This document proposes and evaluates through numerical simulation some innovative shroud designs that aim to improve steel cleanliness during production in a tundish. It first discusses common issues like slag eye formation, re-oxidation, and contamination that occur in traditional tundish systems. It then introduces three shroud designs: a vacuum shroud with argon purging, a novel centrifugal shroud with argon purging, and a conventional shroud for comparison. Numerical simulations show the vacuum and centrifugal shrouds reduce slag eye formation and emulsification compared to the conventional shroud. The centrifugal shroud in particular shows no slag eye formation when the cap rotates and is filled with arg
This document proposes and analyzes a novel filter tundish design aimed at improving steel quality and yield during single strand slab casting. It discusses how inclusion and grade intermixing currently create metal loss issues. The novel design incorporates a multi-reactor tundish with argon purging and special refractories to better remove inclusions and reduce grade mixing compared to conventional tundish designs. Computational fluid dynamics simulations indicate this novel design more effectively separates dissimilar steel grades and improves steel cleanliness over normal tundishes. The goal is to lower inclusion levels and transition slab amounts to improve steel quality and increase caster efficiency and productivity.
Computational study of a trailblazer multi reactor tundish (mrt) for improvin...eSAT Journals
Abstract Increasing the production efficiency of the continuous casting process requires casting longer sequences of ladles without stopping and restarting the caster. As the demand for wider ranges of steel products increases at the same time, the intermixing of dissimilar grades is becoming a problem of growing concern. When high grade dissimilar grade steel intermixed, huge amount of metal is lost from down gradation. With increased usage of steel for critical applications, the demand for cleaner steel has increased. Existing technologies have been improved and new technologies are being introduced all along the process route to minimize the size and quantity of inclusions. The bad effect of inclusion is it creates sliver in the hot rolled coil. To overcome the aforementioned problems a novel multi reactor tundish (MRT) technology has been developed which will decrease the intermixed amount during grade transition. Simultaneously it will increase the quality of steel by removing inclusion by increasing the plug flow and residence time in tundish. A computational study of the newly developed tundish has been done by using Fluent 6.3 computational fluid dynamics software and the results has been compared with two different type of normal tundish used in industry. Keywords: Tundish, Grade Transition, Inclusion, Yield
1) The document presents a computational study of a novel multi-reactor tundish design that aims to improve steel yield and quality during continuous casting.
2) Simulation results show the new design reduces the transition period between steel grades, lowering metal losses from intermixing. It also increases residence time, promoting inclusion removal to produce cleaner steel.
3) Compared to normal and dam-weir tundish designs, the new multi-reactor configuration achieves a shorter transition time of 10 minutes versus 20 minutes, improving yield. It also demonstrates better inclusion removal due to longer residence times and flow toward the top surface.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
IRJET- Quality Improvement of Ductile Iron Casting by Thermal AnalysisIRJET Journal
The document discusses using thermal analysis to improve the quality of ductile iron castings by reducing shrinkage defects. It presents the results of an experiment where cooling curves were recorded for ductile iron castings with different section thicknesses. Nine castings were produced with variations in chemical composition, inoculation amount, and pouring temperature. The cooling curves were analyzed to understand the solidification behavior and identify conditions that led to shrinkage. The results showed that thermal analysis is effective for controlling melt quality in ductile iron and avoiding shrinkage, with nil undercooling indicating sufficient inoculation for a given composition and thickness.
BOILER TUBE FAILURE ANALYSIS IN 210MW POWER PLANT STEAM BOILERIRJET Journal
- The document analyzes the failure of boiler tubes from a 210MW power plant steam boiler. Metallographic investigations were conducted on failed low temperature superheater (LTSH), economizer, and reheater tubes.
- Visual inspection found thinner wall sections and oxide layer formation on the inner surface of tubes, indicating corrosion. Microstructural analysis revealed graphitization, spheroidization of carbides, and microcracking from long-term overheating. Microhardness tests showed softening in thinned tube regions.
- The main causes of tube failure were determined to be steam and flue gas erosion, thinning from corrosion, and creep rupture from overheating and microstructural changes weakening tube material properties
Slurry erosion comparison of d gun sprayed stellite-6, cr3 c2-25nicr coatings-2IAEME Publication
This document discusses a study that compares the slurry erosion performance of detonation gun sprayed Stellite-6 and Cr3C2-25NiCr ceramic coatings on a 13Cr4Ni stainless steel substrate under hydro accelerated conditions. Specimens of the coated materials and uncoated substrate were tested using a high speed erosion tester at angles of 30 and 90 degrees. The Stellite-6 coating performed better than the Cr3C2-25NiCr coating and substrate steel at 30 degrees. However, at 90 degrees the substrate steel performed better than the coatings. The document provides details on the materials, coating process, erosion testing method and parameters used in the study.
The International Journal of Engineering and Science (The IJES)theijes
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
This document proposes and analyzes a novel filter tundish design aimed at improving steel quality and yield during single strand slab casting. It discusses how inclusion and grade intermixing currently create metal loss issues. The novel design incorporates a multi-reactor tundish with argon purging and special refractories to better remove inclusions and reduce grade mixing compared to conventional tundish designs. Computational fluid dynamics simulations indicate this novel design more effectively separates dissimilar steel grades and improves steel cleanliness over normal tundishes. The goal is to lower inclusion levels and transition slab amounts to improve steel quality and increase caster efficiency and productivity.
Computational study of a trailblazer multi reactor tundish (mrt) for improvin...eSAT Journals
Abstract Increasing the production efficiency of the continuous casting process requires casting longer sequences of ladles without stopping and restarting the caster. As the demand for wider ranges of steel products increases at the same time, the intermixing of dissimilar grades is becoming a problem of growing concern. When high grade dissimilar grade steel intermixed, huge amount of metal is lost from down gradation. With increased usage of steel for critical applications, the demand for cleaner steel has increased. Existing technologies have been improved and new technologies are being introduced all along the process route to minimize the size and quantity of inclusions. The bad effect of inclusion is it creates sliver in the hot rolled coil. To overcome the aforementioned problems a novel multi reactor tundish (MRT) technology has been developed which will decrease the intermixed amount during grade transition. Simultaneously it will increase the quality of steel by removing inclusion by increasing the plug flow and residence time in tundish. A computational study of the newly developed tundish has been done by using Fluent 6.3 computational fluid dynamics software and the results has been compared with two different type of normal tundish used in industry. Keywords: Tundish, Grade Transition, Inclusion, Yield
1) The document presents a computational study of a novel multi-reactor tundish design that aims to improve steel yield and quality during continuous casting.
2) Simulation results show the new design reduces the transition period between steel grades, lowering metal losses from intermixing. It also increases residence time, promoting inclusion removal to produce cleaner steel.
3) Compared to normal and dam-weir tundish designs, the new multi-reactor configuration achieves a shorter transition time of 10 minutes versus 20 minutes, improving yield. It also demonstrates better inclusion removal due to longer residence times and flow toward the top surface.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
IRJET- Quality Improvement of Ductile Iron Casting by Thermal AnalysisIRJET Journal
The document discusses using thermal analysis to improve the quality of ductile iron castings by reducing shrinkage defects. It presents the results of an experiment where cooling curves were recorded for ductile iron castings with different section thicknesses. Nine castings were produced with variations in chemical composition, inoculation amount, and pouring temperature. The cooling curves were analyzed to understand the solidification behavior and identify conditions that led to shrinkage. The results showed that thermal analysis is effective for controlling melt quality in ductile iron and avoiding shrinkage, with nil undercooling indicating sufficient inoculation for a given composition and thickness.
BOILER TUBE FAILURE ANALYSIS IN 210MW POWER PLANT STEAM BOILERIRJET Journal
- The document analyzes the failure of boiler tubes from a 210MW power plant steam boiler. Metallographic investigations were conducted on failed low temperature superheater (LTSH), economizer, and reheater tubes.
- Visual inspection found thinner wall sections and oxide layer formation on the inner surface of tubes, indicating corrosion. Microstructural analysis revealed graphitization, spheroidization of carbides, and microcracking from long-term overheating. Microhardness tests showed softening in thinned tube regions.
- The main causes of tube failure were determined to be steam and flue gas erosion, thinning from corrosion, and creep rupture from overheating and microstructural changes weakening tube material properties
Slurry erosion comparison of d gun sprayed stellite-6, cr3 c2-25nicr coatings-2IAEME Publication
This document discusses a study that compares the slurry erosion performance of detonation gun sprayed Stellite-6 and Cr3C2-25NiCr ceramic coatings on a 13Cr4Ni stainless steel substrate under hydro accelerated conditions. Specimens of the coated materials and uncoated substrate were tested using a high speed erosion tester at angles of 30 and 90 degrees. The Stellite-6 coating performed better than the Cr3C2-25NiCr coating and substrate steel at 30 degrees. However, at 90 degrees the substrate steel performed better than the coatings. The document provides details on the materials, coating process, erosion testing method and parameters used in the study.
The International Journal of Engineering and Science (The IJES)theijes
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
This document presents guidelines for designing rigging systems (gating and risering) for different types of castings, including light alloys, ductile iron, and steel. For light alloys, the rigging system is designed to promote sequential solidification and minimize turbulence during filling to prevent oxide entrapment. Specific guidelines are provided for part orientation, locating the parting plane, sizing the sprue and runners, and using filters/screens. The document aims to compile common industry rules and methods engineer practices for different casting materials.
Accelerted testing of deteriorated concrete structures due to carbonationeSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
The computational study of a novel secondary steelmaking reactoreSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
The influence of Rolling process on the porosity and wear behavior of Spray-f...IOSR Journals
Spray forming, also called spray casting or spray deposition, is the inert gas atomization of a liquid metal stream into variously sized droplets. These droplets are interrupted by a substrate which collects and solidifies the droplets into coherent, near fully dense perform. The present work concerns with this techniques. This technology was applied to produce Al-6%Si-20%Pb alloys. The spray droplets were deposited over a copper substrate to achieve a disc shape perform. After spray deposition samples were rolled at room temperature on two high rolling mills and total porosity and wear characteristic of spray deposits were studies. The total porosity decreases with the increase in the percentage of reduction in thickness of the samples. Thickness of the samples in both middle and peripheral region. Wear testing of spray formed and rolled Al-Si-Pb alloy were investigated on a pin on disc type wear machine. Wear rate behavior with applied load and increase in percentage of reduction in thickness of samples was observed. Wear rate increased with increasing the load and decreased with increase in percentage of reduction in thickness of the sample.
This document summarizes research on reusing copper slag in concrete. Copper slag is a byproduct of copper manufacturing that comprises various oxides such as iron, silicon, aluminum and calcium. Studies have shown copper slag can replace Portland cement or aggregates in concrete due to its physical and mechanical properties. The document reviews research on using copper slag in cement production, blended cement, as a concrete aggregate replacement, and as a partial replacement for cement or both cement and sand in concrete. Some studies found compressive and flexural strength increased with copper slag replacements up to certain levels. The document provides context on copper slag production and composition before summarizing key studies.
IRJET- Evaluation of Corrosion Rate in Steel Reinforcement of RCCIRJET Journal
This document evaluates the corrosion rate of steel reinforcement in concrete with varying water-cement ratios (W/C). Specimens with W/C ratios of 0.4, 0.45, 0.5, and 0.55 were tested using accelerated corrosion and weight loss methods. The corrosion rate increased with higher W/C ratios, from 0.0243 mm/year for 0.4 W/C to 0.1436 mm/year for 0.55 W/C. Chloride permeability also increased with W/C ratio, from low permeability for 0.4 W/C to moderate permeability for 0.55 W/C. The study found that corrosion rate and chloride permeability rise with increasing water
IRJET- Impact of Accelerated Corrosion Test in Flexural Behaviour of RC B...IRJET Journal
This document summarizes a study on the impact of accelerated corrosion on the flexural behavior of reinforced concrete beams. Beams with 5%, 10%, and 15% corrosion were tested and their ultimate load carrying capacity and deflection behavior were compared to control beams. The accelerated corrosion was induced using an impressed current technique with NaCl solution. The results showed that as the level of corrosion increased, the ultimate load capacity of the beams decreased. Beams with 5% corrosion saw a 10% reduction in load capacity compared to control beams, while beams with 10% and 15% corrosion saw 23% and 39% reductions, respectively. Corroded beams also exhibited greater deflection than control beams under loading.
Foundry industries in developing countries suffer from poor quality and productivity due to involvement of number of
process parameter. Even in completely controlled process, defect in casting are observed and hence casting process is also
known as process of uncertainty which challenges explanation about the cause of casting defects. In order to reduce warpage
defects and problem related to warpage defects, the study is aimed in this paper. Many products are made by using casting
process as it is economical and has the ability to produce intricate shapes. So far, casting defect analysis has been carried out
using techniques like finite element method and modulus method to reduce defects. . Casting software can optimize the virtual
castings so that real castings can be produced ‘right first time and every time’.
Wear behavior of stepped austempered ductile iron balls in grinding iron oreeSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Review on Erosion and Corrosion Studies on Steel WeldmentsIRJET Journal
This document provides an extensive literature review on erosion and corrosion studies carried out on various grades of steel weldments. It discusses different types of erosion and corrosion, parameters that affect erosion rates like particle size and impact angle. Methods to analyze erosion and corrosion rates like weight loss tests and SEM imaging are also summarized. The review focuses on erosion and corrosion behavior of carbon steels like A106 grade steel typically used in pipes under various environmental conditions like chemicals and high temperatures.
Corrosion resistance performance of fly ash blended cement concreteseSAT Journals
Abstract Durability of reinforced concrete with respect to corrosion of reinforcement is one of the major aspects to be considered in the management of civil infrastructure systems. An accelerated laboratory test method developed at SERC where the concrete specimen containing rebar is subjected to polarization under a constant voltage in a sodium chloride solution. It is found that the current response with time follows that of a typical service life model indicating depassivation and corrosion propagation. Index terms- Materials, cement, super plasticizer, workability, compressive strength etc.
Corrosion resistance performance of fly ash blended cement concreteseSAT Publishing House
1) The document describes an experimental study on the corrosion resistance of reinforced concrete with different percentages of fly ash replacement.
2) An accelerated corrosion test method was used where concrete cylinders containing rebar were subjected to polarization in a sodium chloride solution. This simulated rebar corrosion in marine environments.
3) The test results showed that concretes with 30% fly ash replacement had the highest corrosion resistance, with initiation times of 54 and 63 days for M25 and M30 grade concrete, respectively.
4) Graphs of current over time showed changes in slope indicating the initiation time and time for cracking, which increased with higher percentages of fly ash replacement up to 30%.
Failure Analysis of Billet Caster Tundish Tilter BoltsIRJET Journal
1. Failure analysis was conducted on bolts from a billet caster tundish tilter that failed prematurely.
2. The bolts were made of 34CrNiMo6 steel but were heat treated at the wrong tempering temperature of 425°C instead of the specified 540-660°C, resulting in poor impact toughness of 19 Joules.
3. Microstructural examination found tempered martensite and inclusions contributing to stress concentrations. Fractography revealed cracks and river marks indicating failure from impact loads during tilting due to the low toughness from the improper heat treatment.
Experimental Investigation on Replacement of Magnetic Water and Partial Repla...IRJET Journal
This document experimentally investigates replacing magnetic water and steel slag as a partial replacement for coarse aggregate in concrete. Three mixtures were tested with 50%, 60%, and 70% steel slag replacing coarse aggregate. Compressive strength, split tensile strength, and flexural strength were tested at 7, 14, and 28 days. Results showed that compressive strength increased up to 1.87% and flexural strength increased up to 1.2% compared to conventional concrete. Using magnetic water and steel slag provided improved strength properties over conventional concrete. The study concluded that 60-70% steel slag with magnetic water replacement can provide higher strengths for concrete.
IRJET - Anti-Corrosion Effect of Curcuma Longa on Petroleum Drilling Equipmen...IRJET Journal
This document summarizes a study on using turmeric to inhibit corrosion of petroleum drilling equipment exposed to acidic environments. Mild steel samples were immersed in 0.1M hydrochloric acid and sulfuric acid solutions both with and without turmeric for one month. Visual observation, weight loss measurements, and SEM analysis were used to analyze corrosion. Results showed turmeric reduced corrosion in both acid solutions as indicated by less visible corrosion, lower weight loss, and smoother steel surfaces compared to acid solutions without turmeric. This suggests turmeric has potential as a natural corrosion inhibitor that could help maintain drilling equipment integrity in acidic downhole conditions.
DURABILITY STUDIES OF SELF- COMPACTING CONCRETE WITH RECYCLED COARSE AGGREGAT...IRJET Journal
1) The study investigated the durability of self-compacting concrete mixtures containing recycled coarse aggregate and waste glass powder.
2) Testing included water absorption and carbonation tests on concrete cubes with 10-50% replacements of cement with glass powder and 0-50% replacements of natural coarse aggregate with recycled aggregate.
3) The results showed that concrete with 10% cement replaced with glass powder and 50% natural aggregate replaced with recycled aggregate performed better in durability tests, with lower water absorption and less carbonation than the control mixtures.
By-Products of Steel Industry as a Complementary Material in ConstructionIRJET Journal
This study evaluated the use of steel industry by-products, slag and slag sand, as partial replacements for river sand and ordinary Portland cement in cement mortar.
The compressive strength of mortar cubes containing 30% slag sand replacement of river sand was 38.71N/mm2 at 90 days, 17% higher than the reference. Mortar with 35% slag replacement of cement achieved 41.84N/mm2 at 90 days, 23% higher than the reference. Blending 30% slag and slag sand yielded 39.37N/mm2 at 90 days, an 18% increase over the reference.
Microstructural analysis using EDS, SEM and XRD confirmed the presence of calcium,
Image segmentation, Rough set Theory, Game Theory, Image processingijsrd.com
Valve is most common part for every Fluid handling industry. Production of cast Valve is critical because, in today's competitive world customer wants fast and accurate Component. Computer simulation tools are used to reduce a time for development of a component. Simulation software is mainly used to visualize a complete process of solidification, which is not possible in real casting process. Defects such as shrinkage porosity, gas porosity, unfilled mould, cold shut etc. can also graphically observe with simulation. Initially CAD model of impeller has been prepared, then export for simulation. Many researchers reported that about 90% of the defects in castings are due to wrong design of gating system and only 10% due to manufacturing problems. Casting simulation process can able to solve these problems. To study the solidification behavior and detection of hot spots in castings with the help of casting simulation software. The simulated results also compared with the experimental works.
Fyp 1 progress report 2 half cell measurement for reinforce steel concrete ...Dr Abdul Aziz Mohamed
This progress report discusses an assessment of reinforcing steels in concrete using non-destructive testing with half-cell potential. The report provides background on corrosion of reinforcing steel and introduces the methodology, which involves two experiments. The first experiment measures corrosion rates of steel rebars in different water types. The second observes corrosion severity in concrete of varying grades. Problems securing equipment and water samples are also noted.
Comparative analysis on mould filling of a413 aluminium alloy in sand and eva...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Redefining brain tumor segmentation: a cutting-edge convolutional neural netw...IJECEIAES
Medical image analysis has witnessed significant advancements with deep learning techniques. In the domain of brain tumor segmentation, the ability to
precisely delineate tumor boundaries from magnetic resonance imaging (MRI)
scans holds profound implications for diagnosis. This study presents an ensemble convolutional neural network (CNN) with transfer learning, integrating
the state-of-the-art Deeplabv3+ architecture with the ResNet18 backbone. The
model is rigorously trained and evaluated, exhibiting remarkable performance
metrics, including an impressive global accuracy of 99.286%, a high-class accuracy of 82.191%, a mean intersection over union (IoU) of 79.900%, a weighted
IoU of 98.620%, and a Boundary F1 (BF) score of 83.303%. Notably, a detailed comparative analysis with existing methods showcases the superiority of
our proposed model. These findings underscore the model’s competence in precise brain tumor localization, underscoring its potential to revolutionize medical
image analysis and enhance healthcare outcomes. This research paves the way
for future exploration and optimization of advanced CNN models in medical
imaging, emphasizing addressing false positives and resource efficiency.
This document presents guidelines for designing rigging systems (gating and risering) for different types of castings, including light alloys, ductile iron, and steel. For light alloys, the rigging system is designed to promote sequential solidification and minimize turbulence during filling to prevent oxide entrapment. Specific guidelines are provided for part orientation, locating the parting plane, sizing the sprue and runners, and using filters/screens. The document aims to compile common industry rules and methods engineer practices for different casting materials.
Accelerted testing of deteriorated concrete structures due to carbonationeSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
The computational study of a novel secondary steelmaking reactoreSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
The influence of Rolling process on the porosity and wear behavior of Spray-f...IOSR Journals
Spray forming, also called spray casting or spray deposition, is the inert gas atomization of a liquid metal stream into variously sized droplets. These droplets are interrupted by a substrate which collects and solidifies the droplets into coherent, near fully dense perform. The present work concerns with this techniques. This technology was applied to produce Al-6%Si-20%Pb alloys. The spray droplets were deposited over a copper substrate to achieve a disc shape perform. After spray deposition samples were rolled at room temperature on two high rolling mills and total porosity and wear characteristic of spray deposits were studies. The total porosity decreases with the increase in the percentage of reduction in thickness of the samples. Thickness of the samples in both middle and peripheral region. Wear testing of spray formed and rolled Al-Si-Pb alloy were investigated on a pin on disc type wear machine. Wear rate behavior with applied load and increase in percentage of reduction in thickness of samples was observed. Wear rate increased with increasing the load and decreased with increase in percentage of reduction in thickness of the sample.
This document summarizes research on reusing copper slag in concrete. Copper slag is a byproduct of copper manufacturing that comprises various oxides such as iron, silicon, aluminum and calcium. Studies have shown copper slag can replace Portland cement or aggregates in concrete due to its physical and mechanical properties. The document reviews research on using copper slag in cement production, blended cement, as a concrete aggregate replacement, and as a partial replacement for cement or both cement and sand in concrete. Some studies found compressive and flexural strength increased with copper slag replacements up to certain levels. The document provides context on copper slag production and composition before summarizing key studies.
IRJET- Evaluation of Corrosion Rate in Steel Reinforcement of RCCIRJET Journal
This document evaluates the corrosion rate of steel reinforcement in concrete with varying water-cement ratios (W/C). Specimens with W/C ratios of 0.4, 0.45, 0.5, and 0.55 were tested using accelerated corrosion and weight loss methods. The corrosion rate increased with higher W/C ratios, from 0.0243 mm/year for 0.4 W/C to 0.1436 mm/year for 0.55 W/C. Chloride permeability also increased with W/C ratio, from low permeability for 0.4 W/C to moderate permeability for 0.55 W/C. The study found that corrosion rate and chloride permeability rise with increasing water
IRJET- Impact of Accelerated Corrosion Test in Flexural Behaviour of RC B...IRJET Journal
This document summarizes a study on the impact of accelerated corrosion on the flexural behavior of reinforced concrete beams. Beams with 5%, 10%, and 15% corrosion were tested and their ultimate load carrying capacity and deflection behavior were compared to control beams. The accelerated corrosion was induced using an impressed current technique with NaCl solution. The results showed that as the level of corrosion increased, the ultimate load capacity of the beams decreased. Beams with 5% corrosion saw a 10% reduction in load capacity compared to control beams, while beams with 10% and 15% corrosion saw 23% and 39% reductions, respectively. Corroded beams also exhibited greater deflection than control beams under loading.
Foundry industries in developing countries suffer from poor quality and productivity due to involvement of number of
process parameter. Even in completely controlled process, defect in casting are observed and hence casting process is also
known as process of uncertainty which challenges explanation about the cause of casting defects. In order to reduce warpage
defects and problem related to warpage defects, the study is aimed in this paper. Many products are made by using casting
process as it is economical and has the ability to produce intricate shapes. So far, casting defect analysis has been carried out
using techniques like finite element method and modulus method to reduce defects. . Casting software can optimize the virtual
castings so that real castings can be produced ‘right first time and every time’.
Wear behavior of stepped austempered ductile iron balls in grinding iron oreeSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Review on Erosion and Corrosion Studies on Steel WeldmentsIRJET Journal
This document provides an extensive literature review on erosion and corrosion studies carried out on various grades of steel weldments. It discusses different types of erosion and corrosion, parameters that affect erosion rates like particle size and impact angle. Methods to analyze erosion and corrosion rates like weight loss tests and SEM imaging are also summarized. The review focuses on erosion and corrosion behavior of carbon steels like A106 grade steel typically used in pipes under various environmental conditions like chemicals and high temperatures.
Corrosion resistance performance of fly ash blended cement concreteseSAT Journals
Abstract Durability of reinforced concrete with respect to corrosion of reinforcement is one of the major aspects to be considered in the management of civil infrastructure systems. An accelerated laboratory test method developed at SERC where the concrete specimen containing rebar is subjected to polarization under a constant voltage in a sodium chloride solution. It is found that the current response with time follows that of a typical service life model indicating depassivation and corrosion propagation. Index terms- Materials, cement, super plasticizer, workability, compressive strength etc.
Corrosion resistance performance of fly ash blended cement concreteseSAT Publishing House
1) The document describes an experimental study on the corrosion resistance of reinforced concrete with different percentages of fly ash replacement.
2) An accelerated corrosion test method was used where concrete cylinders containing rebar were subjected to polarization in a sodium chloride solution. This simulated rebar corrosion in marine environments.
3) The test results showed that concretes with 30% fly ash replacement had the highest corrosion resistance, with initiation times of 54 and 63 days for M25 and M30 grade concrete, respectively.
4) Graphs of current over time showed changes in slope indicating the initiation time and time for cracking, which increased with higher percentages of fly ash replacement up to 30%.
Failure Analysis of Billet Caster Tundish Tilter BoltsIRJET Journal
1. Failure analysis was conducted on bolts from a billet caster tundish tilter that failed prematurely.
2. The bolts were made of 34CrNiMo6 steel but were heat treated at the wrong tempering temperature of 425°C instead of the specified 540-660°C, resulting in poor impact toughness of 19 Joules.
3. Microstructural examination found tempered martensite and inclusions contributing to stress concentrations. Fractography revealed cracks and river marks indicating failure from impact loads during tilting due to the low toughness from the improper heat treatment.
Experimental Investigation on Replacement of Magnetic Water and Partial Repla...IRJET Journal
This document experimentally investigates replacing magnetic water and steel slag as a partial replacement for coarse aggregate in concrete. Three mixtures were tested with 50%, 60%, and 70% steel slag replacing coarse aggregate. Compressive strength, split tensile strength, and flexural strength were tested at 7, 14, and 28 days. Results showed that compressive strength increased up to 1.87% and flexural strength increased up to 1.2% compared to conventional concrete. Using magnetic water and steel slag provided improved strength properties over conventional concrete. The study concluded that 60-70% steel slag with magnetic water replacement can provide higher strengths for concrete.
IRJET - Anti-Corrosion Effect of Curcuma Longa on Petroleum Drilling Equipmen...IRJET Journal
This document summarizes a study on using turmeric to inhibit corrosion of petroleum drilling equipment exposed to acidic environments. Mild steel samples were immersed in 0.1M hydrochloric acid and sulfuric acid solutions both with and without turmeric for one month. Visual observation, weight loss measurements, and SEM analysis were used to analyze corrosion. Results showed turmeric reduced corrosion in both acid solutions as indicated by less visible corrosion, lower weight loss, and smoother steel surfaces compared to acid solutions without turmeric. This suggests turmeric has potential as a natural corrosion inhibitor that could help maintain drilling equipment integrity in acidic downhole conditions.
DURABILITY STUDIES OF SELF- COMPACTING CONCRETE WITH RECYCLED COARSE AGGREGAT...IRJET Journal
1) The study investigated the durability of self-compacting concrete mixtures containing recycled coarse aggregate and waste glass powder.
2) Testing included water absorption and carbonation tests on concrete cubes with 10-50% replacements of cement with glass powder and 0-50% replacements of natural coarse aggregate with recycled aggregate.
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Innovative Shroud - A New Possibility for Production of Clean Steel In Tundish
1. _____________________________________________________________________________________________________
*Corresponding author: Email: deb100dmt@gmail.com;
J. Mater. Sci. Res. Rev., vol. 6, no. 3, pp. 329-340, 2023
Journal of Materials Science Research and Reviews
Volume 6, Issue 3, Page 329-340, 2023; Article no.JMSRR.102053
“Innovative Shroud” – A New
Possibility for Production
of Clean Steel in Tundish
Debasish Chatterjee a*
a
Department of Metallurgy and Materials Engineering, IIEST Shibpur, Howrah, India.
Author’s contribution
The sole author designed, analysed, inteprted and prepared the manuscript.
Article Information
Open Peer Review History:
This journal follows the Advanced Open Peer Review policy. Identity of the Reviewers, Editor(s) and additional Reviewers,
peer review comments, different versions of the manuscript, comments of the editors, etc are available here:
https://www.sdiarticle5.com/review-history/102053
Received: 17/04/2023
Accepted: 19/06/2023
Published: 26/06/2023
ABSTRACT
Last decade steel productions around the world have increased significantly. But there is a high
demand of clean steel in domestic as well as international market. For that reason currently many
research is going on in this direction. In present investigation, few innovative shrouds were
developed conceptually which can be useful in terms future perspective for production of clean and
green steel within the last metallurgical reactor tundish. Vacuum shroud and Novel Centrifugal
Shroud with argon purging can eliminate formations of tundish open eye (TOE) during ladle transfer
operation. 3D Numerical simulation by using ANSYS FLUENT software shows that these flow
control products will able to reduce re- oxidation of liquid steel by suppressing slag eye formation or
protecting the reaction of liquid steel from ambient air by covering inert argon gas within the tundish
vessel.
Keywords: Centrifugal shroud; tundish; slag eye; re-oxidation; vacuum shroud.
Original Research Article
2. Chatterjee; J. Mater. Sci. Res. Rev., vol. 6, no. 3, pp. 329-340, 2023; Article no.JMSRR.102053
330
1. INTRODUCTION
Slag eye, re-oxidation and contamination of the
steel melt are common problems of many steel
industries around the world. Although it is known
to all that tundish act as refining vessel. But
sometimes it behaves as a contaminator rather
than metallurgical refinery due to adverse fluid
flow within the tundish reactor. It is mentioned in
Fig. 1 that, approximately 40% re-oxidation of
steel melt took place during transfer of liquid
steel from ladle to tundish and totally 55% melt
contamination occur if slag entrainment and slag
thinning is considered along with re-oxidation.
This re-oxidation, slag entrainment, slag metal
emulsifications from melt flow generates macro
inclusions which sometimes clog the tundish
submerged entry nozzle and indirectly hindered
casting as well as is the source of major defects
in final products [1].
Fig. 2 (a) and (b) explore the real conditions of
slag eye at billet and slab caster during pouring
of liquid steel from ladle to tundish at normal
condition. Generally 30-40 minutes is the
processing time of transfer of liquid metal from
ladle to tundish during each heat casting. During
this period the casting powder near the ladle
shroud pushed aside for a period of 20-30
minutes if unnoticed which cause pick up of
oxygen around 30-40 ppm as found from many
industrial data [2]. Argon injection enhance
strong surface flow which aggravate formation of
‘Tundish Open Eye’ as depicted in the Fig. 2 (c)
and Fig. 2 (d) is showing the splashing behavior
of impact pad during initial poring period [3].
To overcome those abnormalities mentioned
earlier researchers have tried to develop different
shroud and pour box as well as turbo-stop
configurations which will help to make clean steel
in tundish. Those developments are
schematically shown in the Fig. 3 (a) to (f)
respectively. Besides conventional shroud with
turbo-stop, many advanced flow control
refractory products were developed over the
decades like innovative turbo-stop, trumpet-
shaped shroud, dissipative shroud, swirling
shroud, velocity break shroud, bending nozzle,
advanced pouring box etc. [5-12]. Those shrouds
and advanced pouring boxes are capable to
remove of slag eye formation, reducing of liquid
contamination from re-oxidation at open eye,
eliminating emulsification during ladle changing
period as well as improving the indigenous and
exogenous floatation of inclusions at some
extent. But clean steel production is not possible
to achieve by incorporating above mentioned
technology or steel flow control refractory’s still
today. Especially in mini mill, it is very difficult
task to achieve quality steel as well as high
production simultaneously due to small size of
the tundish. Hence some new innovative shrouds
are required to develop to reach both targets.
Fig. 1. Percentages of causes behind generations of inclusions in tundish (Reprinted from [1])
3. Chatterjee; J. Mater. Sci. Res. Rev., vol. 6, no. 3, pp. 329-340, 2023; Article no.JMSRR.102053
331
Fig. 2. Industrial observations of slag eye (a), (b) Normal condition(c) Shroud argon purging
period and (d) ‘Blow Back’ effect (Reprinted from [2-3])
Several efforts were made by academics and
industry collaboration over the last 2 decades to
enhance the performance of tundish reactor
[13,14]. It was found from numerous physical and
mathematical modeling as well as plant trials
that, flow modifiers like baffle, dam, impact pad,
slotted baffle, weir, electromagnetic stirring,
argon shrouding, centrifugal flow tundish, swirling
ladle shroud and extended shroud have a great
impact on RTD (Residence Time Distribution),
inclusion separation, grade mixing, emulsification
(especially during ladle change over period),
open eye formation of tundish vessel [13-21]. So
fluid flow in metallurgical reactor act as integral
part of producing high quality steel and cast
microstructures as well as help to develop new
process for improving the plant performance and
productivity [22]. Especially for small tundish it is
very difficult task to remove inclusions due to low
residence time. In those cases innovative shroud
concept can take a leading role towards
production of clean and green steel.
(d)
(a)
(c)
(b)
4. Chatterjee; J. Mater. Sci. Res. Rev., vol. 6, no. 3, pp. 329-340, 2023; Article no.JMSRR.102053
332
Fig. 3. Typical innovative shroud and pouring box development over last three decades
(Reprinted from [4])
From 1975 to 2010, significant United States
patents have been contributed by several
researchers to control turbulence, open eye
formation, emulsification and enhancing inclusion
floatation within the tundish reactor [23-29].
2. METHODS
In the present investigation along with
conventional shroud with turbo-stop, innovative
vacuum shroud with argon purging and new
concept Novel Centrifugal Shroud with argon
purging were used to control slag eye formation
and inclusion removal in tundish as depicted in
the Fig. 4 (a), (b), (c) and Fig. 5 (a), (b), (c)
respectively. Numerical investigations were
performed by ANSYS FLUENT simulation
software.
Fig. 4. Schematic of (a) Conventional shroud and turbo-stop, (b) Vacuum shroud with argon
purging (Invented by Dr. Debasish Chatterjee) and (c) Novel centrifugal shroud (Invented Dr.
Debasish Chatterjee)-Turbo-stop with argon purging
5. Chatterjee; J. Mater. Sci. Res. Rev., vol. 6, no. 3, pp. 329-340, 2023; Article no.JMSRR.102053
333
Fig. 5. Grid displays of (a) Conventional Shroud with turbo-stop (b) Vacuum Shroud (c) Novel
Centrifugal Shroud + Argon purging + Turbo-stop
3. RESULTS AND DISCUSSION
The 3D numerical studies were performed by
using some mathematical models like continuity
equation, momentum equation, turbulence and
kinetic model, VOF (Volume Fraction Equation),
DPM (Discrete Phase Model) etc. [4,30-31]. Most
of the dimensions and numerical data were used
in earlier research papers regarding this are
same for this papers also and those parameters
were not mentioned earlier are explained in
Table 1. The velocity used in current study was 5
m/sec which is high due judge the adverse effect
of velocity on slag eye, turbulence as well as
emulsification. In vacuum shroud and Novel
Centrifugal Shroud argon purging were
introduced from the upper side of the nozzle to
avoid air aspiration at the ladle shroud
joining and at the same time enhance the
inclusion floatation to the top surface of the
tundish.
Fig. 6 (a), (b), (c), (d) and (e) are embodying the
Molecular viscosity properties of various fluids
after pouring of water inside the bath for
conventional shroud + turbo-stop, conventional
shroud + turbo-stop + argon purging, vacuum
shroud without argon purging and with argon
purging, Novel Centrifugal Shroud + turbo-stop +
argon purging respectively. The water, oil, air
and argon phases are representing by the green,
red, blue and light blue colors. It is observed from
the figures that for conventional shroud without
or with argon purging the oil phase is removed
more towards bath wall rather than vacuum
shroud with or without argon purging and Novel
Centrifugal Shroud with argon purging. The oil
layer is dispersed and emulsified more for
conventional shroud system as found from the
simulated results. It signifies that in case of
traditional system, generally use in steel industry,
the contamination of liquid steel will be more due
to formation of large exposed eye as well as from
emulsification of slag and metal.
(a
)
(b
)
6. Chatterjee; J. Mater. Sci. Res. Rev., vol. 6, no. 3, pp. 329-340, 2023; Article no.JMSRR.102053
334
Table 1. Dimensional and Numerical Parameters used in present investigation
Sl. No. Dimensions & Parameters Value Remarks
1 Initial Velocity of pouring from velocity inlet 5 meter/sec High Velocity
2 Bath diameter and height L & W = 1.0 meter, H = 1.0 meter, D = 1 meter Turbostop diameter = 0.3 meter
3 Turbulent Kinetic Energy (k) 12.5 K=0.5v
2
[32,33]
4 Turbulent Dissipation rate (€) 2.8 €=Cµ*k
2
/v[32,33]
5 Argon (secondary phase) Density – 1.629 kg/m
3
Flow rate-20% volume fraction of water
from velocity inlet
6 Vacuum Used
Atmospheric pressure-760 torr, Pressure maintained
Vacuum Chamber of Shroud 720-750 torr
This vacuum pressure maintained within
the vacuum chamber of the shroud
7. Chatterjee; J. Mater. Sci. Res. Rev., vol. 6, no. 3, pp. 329-340, 2023; Article no.JMSRR.102053
335
Fig. 6. Molecular properties of fluids (water + oil + air + argon) (a) Conventional shroud +
Turbo-stop (b) Conventional shroud + Turbo-stop + Argon purging (c) Vacuum Shroud (d)
Vacuum Shroud + Argon purging (e) Novel Centrifugal Shroud + Turbo-stop + Argon purging
Fig. 7 (a) and (b) are showing the slag eye or
open eye formation for conventional shroud with
and without argon purging. The exposed eye is
large and approximately 0.5 meter diameter. For
conventional shroud with argon purging system
some dispersed slag eye are also found along
with large exposed eye due to inert gas
shrouding. Fig. 7 (c), (d) and (e) are top view
images of slag phase for vacuum shroud without
vacuum condition as well as vacuum without
8. Chatterjee; J. Mater. Sci. Res. Rev., vol. 6, no. 3, pp. 329-340, 2023; Article no.JMSRR.102053
336
argon purging and with argon purging situation
respectively. When vacuum is not applied to
vacuum shroud, air infiltration to flowing fluid took
place due to large outer diameter of shroud.
These infiltrated air exposed to bath surface and
remove the top slag layer which creates
dispersed slag eye as seen from image. When
vacuum is applied air infiltration or aspiration is
inhibited caused removal of formation of open
eye. After argon shrouding from side wall of
vacuum shroud, more effect of reduction of
turbulence is observed as found from images at
Fig. 6 (d) and Fig. 7 (e) respectively. Novel
Centrifugal Shroud with argon purging indicates
no slag eye formation at Fig. 7 (f). There is also
no dispersed slag eye was found. But from
mixing of liquid steel, drained argon from cap and
slag layer the top surface is not showing 100%
slag layer as depicted in the Fig. 6 (e) and 7 (f).
This will indirectly help to remove inclusions from
melt by better slag metal interactions due to
centrifugal motion.
Fig. 7. Slag eye (a) Conventional shroud without argon purging (b) argon purging (c) Dispersed
Slag eye for vacuum shroud without vacuum (d) No slag eye for vacuum shroud with vacuum
(e) No slag eye for Vacuum Shroud with vacuum and argon purging (f) No slag eye for novel
centrifugal shroud with argon purging
9. Chatterjee; J. Mater. Sci. Res. Rev., vol. 6, no. 3, pp. 329-340, 2023; Article no.JMSRR.102053
337
Fig. 8. Velocity vector plots of (a) Conventional shroud (b) Vacuum shroud with argon purging
(c) (d) (e) Novel Centrifugal shroud with argon purging
10. Chatterjee; J. Mater. Sci. Res. Rev., vol. 6, no. 3, pp. 329-340, 2023; Article no.JMSRR.102053
338
Fig. 9. Top view of centrifugal flow Shroud (a) Before centrifugal rotation showing many slag
eye and (b) After centrifugal rotation of cap showing no slag eye
The velocity vector and corresponding velocity
vector plots for conventional shroud, vacuum
shroud with argon purging and Novel Centrifugal
Shroud with argon purging have been shown in
the Fig. 8 (a) to (e) respectively. It is found from
Fig. 8 (a) that, after impinging on the turbo-stop
the fluid is moving upwards at a high speed and
the velocity ranges are between 1.0 meter/sec to
3.0 meter/sec. For vacuum shroud with argon
purging the velocity of fluid outside nozzle/shroud
is extremely low less than 0.5 meter/sec as
depicted in the Fig. 8 (b). Within the nozzle or
shroud the velocity drops drastically from <0.5
meter/sec to 2.5 meter/sec. For Novel centrifugal
shroud with argon purging the overall velocity is
low within the range from 0.5 meter/sec to 1.5
meter/sec as depicted in Fig. 8 (c), (d) and (e).
For this type shroud argon shrouding is essential.
Because within the cap the slag eye or open eye
will be generated and this will be protected from
re-oxidation due to presence or filling of cap from
the shrouded argon. Not only re-oxidation will be
hindered, simultaneously inclusions will be
entrapped within the cap by slag and baffle
refractory. So it will indirectly help to produce
clean steel especially mini steel plant where
small tundish is used during continuous casting.
Those tundish have high prone to choking due to
low residence time of fluid within the reactor. Fig.
9 (a) and (b) are showing that the many slag eye
exposed for centrifugal shroud without cap
rotation and no slag eye exposed after
centrifugal rotation of cap.
4. CONCLUSIONS
The following conclusions can be drawn from the
above numerical study of different shroud
configurations.
• Vacuum shroud and Novel Centrifugal
Shroud are two innovative flow
control devices which can avoid re-
oxidation of steel melt during pouring
from ladle to tundish by reducing/
suppressing tundish open eye (TOE)
formation.
• Not only slag eye, liquid turbulence within
the reactor will be dropped for those above
mentioned shrouds due to suction effect of
vacuum as well as centrifugal motion
generated by cap wall of the Novel
Centrifugal Shroud.
• Due to presence of argon inert gas within
the cap of Novel Centrifugal Shroud re-
oxidations from ambient air can be
avoided.
• 7 numbers small slag eye observed before
rotation of cap which has been totally
eliminated after centrifugal rotation of cap
in centrifugal flow shroud.
5. FUTURE STUDY
As a future scope of study the author wants to do
water modeling investigations of those new
conceptual flow control device. For Novel
Centrifugal Shroud along with argon shrouding at
upper side wall of the shroud nozzle, basic flux
injection will be incorporated from the top of the
cap to enhance inclusion removal from the
upward driven liquid steel. Both novel shrouds
like vacuum shroud and Novel Centrifugal
Shroud are required to implement in steel plants
and finally patent file will be tried for future
perspective of these steel flow control refractory
products.
11. Chatterjee; J. Mater. Sci. Res. Rev., vol. 6, no. 3, pp. 329-340, 2023; Article no.JMSRR.102053
339
COMPETING INTERESTS
Author has declared that no competing interests
exist.
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