1) The document discusses various defects that can occur during steel ingot solidification such as pipe, columnar structure, blow holes, and segregation.
2) It provides remedies for preventing these defects, such as using a hot top feeder head to avoid pipe formation and soaking ingots to minimize segregation.
3) The document also covers the mechanisms of ingot solidification, describing how killed, rimmed, and semi-killed steels solidify into chill, columnar, and equiaxed zones within the ingot.
FellowBuddy.com is an innovative platform that brings students together to share notes, exam papers, study guides, project reports and presentation for upcoming exams.
We connect Students who have an understanding of course material with Students who need help.
Benefits:-
# Students can catch up on notes they missed because of an absence.
# Underachievers can find peer developed notes that break down lecture and study material in a way that they can understand
# Students can earn better grades, save time and study effectively
Our Vision & Mission – Simplifying Students Life
Our Belief – “The great breakthrough in your life comes when you realize it, that you can learn anything you need to learn; to accomplish any goal that you have set for yourself. This means there are no limits on what you can be, have or do.”
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This Presentation covers the basic concepts of Hot cracks and cold cracks in welding. For more information, please refer the books mentioned in the references slide.... Thank you
TRADITIONAL ingots vs. REMELTED, Comparing Metallurgical ResultsASO Group
As everyone know, remelted ingots are, from a purely metallurgical point of view, preferable to the traditional bottom poured ingots because of a series of reason:
chemical homogeneity
micro inclusions content
ultrasonic results test
absence of segregation
fine and uniform structure.
For a better understanding, we compared characteristics of a remelted ingot around 40tons, with a poly ingot with a similar traversal section of 1500mm and a gross weight near 32tons.
FellowBuddy.com is an innovative platform that brings students together to share notes, exam papers, study guides, project reports and presentation for upcoming exams.
We connect Students who have an understanding of course material with Students who need help.
Benefits:-
# Students can catch up on notes they missed because of an absence.
# Underachievers can find peer developed notes that break down lecture and study material in a way that they can understand
# Students can earn better grades, save time and study effectively
Our Vision & Mission – Simplifying Students Life
Our Belief – “The great breakthrough in your life comes when you realize it, that you can learn anything you need to learn; to accomplish any goal that you have set for yourself. This means there are no limits on what you can be, have or do.”
Like Us - https://www.facebook.com/FellowBuddycom
This Presentation covers the basic concepts of Hot cracks and cold cracks in welding. For more information, please refer the books mentioned in the references slide.... Thank you
TRADITIONAL ingots vs. REMELTED, Comparing Metallurgical ResultsASO Group
As everyone know, remelted ingots are, from a purely metallurgical point of view, preferable to the traditional bottom poured ingots because of a series of reason:
chemical homogeneity
micro inclusions content
ultrasonic results test
absence of segregation
fine and uniform structure.
For a better understanding, we compared characteristics of a remelted ingot around 40tons, with a poly ingot with a similar traversal section of 1500mm and a gross weight near 32tons.
Topic related to material science and metallurgy, Includes basic information about steel.Also the Iron-Iron Carbon Diagrams and its structures with various features of fe-c diagram.
Details of the Casting process is included in a single PPTAshutoshPattanaik12
Casting is a manufacturing process used to create solid objects by pouring molten material (usually metal or plastic) into a mold cavity that replicates the desired final shape. Once the material cools and solidifies, the solidified part, called a casting, is ejected or broken out of the mold. This process is used for a wide variety of products, from engine blocks to jewelry.
Here's a breakdown of the key steps involved in casting:
Patternmaking: The first step involves creating a replica of the final product, called a pattern. This pattern can be made from various materials such as wood, metal, plastic, or even sand. The pattern's accuracy is crucial as it determines the final shape and dimensions of the casting.
Molding: The mold is created using the pattern as a negative form. The molding material depends on the type of casting process being used. Common molding materials include sand, metal, and refractory ceramics. In some cases, the pattern itself can be used as the mold (expendable pattern casting).
Melting and Pouring: The casting material is then melted in a furnace or other heating device. Once molten, the liquid metal is carefully poured into the mold cavity. Techniques like gating systems are used to ensure proper filling and avoid defects.
Solidification: The molten material is allowed to cool and solidify within the mold cavity. The solidification time depends on the material's properties and the mold size.
Shakeout and Cleaning: Once solidified, the casting is removed from the mold. This process, called shakeout, may involve breaking the mold (expendable mold casting) or separating the mold halves (reusable mold casting). Excess material like sprues and gates is then removed from the casting.
Finishing: The final casting may undergo additional finishing processes such as heat treatment, machining, or grinding to achieve the desired surface finish and dimensional tolerances.
There are various types of casting processes, each with its own advantages and limitations. Some common casting methods include:
Sand casting: This is the oldest and most versatile casting process, using sand as the mold material. It's suitable for a wide range of metals and production volumes.
Die casting: This process utilizes a permanent metal mold for high-pressure injection of molten metal. It offers high production rates, good dimensional accuracy, and a smooth surface finish.
Investment casting: This process involves creating a wax pattern, which is then invested in a ceramic mold material. It's known for its high accuracy and ability to produce complex shapes.
Continuous casting: This method continuously produces long, solid sections by solidifying molten metal as it's withdrawn from a mold.
The choice of casting process depends on factors like the type of material being cast, the desired shape and size of the final product, production volume, and cost considerations.
Chapter 3: Metal Works, Casting & Heat Treatmentsyar 2604
This topic explains the processes of metal works and casting. It also describes the types and purpose of heat treatment for steels and the effects of heat treatment on mechanical properties of steels.
This presentation covers all the processes and sub-processes undergoing in the newly installed department in Tata Steel ,i.e., LD3 & TSCR.
This presentation deals with the all the problems faced by this department midway through the process, and mainly focussing on "Bleeding Breakout" problem in TSCR shop.
Also an attempt is made to improve the so-called problem by suggesting certain measures at the end.
Embracing GenAI - A Strategic ImperativePeter Windle
Artificial Intelligence (AI) technologies such as Generative AI, Image Generators and Large Language Models have had a dramatic impact on teaching, learning and assessment over the past 18 months. The most immediate threat AI posed was to Academic Integrity with Higher Education Institutes (HEIs) focusing their efforts on combating the use of GenAI in assessment. Guidelines were developed for staff and students, policies put in place too. Innovative educators have forged paths in the use of Generative AI for teaching, learning and assessments leading to pockets of transformation springing up across HEIs, often with little or no top-down guidance, support or direction.
This Gasta posits a strategic approach to integrating AI into HEIs to prepare staff, students and the curriculum for an evolving world and workplace. We will highlight the advantages of working with these technologies beyond the realm of teaching, learning and assessment by considering prompt engineering skills, industry impact, curriculum changes, and the need for staff upskilling. In contrast, not engaging strategically with Generative AI poses risks, including falling behind peers, missed opportunities and failing to ensure our graduates remain employable. The rapid evolution of AI technologies necessitates a proactive and strategic approach if we are to remain relevant.
Honest Reviews of Tim Han LMA Course Program.pptxtimhan337
Personal development courses are widely available today, with each one promising life-changing outcomes. Tim Han’s Life Mastery Achievers (LMA) Course has drawn a lot of interest. In addition to offering my frank assessment of Success Insider’s LMA Course, this piece examines the course’s effects via a variety of Tim Han LMA course reviews and Success Insider comments.
The Roman Empire A Historical Colossus.pdfkaushalkr1407
The Roman Empire, a vast and enduring power, stands as one of history's most remarkable civilizations, leaving an indelible imprint on the world. It emerged from the Roman Republic, transitioning into an imperial powerhouse under the leadership of Augustus Caesar in 27 BCE. This transformation marked the beginning of an era defined by unprecedented territorial expansion, architectural marvels, and profound cultural influence.
The empire's roots lie in the city of Rome, founded, according to legend, by Romulus in 753 BCE. Over centuries, Rome evolved from a small settlement to a formidable republic, characterized by a complex political system with elected officials and checks on power. However, internal strife, class conflicts, and military ambitions paved the way for the end of the Republic. Julius Caesar’s dictatorship and subsequent assassination in 44 BCE created a power vacuum, leading to a civil war. Octavian, later Augustus, emerged victorious, heralding the Roman Empire’s birth.
Under Augustus, the empire experienced the Pax Romana, a 200-year period of relative peace and stability. Augustus reformed the military, established efficient administrative systems, and initiated grand construction projects. The empire's borders expanded, encompassing territories from Britain to Egypt and from Spain to the Euphrates. Roman legions, renowned for their discipline and engineering prowess, secured and maintained these vast territories, building roads, fortifications, and cities that facilitated control and integration.
The Roman Empire’s society was hierarchical, with a rigid class system. At the top were the patricians, wealthy elites who held significant political power. Below them were the plebeians, free citizens with limited political influence, and the vast numbers of slaves who formed the backbone of the economy. The family unit was central, governed by the paterfamilias, the male head who held absolute authority.
Culturally, the Romans were eclectic, absorbing and adapting elements from the civilizations they encountered, particularly the Greeks. Roman art, literature, and philosophy reflected this synthesis, creating a rich cultural tapestry. Latin, the Roman language, became the lingua franca of the Western world, influencing numerous modern languages.
Roman architecture and engineering achievements were monumental. They perfected the arch, vault, and dome, constructing enduring structures like the Colosseum, Pantheon, and aqueducts. These engineering marvels not only showcased Roman ingenuity but also served practical purposes, from public entertainment to water supply.
Acetabularia Information For Class 9 .docxvaibhavrinwa19
Acetabularia acetabulum is a single-celled green alga that in its vegetative state is morphologically differentiated into a basal rhizoid and an axially elongated stalk, which bears whorls of branching hairs. The single diploid nucleus resides in the rhizoid.
Macroeconomics- Movie Location
This will be used as part of your Personal Professional Portfolio once graded.
Objective:
Prepare a presentation or a paper using research, basic comparative analysis, data organization and application of economic information. You will make an informed assessment of an economic climate outside of the United States to accomplish an entertainment industry objective.
Operation “Blue Star” is the only event in the history of Independent India where the state went into war with its own people. Even after about 40 years it is not clear if it was culmination of states anger over people of the region, a political game of power or start of dictatorial chapter in the democratic setup.
The people of Punjab felt alienated from main stream due to denial of their just demands during a long democratic struggle since independence. As it happen all over the word, it led to militant struggle with great loss of lives of military, police and civilian personnel. Killing of Indira Gandhi and massacre of innocent Sikhs in Delhi and other India cities was also associated with this movement.
Biological screening of herbal drugs: Introduction and Need for
Phyto-Pharmacological Screening, New Strategies for evaluating
Natural Products, In vitro evaluation techniques for Antioxidants, Antimicrobial and Anticancer drugs. In vivo evaluation techniques
for Anti-inflammatory, Antiulcer, Anticancer, Wound healing, Antidiabetic, Hepatoprotective, Cardio protective, Diuretics and
Antifertility, Toxicity studies as per OECD guidelines
The French Revolution, which began in 1789, was a period of radical social and political upheaval in France. It marked the decline of absolute monarchies, the rise of secular and democratic republics, and the eventual rise of Napoleon Bonaparte. This revolutionary period is crucial in understanding the transition from feudalism to modernity in Europe.
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Instructions for Submissions thorugh G- Classroom.pptxJheel Barad
This presentation provides a briefing on how to upload submissions and documents in Google Classroom. It was prepared as part of an orientation for new Sainik School in-service teacher trainees. As a training officer, my goal is to ensure that you are comfortable and proficient with this essential tool for managing assignments and fostering student engagement.
Instructions for Submissions thorugh G- Classroom.pptx
Steel Making: Ingot casting defects
1. MY: 301 Steel Making Processes
Ingot defects and Remedies: (Chapter No: 26, Tupkary)
1) Pipe………..Cause:
• The volumetric contraction resulting on solidification appears in
the form of a cavity known as pipe.
• This amounts of about 2.5-3.0% of the total apparent volume of
the ingot.
• Rimming and semi-killed steels show tendency for piping which
can be eliminated by careful practice.
• Capped steel is particularly free of pipe.
• In a WEU mould the pipe is short and wide, while in a NEU
mould the pipe is narrow and long.
Figure (a) Narrow end up mould showing long pipe in killed steel
Figure (b) Wide end up mould showing pipe in killed steel
Figure (c) Wide end up mould with hot top
Figure (d) Narrow end up mold with hot top. Pipe is confined to the
top.
2. MY: 301 Steel Making Processes
Remedies of pipe formation:
• By adopting hot top feeder head. It acts as a reservoir to feed
the metal to the main part of the ingot and avoid the formation
of pipe. The volume of the hot top is 10-15% higher than ingot
volume
• Use of exothermic materials in the hot top keeps the metal hot
in the top portion and pipe formation can be avoided
• Another method = to pour little more metal after partial
solidification, but this is not a very common practice.
3. MY: 301 Steel Making Processes
2) Columnar Structure:
• After the formation of initial chill layer further solidification
results in the formation of dendrites which grow along their
principal axis perpendicular the mold wall.
• It is tree like structure…Dendrites initially grow as primary arms
and depending upon the cooling rate, composition and
agitation, secondary arms grow outward from the primary arms.
Likewise, tertiary arms grow outward from the secondary arms.
Figure: Dendritic structure
• Their lateral growth is restricted due to the growth of adjoining
dendrites giving rise to the elongated crystal.
• If the length of these is appreciable it is known as columnar
structure.
4. MY: 301 Steel Making Processes
• Ingot possessing columnar structure tends to crack during
rolling.
3) Blow Holes:
• The entrapment of gas evolved during solidification of
steel produce cavities known as blow holes in all except killed
steels.
• These are of two types.
i. Primary blow holes are elongated or like honeycomb
and are located next to the ingot skin.
ii. Secondary blow holes are more spherical and are
located further in.
Remedy: Control of gas evolution during solidification so that blow
hole forms only within the ingot skin of adequate thickness.
5. MY: 301 Steel Making Processes
4) Segregation:
• It is the difference in composition of steel within the ingot than
some average composition. Segregation is due to
a) Difference in solubility of solute elements in liquid and solid steel
i.e. partition coefficient of element in steel. Partition coefficient
of solute (K) is defined as
The value of K ≤ 1.
The solute elements whose K = 1 do not segregate.
All elements whose K < 1 tend to segregate.
b) Rate of solidification: faster rate of solidification avoids the
elements to segregate. The initial chill layer of ingot has
practically the same composition as that of liquid steel.
Decrease in rate of solidification causes elements to
segregate.
c) Larger size ingots: are susceptible to segregation than smaller
size ones. Larger size ingots require more time for solidification.
Remedy: soaking of ingots at high temperature can minimize
segregation.
6. MY: 301 Steel Making Processes
5) Non-metallic inclusions:
• Inclusions are foreign particles that contaminate the metal
surface during rolling or other metal forming processes.
Common inclusion particles include oxides, sulfides or
silicates. Inclusions can be characterized by their shape, size
and distribution.
• Non metallic inclusions are inorganic oxides, sulphides and
nitrides formed by reaction between metal like Fe, Ti, Zr, Mn,
Si & Al with non metallic elements like oxygen, nitrogen,
sulphur etc...
7. MY: 301 Steel Making Processes
Types of non-metallic inclusions:
• Oxides
FeO, Al2O3, SiO2, MnO, Cr2O3 etc.
Al2O3*SiO2, Al2O3*FeO, Cr2O3*FeO, MgO*Al2O3, MnO*SiO2 etc.
• Sulfides
FeS, MnS, CaS, MgS, Ce2S3 etc.
• Oxysulfides
MnS*MnO, Al2O3*CaS, FeS*FeO etc.
• Carbides
Fe3C, WC, Cr3C2, Mn3C, Fe3W3C etc.
• Nitrides
TiN, AlN, VN, BN etc.
• Carbonitrides
Titanium carbonitrides, vanadium carbonitrides, niobium carbonitrides etc.
• Phosphides
Fe3P, Fe2P, Mn5P2
• Depending on the source, from which non-metallic inclusion are
derived, they are subdivided into two groups: indigenous and
exogenous inclusions.
8. MY: 301 Steel Making Processes
1. Indigenous inclusions are formed in liquid, solidified or solid steel
as a result of chemical reactions (deoxidation, desulfurization)
between the elements dissolved in steel.
2. Exogenous inclusions are derived from external sources such as
furnace refractories, ladle lining, mold materials etc. Amount of
exogenous inclusions and their influence on the steel properties are
insufficient.
Distribution of non-metallic inclusions:
Besides of the shape of non-metallic inclusions their distribution throughout
the steel grain structure is very important factor determining mechanical
properties of the steel.
1. Homogeneous distribution of small inclusions is the most desirable
type of distribution. In some steels microscopic carbides or nitrides
homogeneously distributed in the steel are created by purpose in order to
increase the steel strength.
2. Location of inclusions along the grain boundaries is undesirable
since this type of distribution weakens the metal.
3. Clusters of inclusions are also unfavorable since they may result in
local drop of mechanical properties such as toughness and fatigue
strength.
10. MY: 301 Steel Making Processes
Solidification of Ingots: (Chapter No. 25, Tupkary)
Types of steels
• Molten steel contains dissolved gases. During cooling of the
steel the solubility of dissolved gases is decreases and the
excess come out of solution. (e.g., in liquid steel solubility of
oxygen is 0.16% but in solid steel is only 0.003%)
• The amount of oxygen in solution and the amount that is
expelled as CO is decided by its carbon content, the type and
amount of deoxidizer added to steel prior to solidification.
• Steel that is fully oxidized by a strong deoxidizer is called Killed
Steel.
• If the evolution of the gas is appreciable, in other words
deoxidation is not fully carried out, it gives appearance of boiling
to liquid steel in the mould. This boiling action is termed as
Rimming and the steel known as Rimming Steel.
• In between violently rimming and killed steel lies the Semi Killed
Steel, which is only partially deoxidized such that some gas
evolution takes place during later stages of solidification.
• The capped steel is only a special variety of rimming steels in
which the rimming action is less violent.
11. MY: 301 Steel Making Processes
Mechanism of Solidification:
• Killed steel solidifies in three zones in an ingot.
• The metal next to the mould walls and bottom is chilled by the
cold mould surfaces. This is a thin layer and is known as chill,
shell or skin of an ingot and has a fine equiaxed grains.
• The rate of solidification is very high in forming the skin, however
the rate of solidification soon slow down.
• The mould expands on heating and the skin contracts on
solidification; it reduces the rate of heat flow and thereby slows
down the cooling of an ingot.
• The solidification front moves inwards perpendicular to the
mould faces resulting in columnar grains next to the chill. OR
• After the formation of initial chill layer further solidification results
in the formation of dendrities which row along their principal axis
perpendicular to the mould walls.
• Their lateral growth is restricted due to the growth of adjoining
dendrities giving rise to elongated crystal. If the length of these is
appreciable is known as columnar structure
12. MY: 301 Steel Making Processes
• In general columnar structure does not extend to the centre of
the ingot. The central portion solidifies as equiaxed grains of
bigger sizes than those in the chill due to slow cooling.
• One zone blends into the next gradually. The extent of each
zone varies with composition and temperature of liquid steel,
mould design and its temperature at the time of teeming.
13. MY: 301 Steel Making Processes
Segregation:
• Segregation means departure from the average
composition.
• Segregation is the result of the differential solidification
characteristic of all liquid solution.
• In case of Steel, is an alloy (liquid solution) of S, Si, C, P,
Mn etc. in iron and hence is prone to segregate during
solidification.
• The initial chill layer of the ingot has practically the same
composition as that of the steel poured in the mould, i.e. there
is no segregation in the chill layer because of vary rapid rate of
solidification.
• The progressive solidification there after results in
solidification of purer phase (rich in iron) while the remaining
liquid gets richer in impurity contents.
• If the concentration > the average it is called positive
segregation.
• If the concentration < the average it is called positive
segregation.
14. MY: 301 Steel Making Processes
• It can be minimized by prolonged soaking of ingots before
working.