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IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Bottom Pour Flux Bottom Pour Flux Bottom Pour Flux Development and TestingDevelopment and TestingDevelopment and Testing
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Outline
Product Development ProcessDesign InputsProduct FormulationDevelopment TestingProductionQuality Control
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Design Inputs
Steel Grade(s)
Ingot Size / Shape
Pour Rate / Temperature
Mold Condition
Spent Flux Samples
Hot Top System
Environmental concerns
Quality issues
Flux ApplicationMethodRate
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Product Formulation
SAP Development DatabaseHistorical reviewKnowledge sharing
Raw Material SelectionOxide ChemistryPhysical PropertiesChemical RestrictionsProcessing Method
• Powder• Spray Dried granular
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Bottom Pour Flux Application
0.440.050.440.09Basicity
14.34.6--23.6C(free)
----1.8--F2.03.70.32.2K2O
11.05.16.04.8Na2O5.06.70.36.5Fe2O3
14.522.32.218.0Al2O3
1.51.50.31.3MgO11.52.225.03.0CaO26.046.556.334.0SiO2
Special-SteelsC-Steels, StainlessStainlessC-SteelsApplication
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Product Development Testing
Primary FunctionsThermal InsulationOxidation ProtectionLubricationAbsorption of nonmetallic inclusions
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Thermal Insulation
Thermal Conductivity / Insulation
Heat Flux – induction furnace• 500°C / 800°C
High Temperature test• 1300 - 1400°C• Surface temperature• Sintering
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Thermal Conductivity
Sample placed into crucible at room temp (600 mL)Temperature increased to max temp (500-800°C)Hold at temp to reach steady stateDetermine heat flux & thermal conductivity
Density: 0.66 g/mlMoisture: 0.15 %
Avg. SS ⎝ T: 451.5 °CAvg. SS HF: 1097.3 W/cm2
Avg. SS TC: 0.146 W/m*K
Thermal Results
0
100
200
300
400
500
600
0:00:01
0:05:21
0:10:41
0:16:01
0:21:21
0:26:41
0:32:01
0:37:21
0:42:41
0:48:01
0:53:21
0:58:41
Time
Tem
pera
ture
(°C)
0.05
0.07
0.09
0.11
0.13
0.15
0.17
0.19
0.21
0.23
0.25
Ther
mal
Con
duct
ivity
(W/m
K)
TC0
TC1
TC2
TC3
ThermalConductivity
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
High Temperature Insulation / Sinter Test
Sample size – 400 mLTemperature: 1300 – 1400°CTime – 1 hour
Decarburized layer
Temperature
0
100
200
300
400
500
600
700
800
900
1000
00:50
04:10
07:30
10:50
14:10
17:30
20:50
24:10
27:30
30:50
34:10
37:30
40:50
44:10
47:30
50:50
54:10
57:30
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Melting Temperature
Hot Stage MicroscopeAutomated data collection and report generationDynamic Temperature RampSmall sample size
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Melting Rate
Pan Box Test Bottom Pour Melt TestVideo Melt Rate TestGraphite Crucible Test
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Pan Box Melt Test
50 gram sample1300°CVarying timesComparative melt rate
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Bottom Pour Melt Test
Sample size – 2 grams1300°CVarious times
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Graphite Crucible Test
Method5 gram sampleGraphite crucible1300°C30 minutesCool to room temp
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
High Temperature Video Melt Test
High temperature furnace and video cameraVideo analysisMelt Rate measurementMelt behavior analysis
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Reporting Results
ResultsMelt Rate (mg/sec)Video captureMelt behavior
Total Melting Time: 0:03:24 hrs:min:sec
Total Mass: 8.00 g
Melt Rate: 39.2 mg/sec
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Flowability
Powder
Granular
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Particle Size
Ro-TapMechanical sieve shaker100 gram sample size15 minutes
Laser Diffraction AnalyzerShort analysis timeGood small particle resolution
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Slag Viscosity
Test methodHigh temp rotational viscometer130 gram sample size (prefused)Graphite spindle / crucibleControlled temperature ramp down (1360°C to solidification)Automated data collection and analysis
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Slag Viscosity
Calculated Viscosity Equations
Oxide basedTemperature dependent
Viscosity is important to ingot surface quality
Must be matched to teeming speedIf not matched, quality issues may result
• Flux entrapment• Interrupted slag film, loss
of lubrication
Viscosity Results
1.00
10.00
100.00
1000.00
10000.00
100010501100115012001250130013501400
Temperature CV
isco
sity
(poi
se)
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Production
Powder formMechanical mixer
• Batch size• Mix time• Weighing accuracy /
tracking• High shear
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Air Blender
Air MixerLarge batch capacityLow shear mixingVariable blending control
• Pulse duration• Pulse frequency• Air pressure• Total mix cycle
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Production
Granular – spray driedHigh shear slurry preparation –homogeneous batchesExcellent flowabilityLess dust – better working environmentExtra costCan limit raw material selection
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Production
PackagingCustomer specific packaging
• Bag weights• Bag materials• Other; ropes, grommets, etc.
Automated heat sealed poly bagging unit• Bag weight verification• Product identification• High throughput
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Quality Control
SAP Quality ModuleSample identification / trackingDesign verification
Oxide ChemistryFused bead sample prepXRF analysis
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Quality Control
Total Carbon %CO2 %MoistureBulk DensityParticle SizeColor
Carbon Analyzer
CO2 Analyzer
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Quality Control
Melt PointHot stage microscope
Melt RateBottom pour melt testPan box melt test
Slag PropertiesViscositySurface tension
IMF Fall Meeting Niagara Falls, NY Oct. 27 – 28, 2010
Thank You For Your Attention.
