Hot rolling process is heat input process. The heat energy in hot rolled steel coils can be utilized. At SSAB Strip Product Borlänge when the hot rolled steel coils came out of the hot rolling mill they are at the temperature range of 500°C to 800°C. Heat energy contained by the one hot rolled steel coil is about 1981Kwh whereas the total heat energy for the year 2008 is 230 GWh/year.The potential of heat is too much but the heat dissipation rate is too slow. Different factors on which heat dissipation rate depends are discussed.Three suggestions are proposed to collect the waste heat from hot rolled steel coils.The 2nd proposal in which water basin is suggested would help not only to collect the waste heat but to decrease in the cooling time.

O presente trabalho visa entender as relações entre as propriedades mecânicas e a composição química de fio-máquinas produzidos com aços SAE 1005 e SAE 1405 modificados e os parâmetros de controle de um laminador a fim de se obter, após a laminação a quente, as propriedades mecânicas semelhantes para os dois tipos de aço. A metodologia adotada envolveu as etapas de revisão da literatura e procedimento experimental D.O.E (Design of Experiments), com coleta de amostras de fio-máquina 5,50 mm produzido com o aço SAE 1005 modificado e outras de fio-máquina 5,50 mm produzido com o aço SAE 1405 modificado, nas condições normais de operação para avaliação das propriedades mecânicas através de ensaios de tração e análise metalográfica. Esse resultado visa criar uma alternativa para a fabricação de arames recozidos com o uso do fio-máquina produzido com o aço SAE 1005 modificado, com um menor custo do produto final. / The present work aims to understand the relationships between the mechanical properties and chemical composition of wire rod produced with SAE 1005 and SAE 1405 modified steels and the parameters of a rolling mill in order to obtain, after hot rolling, mechanical properties similar for both types of steel. The methodology involved the steps of literature review and experimental procedure DOE (Design of Experiments), with sampling of 5.50 mm wire rod produced with the SAE 1005 modified and other samples of 5.50 mm wire rod made from steel SAE 1405 modified under normal conditions of operation for evaluation of mechanical properties through tensile testing and metallographic analysis. This result created an alternative for the fabrication of annealed wire using the wire rod produced with the SAE 1005 modified, with a lower total cost of the final product.

Abstract Non-metallic inclusions are unavoidable particles in steel and are often detrimental to the steelmaking process and the mechanical properties of the steel. While it is not feasible to remove all inclusions, in the well-established calcium treatment of aluminium-killed steel, solid aluminium oxides are transformed into less harmful liquid calcium aluminates. The main objective of this work was to develop a new inclusion identification and classification method. The presented method offers valuable information on phases of the inclusions. This data is often buried within simple inclusion classification criteria. The method offers the best approximation of the phases in each inclusion detected with minimal time, if no time-consuming elemental map analyses are available. In this work, applications for the inclusion phase identification method are presented. Utilising the method, the dispersion and evolution of inclusions during the sampling of liquid steel in lollipop samples is investigated, as well as the evolution of inclusions during continuous casting. New information is obtained on the elongation of inclusions and formation of oxide–sulphide stringers during hot rolling. The results for the investigated steels show that with sulphur contents higher than 10 ppm, calcium aluminates were back-modified to alumina and spinel inclusions during casting. However, with decreasing sulphur contents, and adequate simultaneous calcium treatment of oxides, Al₂O₃ and spinel formation is hindered or even avoided. The most elongated inclusions are often also found in stringers. According to the results of this study, low melting calcium aluminate inclusions are not the most elongated oxide inclusions in the hot rolled product. With moderate calcium treatment, an optimal oxide composition can be obtained, found within the C12A7–CA–MgO composition. These liquid inclusions ensure good castability, while they do not easily elongate or fragment into detrimental stringers after continuous casting. / Tiivistelmä Epämetalliset sulkeumat ovat väistämättä osa terästä, ja ne aiheuttavat ongelmia prosessille ja teräksen mekaanisille ominaisuuksille. Sulkeumien poiston sijaan niiden koostumusta muokataan kalsiumkäsittelyllä. Tällöin kiinteät alumiinioksidit muuttuvat vähemmän ongelmallisiksi suliksi kalsiumaluminaateiksi. Tämän työn päätavoitteena oli kehittää uusi sulkeumien tunnistus- ja luokittelumenetelmä. Sulkeuma-analyysien data voi jäädä hyödyntämättä, jos luokitteluun käytetään yksinkertaisia kriteerejä. Työssä esitetty menetelmä antaa parhaan arvion sulkeumissa olevista faaseista, mikäli sulkeumista ei ole alkuainekarttoja, joiden muodostaminen vie huomattavasti aikaa. Väitöskirjassa esitetään sulkeumien tunnistus- ja luokittelumenetelmän soveltamiskohteita. Menetelmän avulla tutkitaan sulkeumien muutosta ja jakaantumista sulan teräksen näytteenotossa ja sulkeumakuvan muutosta jatkuvavalun aikana. Uutta tietoa esitetään oksidi-sulfidiketjujen muodostumisesta kuumavalssauksen aikana. Tutkituilla teräksillä rikkipitoisuuden noustessa yli 10 ppm:n sulat kalsiumaluminaatit takaisinmuokkautuvat kiinteiksi alumiinioksideiksi tai spinelleiksi jatkuvavalun aikana. Riittävän matalalla rikkipitoisuudella ja kohtuullisella kalsiumkäsittelyllä alumiinioksidien ja spinellien muodostumista voidaan hillitä tai jopa estää se. Tutkimuksessa esitetään, että kuumavalssauksessa venyvimmät sulkeumat muodostavat myös lukuisten sulkeumien oksidi-sulfidiketjuja, jotka ovat tuotteen ominaisuuksien kannalta haitallisia. Tulosten mukaan kalsiumaluminaatit, jotka sulavat matalimmissa lämpötiloissa, eivät kuitenkaan ole taipuvaisimpia venymään valssauksessa. Maltillisella kalsiumkäsittelyllä saavutetaan optimaalinen oksidikoostumus C12A7–CA–MgO-faasiseurueesta. Nämä sulkeumat ovat sulia jatkuvavalussa varmistaen teräksen valettavuuden. Toisaalta ne eivät helposti veny tai rikkoonnu ketjuiksi valssauksessa jatkuvavalun jälkeen.

O presente trabalho visa entender as relações entre as propriedades mecânicas e a composição química de fio-máquinas produzidos com aços SAE 1005 e SAE 1405 modificados e os parâmetros de controle de um laminador a fim de se obter, após a laminação a quente, as propriedades mecânicas semelhantes para os dois tipos de aço. A metodologia adotada envolveu as etapas de revisão da literatura e procedimento experimental D.O.E (Design of Experiments), com coleta de amostras de fio-máquina 5,50 mm produzido com o aço SAE 1005 modificado e outras de fio-máquina 5,50 mm produzido com o aço SAE 1405 modificado, nas condições normais de operação para avaliação das propriedades mecânicas através de ensaios de tração e análise metalográfica. Esse resultado visa criar uma alternativa para a fabricação de arames recozidos com o uso do fio-máquina produzido com o aço SAE 1005 modificado, com um menor custo do produto final. / The present work aims to understand the relationships between the mechanical properties and chemical composition of wire rod produced with SAE 1005 and SAE 1405 modified steels and the parameters of a rolling mill in order to obtain, after hot rolling, mechanical properties similar for both types of steel. The methodology involved the steps of literature review and experimental procedure DOE (Design of Experiments), with sampling of 5.50 mm wire rod produced with the SAE 1005 modified and other samples of 5.50 mm wire rod made from steel SAE 1405 modified under normal conditions of operation for evaluation of mechanical properties through tensile testing and metallographic analysis. This result created an alternative for the fabrication of annealed wire using the wire rod produced with the SAE 1005 modified, with a lower total cost of the final product.

O presente trabalho visa entender as relações entre as propriedades mecânicas e a composição química de fio-máquinas produzidos com aços SAE 1005 e SAE 1405 modificados e os parâmetros de controle de um laminador a fim de se obter, após a laminação a quente, as propriedades mecânicas semelhantes para os dois tipos de aço. A metodologia adotada envolveu as etapas de revisão da literatura e procedimento experimental D.O.E (Design of Experiments), com coleta de amostras de fio-máquina 5,50 mm produzido com o aço SAE 1005 modificado e outras de fio-máquina 5,50 mm produzido com o aço SAE 1405 modificado, nas condições normais de operação para avaliação das propriedades mecânicas através de ensaios de tração e análise metalográfica. Esse resultado visa criar uma alternativa para a fabricação de arames recozidos com o uso do fio-máquina produzido com o aço SAE 1005 modificado, com um menor custo do produto final. / The present work aims to understand the relationships between the mechanical properties and chemical composition of wire rod produced with SAE 1005 and SAE 1405 modified steels and the parameters of a rolling mill in order to obtain, after hot rolling, mechanical properties similar for both types of steel. The methodology involved the steps of literature review and experimental procedure DOE (Design of Experiments), with sampling of 5.50 mm wire rod produced with the SAE 1005 modified and other samples of 5.50 mm wire rod made from steel SAE 1405 modified under normal conditions of operation for evaluation of mechanical properties through tensile testing and metallographic analysis. This result created an alternative for the fabrication of annealed wire using the wire rod produced with the SAE 1005 modified, with a lower total cost of the final product.

O aço 10B06 é utilizado na produção de fio máquina para trefilação. Por ser produzido em aciaria elétrica, o teor de nitrogênio desse aço tende a ser elevado, o que pode causar o fenômeno de envelhecimento, resultando em aumento de resistência e queda de ductilidade. Reduzir o teor de nitrogênio livre é uma forma de minimizar esse efeito, o que é realizado pela adição de boro. Dessa forma, o presente trabalho teve como objetivo estudar o efeito do boro no aço 10B06. Foram utilizadas amostras de fio máquina, diâmetro 5,50mm, e arame trefilado com teores de boro variando de 55 a 112ppm. Os dois principais fatores que influenciam a microestrutura e propriedades mecânicas do material são a composição química e o processo produtivo. Por esse motivo, inicialmente foi avaliada a etapa de resfriamento durante a laminação do fio máquina, por meio de uma análise termográfica. Foi encontrada a temperatura de 767ºC no início do resfriamento do material, valor próximo de Ac1, limite inferior do intervalo intercrítico. Esse fato favorece o enriquecimento da austenita em carbono, facilitando a formação de martensita e/ou austenita retida. Os resultados da análise metalográfica com Nital revelaram microestrutura composta de aproximadamente 88% de ferrita e 12% de perlita. Já o reagente Le Pera identificou ilhas de martensita e/ou austenita retida (MA), o que foi comprovado por análises de microscopia eletrônica de varredura. Os resultados de microdureza mostraram uma tendência de queda com o aumento do teor de boro. As medições de nanodureza confirmaram a presença do microconstituinte MA. A ferrita apresentou dureza na faixa de 280 - 320 HV, enquanto o MA ficou no intervalo de 349 - 424 HV. Comparando-se o limite de resistência obtido no fio máquina com menor teor de boro (55ppm - 434MPa) com o de maior (112ppm - 394MPa), observasse uma redução de 40MPa para um acréscimo de 57ppm de boro, confirmando o efeito esperado para esse elemento pela formação de BN. Utilizando os dados da curva tensão versus deformação foram obtidos os coeficientes de encruamento dos fios máquina, que apresentaram uma tendência de crescimento com o teor de boro, sendo que o material com 101ppm de boro mostrou o melhor valor para aplicação em processos de conformação. As análises fractográficas revelaram que os mecanismos de fratura presentes em todos os materiais foram a formação e coalescimento de microvidades. Considerando-se todas as análises realizadas nesse trabalho foi possível evidenciar o efeito do boro na redução do efeito do envelhecimento provocado pelo nitrogênio. Entre os testes realizados, os que apresentaram as melhores relações B/N foram os de teores 109 e 112ppm de boro. Essas relações estão próximas do valor máximo indicado de 0,8. / The 10B06 steel grade is applied to the production of wire rod for drawing. The steel is produced in an Electric Arc Furnace and this process can lead to higher nitrogen levels that cause strain aging resulting in an increase of the strength and ductility loss. The reduction of free nitrogen content through boron addition is one way to minimize this effect that can be done through boron addition. In this way, the present work aims to study boron effect on 10B06 steel. It was used wire rod, diameter 5,50mm and a cold-drawn wire rod with chemical composition from 55 to 112ppm of boron. The main factors that influence the microstructure and mechanical properties of the material are the chemical composition and the productive process. For this reason, initially, the cooling treatment was analyzed using thermography and it was found at the beginning of the cooling process a temperature of 767oC in the material, close to Ac1, lower limit of the intercritical interval. This temperature can facilitate the enrichment of carbon in the austenite, making easier martensite and/or retained austenite formation. The metallographic analysis with Nital etchant showed a microstructure composed of about 88% ferrite and 12% perlite, and Le Pera etchant identified martensite and/or retained austenite (MA), what was confirmed by scanning electron microscope analysis. Furthermore, nanohardness measurements confirmed the presence of the microconstituent MA, as ferrite presented hardness from 280 to 320 HV and MA from 349 to 424 HV. Microhardess results decreased with increasing boron content. A decrease of 40MPa in the tensile strength was observed between the wire rod with boron content of 55ppm (434MPa) and the one with 112ppm (394MPa), in agreement with the expected effect of the BN formation. It was possible to obtain hardening coefficient of the wire rod using the data of the stress versus strain curve, which increased with boron content, and the material with 101ppm of boron showed the best value for forming application. Fractographic analysis revealed that the fracture mechanisms in all the materials were the development and coalescing of microcavity. Considering all the analysis of this study it was possible to confirm boron\'s effect to reduce strain aging caused by nitrogen. Materials with 109 and 112ppm of boron presented the best B/N ratio, with values close to the maximum indicated, 0,8.

Embora a literatura disponível sobre conformação mecânica disponha de grande número de trabalhos relacionados à fadiga térmica em cilindros de laminação a quente, poucos autores abordam como esse tipo de dano é influenciado por algumas características do processo - em especial a oxidação na superfície de trabalho dos cilindros, tanto enquanto formação de uma camada de óxido uniforme sobre essa superfície quanto na forma de corrosão. Essa lacuna ocorre a despeito do volume de referências que relacionam a oxidação à fadiga térmica em escala laboratorial. O presente trabalho busca relacionar ambas as linhas de investigação, utilizando métodos analíticos e numéricos comparados com experimentos em diferentes escalas, para compreender sob quais condições são formados os óxidos presentes nos cilindros, qual seu comportamento mecânico no decorrer dos ciclos de laminação e como os óxidos influenciam na ocorrência de trincas de laminação a quente. A análise da superfície de trabalho de um cilindro em escala piloto revela a presença de trincas térmicas na superfície de trabalho. Os padrões de defeitos obtidos se mostram de acordo com o exposto em diversas referências publicadas sobre ensaios de fadiga térmica e termomecânica, em relação à presença e distribuição de óxidos no interior das trincas e na superfície externa das amostras. Em paralelo, foram desenvolvidos modelos numéricos do processo de laminação a quente, inicialmente em escala macroscópica, para obter detalhes sobre distribuições de temperatura, tensões e deformações nos cilindros, de difícil obtenção experimental. Estes modelos foram simulados e seus resultados comparados com valores medidos no laminador piloto, validando seu uso para avaliação do comportamento dos cilindros durante uma série de campanhas de laminação. Os resultados obtidos mostram que o mecanismo de fadiga de baixo ciclo normalmente associado ao dano térmico não é suficiente para explicar a nucleação das trincas de fadiga térmica observadas no experimento. O erro na predição pela teoria de fadiga de baixo ciclo tradicional, em conjunto com a caracterização dos cilindros em escala piloto e com observações de cilindros em escala industrial presentes na literatura, permite levantar a hipótese de que os fenômenos de oxidação e corrosão em curso durante o processo de laminação contribuem para uma redução significativa da resistência dos cilindros à fadiga termomecânica. Cálculos analíticos e simulações adicionais em escala microscópica foram realizados, incluindo os efeitos da oxidação e da corrosão, confirmando a hipótese e oferecendo uma linha de investigação mais assertiva para a nucleação e evolução do dano nos cilindros. / Although the literature on metal forming presents a considerable amount of references related to thermal fatigue in hot rolling, only few authors discuss how this type of damage is influenced by some characteristics of the rolling process - specially the oxidation that develops at the surface of the rolls. This gap occurs despite the amount of references relating oxidation to thermal fatigue in laboratory scale. The current work aims to relate both investigation paths, employing analytical and numerical methods in comparison with experiments in different scales, to provide understanding about the conditions at which the oxides observed upon the rolls are formed, their mechanical behaviour during the rolling process and how they influence thermal fatigue cracking in the rolls. The analysis of the roll surface in a pilot scale mill reveals the presence of thermal fatigue cracks on the work surface. The patterns of defects observed are in accordance with several references on thermal and thermomechanical fatigue, regarding the presence and distribution of oxides inside the cracks and at the external surface of the samples. In parallel, numerical models of hot rolling were developed, initially at macroscopic scale, to obtain details on temperature, stress and strain distribution in the rolls, which are difficult to obtain experimentally. These models were simulated and their results were compared with values measured in the pilot scale mill, validating their use to evaluate the behaviour of the rolls throughout a series of rolling campaigns. The obtained results show that the low-cycle fatigue mechanism commonly associated to thermal damage is not enough to explain the nucleation of thermal cracks seen in the experiments. The error in the prediction using the traditional low-cycle fatigue theory, in conjunction with the characterization of the pilot-scale rolls and with observations of industrial scale rolls, yields the hypothesis that oxidation and corrosion phenomena occurring throughout the rolling process contribute to a significative reduction in the resistance of the rolls to thermomechanical fatigue. Analytical calculations and additional simulations in microscopic scale were conducted, including effects of oxidation and corrosion, confirming the hypothesis and providing a more assertive line of research for damage nucleation and evolution in the rolls.

This work has been performed at Outokumpu Stainless AB, QPE, in Degerfors where focus is on production of hot rolled tailor-made quarto plate in special stainless steel grades such as highly alloyed austenitics and duplex steel grades. After a period with low values in strength and a lot of deviations in tensile tests for the highly alloyed austenitic stainless steel, 254 SMO, there was a need to investigate what influence some parameters during process has on strength values. Process parameters during hot rolling and levelling have been examined to see if there is a connection between these and the strength. A statistical data base has been created to investigate the connection with strength. There has been experimental work involving two test plates in different dimensions to see how a double/extended heat treatment influence the sigma phase values and grain size, and if these can be connected to the strength values. The test plates have also been used to investigate how the position of the test coupon is affecting the tensile test result. Moreover, there have been tests performed in the cold plate leveller. The strength is a complex problem since there are many parameters that contribute to a variation in strength value. It is possible to see an influence from the investigated parameters, but their individual impact on strength varies. There are several indications in the results that the flatness seems to be a factor affecting the variation in strength. However, there is a need for more thorough investigations where the flatness can be measured to completely verify this / Det här arbetet har utförts på Outokumpu Stainless AB, QPE, i Degerfors där man inriktar sig på produktion av varmvalsad, skräddarsydd kvartoplåt i olika specialstål som höglegerade austeniter och duplexa stålsorter. Efter en period med låga värden i hållfasthet och många avvikelser i provning för ett höglegerat austenitiskt stål, 254 SMO, så fanns ett behov av att undersöka vissa parametrars inverkan på hållfastheten. Processparametrar vid valsning och riktning har undersökts för att se om det går att se ett samband mellan dessa och hållfastheten. Statistisk data har tagits fram för att undersöka sambandet med hållfastheten. Även experimentella försök har gjorts, främst på två testplåtar i olika dimensioner, för att se hur en dubbel/förlängd värmebehandling påverkar sigmafas och kornstorlek men även om dessa värden, genom försöken, kan kopplas till hållfasthetsvärden. Plåtarna har också använts till att se hur testresultatet påverkas av var i plåten som testkupongen tas ut. Dessutom har det gjorts försök i riktverket med olika parametrar. Hållfastheten är ett komplext problem att utreda eftersom det finns så många parametrar som ger en variation i resultaten. Det är möjligt att se en påverkan från flera av de undersökta parametrarna men deras individuella påverkan på hållfastheten varierar. Det finns många indikationer i resultaten som pekar på att planheten verkar vara en faktor som påverkar den variation som finns i resultat. Dock behövs det grundligare undersökningar där planheten kan mätas för att helt verifiera detta.

The thesis deals with technology of hot-rolled profiles, describing total summary of principles and conditions this process is based on. There is a draft of a calibration of profile, the application of which is subsequently verified through a numerical simulation. Futher in the thesis also was verified the mechanical properties of applied construction steel S355J2 through the up-setting test and compared the results with the used material model in the simulation software Simufact Forming. Then, the test rolling of the calibrated profile was carried out. As a next step, the dimensions of the rolled bars were compared with the results of the simulation, on the basis of which the applicability and suitability of the simulation in the future development of other profiles was verified and evaluated.

The last seven hot rolling passes of the ferritic stainless steels (FSS) AISI 430 and AISI 433 (the latter an Al-added variant of 430) were simulated on Gleeble-1500D® and Gleeble-3800TM® thermo-mechanical simulators to investigate the effect of temperature, strain rate and inter-pass time on the development of texture in these steel grades and its subsequent influence on ridging. The compression tests were carried out over a wide range of strain rates (0.1 s-1 to 5 s-1, 25 s-1 and 50 s-1) and temperatures (1100 to 820 oC) with different inter-pass times (2 s, 10 s, 20 s and 30 s). The transition temperature from dynamic recrystallization (which may introduce a texture change) to dynamic recovery (in which no texture changes are expected) was determined by examining the relationship between the mean flow stress and the deformation temperature in multi-pass tests. Both macrotexture (XRD) and microtexture (EBSD) analyses were employed to characterise and study the texture present in these steels. It was found that the texture in the central layer of the compressed sample is a strong recrystallization-type. The through-thickness textural and microstructural banding was found to be responsible for ridging in these grades of stainless steels. Dynamic recrystallization which promotes the formation of the desired ã-fibre texture leading to high ductility, formability and eventually reduction or elimination of ridging, was found to occur in both AISI 430 and AISI 433 at high temperatures, low strain rates and longer inter-pass times with multi-pass testing. Generally AISI 433 has a stronger gamma texture developed than the AISI 430 when hot rolled under similar conditions, which leads to improved ductility and less ridging in AISI 433 than AISI 430. / Dissertation (MSc)--University of Pretoria, 2012. / Materials Science and Metallurgical Engineering / unrestricted