreases the life of the bearing Casting of strands
made from it. Only a certain extent of banding
The investigated strands were cast on a six strand bloom
(expressed in terms of an index number) is accepted by
caster of Georgsmarienhütte (GMH). The caster has a
the ball bearing manufacturers.
radius of 10 m. The strand section was then 2406
The centre segregation of continuously cast ball
200 mm2. The mould had an active length of 600 mm. In
bearing steel has been investigated in several papers.1–6
the foot roll segment linear stirrers were installed behind
Hence, there is knowledge on the subject but it is not
austenitic rolls. These stirrers were operated in all
detailed, i.e. the dependences on the casting variables are
normal castings. The spray cooling zone was divided
not well known. The present study was intended to be of
a systematic nature. It had the purpose to elucidate the into three zones: zone 1 from 600 to 1420 mm below the
effect of casting parameters (casting speed and super- meniscus, zone 2 from 1420 to 3500 mm and zone 3
heat) on the centre segregation and related phenomena. from 3500 to 5100 mm. In the normal operation, 56% of
Long strand sections were used in the investigations to the cooling water was applied in zone 1, 26% in zone 2
obtain meaningful averages. Particularly, the work had and 18% in zone 3. The total flow was between 45 and
the aim to explore the possibility for decreasing 74 L min21 depending on the casting speed and the
segregation by electromagnetic stirring in the final particular experimental series. The stirrers for electro-
solidification zone (F-EMS). magnetic stirring in the lower region of the strand (called
F stirring subsequently), as applied in the experimental
1
programme, were rotary stirrers, made by AEG
Technische Universität Clausthal, Institut für Metallurgie, Robert-Koch-
Strasse 42, Clausthal-Zellerfeld 38678, Germany Elotherm (now SMS Elotherm). They had a total length
2
Georgsmarienhütte GmbH, Neue Hüttenstr. 1, 49124 Georgsmarienhütte, of 750 mm and a sheet package length of 500 mm. The
Germany voltage, current and frequency were 400 V, 1280 A and
*Corresponding author, email schwerdtf@t-online 49 Hz respectively. The maximum magnetic induction

ß 2008 Institute of Materials, Minerals and Mining


Published by Maney on behalf of the Institute
Received 7 June 2007; accepted 29 June 2007
DOI 10.1179/030192307X233511 Ironmaking and Steelmaking 2008 VOL 35 NO 2 137
Bode et al. Influence of casting parameters on void volume and centre segregation in 100Cr6 blooms

1 Sample position in strand (half of 2 m long strand


piece)

was y100 mT. These stirrers were inserted into the


segments instead of support rolls.
The casting speed was varied from 0?50 to
0?95 m min21. The superheat in the tundish was a explanation of method; b example for X-ray photo
2 Determination of void volume in strand centre by X-
between 22 and 32uC. The solidification structure in
ray method
the centre region of the strands was equiaxed (dendritic
equiaxed or globular) in all the studied strands. In total
31 strands were investigated. enclosed almost completely. That is only in a few
samples void ends penetrated through the surfaces of the
30 mm thick slice. But also in theses cases the void
Sampling and investigation of samples volume beyond the slice was comparatively small, and
The void formation and associated segregation can be the void was obtained almost completely.
rather non-uniform in billets and blooms along their
length and must be investigated over a sufficiently long Segregation
strand length for obtaining reproducible averages. In the For the segregation measurements the 25062006
present work, strand samples of 2 m long were used. 30 mm3 slices were machined on one side to 10 mm in
From these pieces at first two transverse sections were thickness so that the centre plane became free. The
cut at the ends. Then the samples were divided into analyses were carried out with a mobile spectrometer.
segments of 250 mm long and 30 mm thick slices were The measurements were taken at the centreline of the
machined from them at the centre of the strand in the strand at distances of 10 mm. Hence, 200 values were
vertical (thickness) plane, as shown in Fig. 1. So, from obtained for the total sample of 2 m long. Figure 3 gives
each studied strand there were two transverse slices and an example of the results for the sample of 1 m long. The
eight longitudinal slices of 250 mm long, 200 mm high contents of carbon, chromium and manganese were
and 30 mm thick. The analyses of the investigated measured. The concentrations of these three elements
strands were in the ranges of 0?91–0?99% carbon, 0?33– run parallel to each other (Fig. 4). Therefore, the extent
0?40% manganese and 1?47–1?50% chromium. of segregation can be characterised by that of one of the
elements. Carbon exhibits the strongest segregation. In
Volume of voids the following the data will be given for carbon.
The void volume was measured with an X-ray technique
which is explained in Fig. 2. The X-ray installation has Results of investigation
an opening of 3?663?6 mm2 and an exit angle of 40u.
Two of the 30 mm thick slices were exposed at the same Void formation
time. The radiation penetrates through the sample and is The voids at the centre of the bloom can have different
weakened according to the local material thickness, and morphologies as is well known. The main four kinds of
blackens the film. The exposure time was y1 min. In appearance observed in the present work are depicted in
order to relate the extent of blackening of the film to the Fig. 5. In type a the voids are in a narrow centre region.
local void volume two calibration wedges were X-rayed There is one large main void with a sharp end at its top,
with each exposure. Their thickness varies in steps and and with several small voids under it. V lines emerge
so a greyscale is produced by them giving the blackness from the top void. But the chain of small voids below is
as a function of the steel thickness. The blackness was free or almost free of V lines. In type b the chain of large
measured with a photometer and converted to total void voids at the centre is more uniform and V lines appear
volume using an image analysis system. The form of the along it, although non-uniformly. Type c consists of a
voids was recorded by manually copying the film picture band of very uniform V lines. There are some medium
to paper. In the 30 mm thick slices the void band was size voids at the centre. Some V lines broaden and go

138 Ironmaking and Steelmaking 2008 VOL 35 NO 2


Bode et al. Influence of casting parameters on void volume and centre segregation in 100Cr6 blooms

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

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Bode et al. Influence of casting parameters on void volume and centre segregation in 100Cr6 blooms

method. A comparison between their data and the data


from the present paper is given in Fig. 11. It is known that
columnar solidification structures have a larger void
volume than equiaxed structures. So the void volume for
the columnar strands of Wünnenberg et al. is about twice
the volume for the equiaxed (globular) structure. The
latter is of similar size as the data from the present paper.
Segregation
The local distribution of the elements at the centre is
related to the void geometry as has been reported also in
previous literature.9 Figure 12 presents an example for
the transverse profiles of carbon together with the form
of the void as determined by X-raying. The void is of
type a. The highest concentration peaks exist at the V
lines and at the lower part of the large centre void.
The longitudinal profiles as shown in Fig. 3 were
measured in all the experimental strands. Segregation
ratios of Cmax/Co and Cmin/Co were deduced from the
data by taking the averages of the eight highest (Cmax(8))
and the eight lowest values (Cmin(8)) in each segment of
2 m long. Co is the melt composition. The obtained
ratios are plotted against the casting speed in Fig. 13.
There is a clear increase in Cmax(8)/Co with the casting
speed in experimental series 3 and 4, and the series with
low superheat (series 1 and 3) and equiaxed globular
central structure exhibit lower Cmax(8)/Co values than
the heats with higher superheat (series 2 and 4) and
equiaxed dendritic central structure. It can be concluded
4 Relationship between segregation ratios of carbon, that the macrosegregation in 100Cr6 steel increases with
chromium and manganese at strand centre increasing casting rate and increasing superheat.

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

140 Ironmaking and Steelmaking 2008 VOL 35 NO 2


Bode et al. Influence of casting parameters on void volume and centre segregation in 100Cr6 blooms

5 Different kinds of morphologies of voids at strand centre: length of discs is 250 mm

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

7 Scanning electron microscopic view of V channel


showing fine and coarse dendrites: coarsening may
have occurred by remelting of dendrite arms caused
6 Scanning electron microscopic view of void showing by melt flowing in channel, or by ripening of exposed
pronounced dendritic structure of internal void surface dendrite tips after melt had withdrawn

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Bode et al. Influence of casting parameters on void volume and centre segregation in 100Cr6 blooms

10 Effect of casting speed on average width of void


band in 2 m long pieces of 100Cr6 blooms of
2406200 mm2

stirred zone decreases from 4?3 at roll 9 to 2?1 cm at


roll 13.
The effect of F-EMS on the void volume and centre
segregation is depicted in Figs. 19 and 20. In all cases
there was still mushy material at the strand centre where
the stirrer was positioned or where the upper stirrer was
installed when two stirrers were used. It is evident that
F-EMS did not exert much influence on the void volume
8 Void volume in 25 cm long adjacent segments of 2 m (Fig. 19). The centre segregation expressed in terms of
long strand piece: series 4, no F-EMS the ratio of Cmax(8)/Co increased with the casting speed
also if the stirring was performed and compared to the
increased total width of the mushy zone at the stirrer non-stirred strands, the ratio increased (Fig. 20).
position 9, as is to be expected. At 0?95 m min21 there Many authors have reported that electromagnetic
are other minima within the outer stirring bands, stirring is beneficial with respect to centre segregation in
originating from the stirrer at roll 13. billets and blooms of high carbon steels. But the
By the comparison between the location of the stirring beneficial effect depends on the position of the stirrer
marks (carbon minima) with the computer calculation at the machine and whether the internal structure is
of the fs field it was deduced that the stirring marks already equiaxed without stirring (low superheat cast-
exist where the solid fraction had been y0?25 at the ing) or is made equiaxed by the stirring. In the first case
particular stirrer position (roll 9) during casting there may not be much beneficial effect. But, at high
(Fig. 18). Assuming that this is similar if the first stirrer superheat M and S stirring can cause a shift from
is at roll 11 it is concluded that the F rotary stirrers have columnar to equiaxed crystal structure. The white band
to be positioned, depending on the casting speed, so that formation can be minimised if the stirring is not too
there is still a zone with fs,0?25 in the strand. The data
for the solid fraction at the strand centre and for the
distance from the surface of the contour with fs5 0?25
are given in Table 2. For instance, at 0?5 m min21 there
is a region with fs(0?25 which can be stirred only at roll 9.
At 0?80 m min21 a zone with fs(0?25 is present at all
the three roll positions and the half-thickness of the

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

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Bode et al. Influence of casting parameters on void volume and centre segregation in 100Cr6 blooms

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.

13 Segregation ratio of carbon plotted against casting


speed 14 Roller scheme of bloom caster at GMH

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Bode et al. Influence of casting parameters on void volume and centre segregation in 100Cr6 blooms

17 Transverse carbon profiles of strand stirred at posi-


tions of rolls 9 and 13 (100 mT) and cast subse-
quently with different casting speeds of 0?65, 0?80
and 0?95 m min21: structure shown in Fig. 16 belongs
to part of strand cast with 0?80 m min21

15 Computational results on course of solidification of


100Cr6 bloom at GMH cast with 0?80 m min21: strand
format is 2406200 mm2; possible positions of stirrer
are marked in lowest diagram by vertical straight
lines; wf5centre of wide face, nf5centre of narrow
face

Summary and conclusions


The segregated part of continuously cast billets and 18 Distance from bloom surface x(fs) at which specified
blooms is located around the shrinkage voids. Hence, solid fraction fs exists at stirrer position of roll 9:
void formation and formation of centre segregation are dots indicate location of stirring mark in stirred
strongly interrelated. There is the problem that the strands
solidification structure is so non-uniform at the strand
centre and that it is very difficult, therefore, to define
and measure representative values for void formation

19 Void volume in stirred strand pieces of 2 m long in


comparison to that in non-stirred strands
16 Solidification structure on longitudinal section of
100Cr6 bloom: casting speed was 0?80 m m21 and F- and segregation. In the present work 2 m long strand
EMS was with 100 mT by two stirrers at positions of samples were investigated. The void volume was
rolls 9 and 13; stirred centre zone is clearly visible; determined with an X-ray technique and the segregation
width of picture corresponds to disc height of by spectroscopic analyses at 1 cm distance along the
200 mm centreline, and averaging the eight highest concentration

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Bode et al. Influence of casting parameters on void volume and centre segregation in 100Cr6 blooms

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*

Distance x(fs) in cm of contour with fs50.25 from surface


Distance Solid fraction at centre fs (centre) and half-thickness of mushy region 102x(fs50.25) at
z from at casting speed vc in m min21 casting speed vc in m min21
Number meniscus
of roller in m 0.50 0.65 0.80 0.95 0.50 0.65 0.80 0.95

9 4.12 0.086 ,0.01 ,0.01 ,0.01 8.2(1.8) 6.7(3.3) 5.7(4.3) 5.1(4.9)


11 5.31 0.68 0.049 ,0.01 ,0.01 – 7.9(2.1) 6.6(3.4) 5.9(4.1)
13 6.50 1.00 0.34 0.031 ,0.01 – – 7.6(2.1) 6.7(3.3)
*Bloom dimension is 2006240 mm. Values in ( ) of the last four columns represent the half-thickness of the mushy region with fs>0?25.

the only method to decrease these values during the


casting process appears to be the slow casting at low
superheat.

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