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By Felipe Poffo, Flávio Messas

Due to the high level of competition in tooling sector, a necessity to increase the level of processes and assets management has initiated. Based on the World Class Manufacturing methodology, applied mainly in serial production industries, we have challenged ourselves to adapt the main concepts and implement them in a tooling company. After one work year, we could notice 29% productivity improvement in the bottleneck process, 25% cost reduction in outsourcing, standardization of the processes, 8% reduction in direct labor. Consequently, it was possible to implement a financial reserve and a long term planning cash flow.

Nov 22, 2018

By Josef Maierl

For the production of advanced high strength steel grades (AHSS) like API X80/X100, dual-phase, martensitic and complex-phase grades a number of hot strip mills need to extend their limits in terms of power and flexibility. Especially for cooling and coiling of these new materials, Primetals Technologies developed the “Power Cooling” and “Power Coiling” technologies. Power Cooling combines the advantages of conventional laminar cooling or “low pressure cooling” with the newly developed “high pressure cooling” with highest cooling rates for flexible operation. The Power Coiler which is needed to coil those high strength grades especially at thicker gauges ensures reliable strip-coiling for a most economical production. To enhance the reliable production of high-strength steel grades for a wide range of strip dimensions, the automation system with its advanced models is an integral part to the mechanical design. In this context the paper presents examples for the installation of power cooling and power coiling in new and modernized HSM.

Aug 16, 2017

By Luana Araújo Batista

Na produção de tiras de aço laminadas a frio, o material é encaminhado para linhas de recozimento e decapagem de bobinas. Geralmente, essas linhas de produção possuem sistemas de lavagem para remoção do óleo de laminação e outras impurezas da superfície da tira. Porém, em algumas situações de processo ou por limitações técnicas, o óleo da superfície não é totalmente eliminado. Neste trabalho foi avaliada a influência do óleo de laminação na superfície do aço inoxidável AISI 430 durante o recozimento após laminação a frio. A motivação deste estudo surgiu da necessidade de compreender o fato das amostras oleadas deste aço apresentarem martensita após o recozimento, o que não ocorre para amostras recozidas sem óleo. Para os ensaios foram utilizados dois fornos mufla e diferentes concentrações de oxigênio na atmosfera, sendo utilizados termopares acoplados em todas as amostras. Foi comprovado que a presença de óleo na superfície da tira acelera a taxa de aquecimento e aumenta a temperatura final da tira em aproximadamente 100°C quando comparada às amostras não oleadas para o ciclo estudado.

Aug 16, 2017

By Fabrício Tibúrcio Silva Araújo

O AutoLog é uma solução em tecnologia de automação e informação para controle absoluto do carregamento e descarregamento de caminhões em um grande cliente no ramo de fertilizantes. Seu objetivo é garantir uma operação autônoma que otimize os lucros e reduza os custos em logística. Este trabalho visa demonstrar o problema que originou a solução, a metodologia utilizada no seu desenvolvimento e o seu objetivo final.

Oct 30, 2017

By Glaucon Medeiros Silva

Este trabalho técnico tem por finalidade apresentar a evolução dos ensaios de porosidade em pelotas de minério de ferro. Apresentando as diversas formas de realização deste tipo de ensaio a não correlação entre eles, pois cada método possui uma finalidade distinta e como se ocorreu a evolução do método volumétrico (ótico) desde sua realização manual, na década de 1980, início de medições automatizadas na década de noventa e sua total automatização a partir da década de 2010 até o ano de 2019.

Oct 1, 2019

By Rodrigo Martins, Mauro Trindade

I Reduction of energy consumption in air compressors by the implementation of individualized load control. Reduction of 3,5% from Jun / 18.

Oct 3, 2019

By Tiago Silva Costa

Os tratamentos térmicos são um conjunto de operações que têm por objetivo modificar as propriedades dos aços e de outros materiais através de um conjunto de operações que incluem o aquecimento e o resfriamento em condições controladas. Os aços SAE J403 1045, SAE J403 1075 e DIN 100CrV2 são aplicados em diferentes setores industriais graças às diferentes propriedades que podem ser alcançadas através de tratamentos térmicos. Este trabalho visou caracterizar e descrever as fases formadas nos aços SAE J403 1045, SAE J403 1075 e DIN 100CrV2 após tratamentos térmicos de têmpera, normalização e recozimento pleno.

Aug 16, 2017

By Alessandro Pigani

Over the last 25 years the thin slab casting and rolling process has been gaining a major market share in the production of hot rolled strip, progressively eroding the areas previously of exclusive domain of conventional mills. This is mainly thanks to the competitiveness of the process over conventional ones, and to the growing ability of this technology to cover the majority of market niches, well beyond the boundaries of the commodity market. After having significantly contributed to the continuous expansion of this production mode and after an extensive campaign of theoretical research and physical testing in reference plants, Danieli has progressively developed over the years a new generation of thin slab casting and rolling layout, marking a new phase in the evolution of this process. The new step-ahead is epitomized by the name QSP-DUE. This configuration belongs to the Quality Strip Production (QSP) family, which is Danieli’s strip-quality-oriented thin slab based plants. The innovative features of the process are embodied in the acronym DUE, which stands for Danieli Universal Endless (Danieli patented technology – US patent n. 8087449, January 3rd, 2012). What makes this new concept different is the ability of “universal” rolling modes thanks to the fact that, now, within one single plant it is possible to perform coil-to-coil, semi-endless and endless rolling modes, making this plant a major technology innovation compared to the previous generation.

Aug 16, 2017

By Jörg Schwelberger

Government regulations around the world concerning environmental care are becoming more stringent, also including regulations and restrictions of depositing and use of dust, sludge and slag generated in the iron and steelmaking process. With this scenario, by-products such as iron containing dust, sludge, oxide fines, mill scales and slag, become a valuable resource and recycling may be a profitable activity within a plant. Up to ten percent in mass of the total steel output of dust, sludge and mill scale by-product materials and more than 40% of slag by product are generated within an integrated steel plant with an iron content ranging from 50% to 65% for fines and up to 25% for BOF-slag. Slags are being widely recycled and used in the cement industry, as is the case for BF slag, and in the construction industry in the case of BOF slags and EAF slags. However, value of BOF unmodified slag is typically low and environmental regulations limit the usage of the unmodified BOF slag. This paper describes innovative solutions for recycling of fines using cold briquetting technology and the modification and granulation of slag from steelmaking that increase the value of the by-product and yield a marketable product.

Aug 16, 2017

By Ruy José Feijó Alves

O policarbonato é um polímero quimicamente neutro, 100% reciclável, resistente a altas temperaturas, impermeável, durável que oferece uma combinação fantástica das suas propriedades físicas, químicas, mecânicas, térmicas e eléctricas (isolante eléctrico). O policarbonato é um dos plásticos de maior venda e que mostra a maior taxa de crescimento anual no mundo, devido às suas excepcionais propriedades e versatilidade de aplicação e uso. Devido à grande utilização de polímeros nas mais diversas aplicações ao ar livre, surgiu a necessidade de estudar sua resistência às intempéries, não somente por aspectos estéticos, como descoloração ou perda de brilho, mas também por mudanças nas suas propriedades. Os polímeros quando expostos a luz solar na presença de oxigênio são degradados, no entanto as taxas de degradação foto-oxidativa dependem fortemente da natureza química do polímero. Durante o processo de degradação ocorrem mudanças físicas e químicas no polímero que levam à descoloração, fissuramento, perda de brilho e queda de resistência mecânica. Tais fenômenos estão quase sempre associados a processos de cisão de cadeia e, em alguns casos, ocorrem também reticulações. Para se avaliar a estabilidade, ou mesmo avaliar a eficiência de um polímero, é necessário submetê-los a ensaios que simulem as condições às quais ele estaria exposto durante a sua vida útil. Nesse contexto será apresentada uma avaliação sobre a degradação do polipropileno exposto a radiação ultravioleta.

Aug 8, 2018

By Renan Gurgel Pinho

O objetivo deste trabalho é investigar a esferoidização do aço SAE 1080 e os respectivos efeitos da variação do tempo na microestrutura final e na dureza do material. O aço SAE 1080 foi submetido a recozimento isotérmico, por tempo prolongado, utilizando-se 90, 100 e 120 horas de aquecimento à temperatura de 715ºC. Os resultados mostraram que é possível esferoidizar o aço SAE 1080 nos respectivos tempos escolhidos e perceber aumento da quantidade de esferoiditas, assim como decréscimo na dureza.

Aug 16, 2017

By Manfred Hackl, Sergey Bragin, Alois Seilinger

The demand for hot rolled strip is growing in multiple ways. To remain competitive, new and existing mills must meet arisen challenges in the best possible way. The production of hot strip is a key element of steel production. Since close to half of all steel produced is hot-rolled to strip, mills require maximum throughput and availability combined with geometrical precision and the ability to create optimum material properties. Today there is a clear trend in developing new steel grades with high-strength and improved formability, like 3rd generation AHSS (Advanced High Strength Steels), as well as a trend to produce thinner and wider gauges. This trend challenges hot strip mills because it requires new technologies which provide more flexibility in metallurgical treatment during the rolling process. In order to meet and promote these trends Primetals Technologies is currently working on different concepts and solutions. One example is the development of a new mill stand technology Flex-HI HOT which allows to adapt the last finishing mill stands by efficiently switching from 4-high to a 6-high mode with small work roll diameter based on production needs. Another solution is to apply a permanent 6-high rolling stand at the end of the finishing train. A smaller work roll diameter allows to achieve higher specific thickness reductions and deformation rates resulting in significant thinner hot-strip gauges with valuable metallurgical benefits. The developed solution concepts with technological and metallurgical benefits will be presented in this paper.

Oct 1, 2019

By Ramon Augusto Moretti, Henrique da Rocha Severino, Renato Nascimento de Castro, Fernando Cesar Sousa

Rolling stand 12 (LTx) of long steel, installed in the company A, Piracicaba - SP unit, had presented high levels of vibration, which affected its internal components, such as: shaft, gears and bearings, generating downtime. To evaluate this equipment a study was proposed by the following engineering techniques: Conventional Vibration Analysis, Operational Deflection Shape (ODS) and numerical simulation by the Finite Element Method (FEM). In the Conventional Vibration Analysis, high levels of vibration were observed during manufacturing process, especially when the material reaches the equipment. Impacts generate high values in acceleration, on average 80 m/s² peak to peak. In the moment of impact, misalignment of internal components was observed by ODS. Field results were correlated to those obtained by the Finite Element Method, which allowed to calibrate FEM model. Thus, the most effective structural modification already numerically evaluated was implemented in the system. Afterwards, new measurements by vibration and ODS techniques were performed, and attenuation of vibrational levels and operational mode, which overloaded the internal components rolling stand, were verified.

Oct 1, 2019

By Lucas Silva Fontes

Este estudo trata da metodologia de projeto de tratamento térmico para pinos J. O pino J funciona como fusível mecânico do obturador de produção de petróleo e deve romper numa determinada faixa de carga de cisalhamento, a fim de que não haja excesso de tração no obturador. Foram feitas análise química, análise da intensidade de tensões devida à forma do pino, ensaios de dureza e ensaios de cisalhamento. O estudo foi eficiente para determinar o adequado tratamento térmico a fim de garantir a tensão de cisalhamento estipulada no projeto do pino.

Aug 16, 2017

By Carolina Sartori Marzullo

Apresenta-se a metodologia e sistemática para gestão da capacitação como ferramenta para aumento da competitividade e ganho de resultados do negócio num contexto crítico para o segmento.

Aug 16, 2017

By Alessandro Molinari

In recent times, coke oven machines are acquiring a more prominent role in the coke making process. Apart from the traditional handling of the coal and coke flow, nowadays these machines are also deeply involved in all environmental and process control aspects. Paul Wurth coke oven machines have been developed by Schalke to meet the most recent requirements in terms of emissions control, automation, instrumentation, operability and maintainability. In CSP, Ceará, the new coke making plant represents the status of the art of the technologies applied to the whole coking process; starting from the Coke Oven Batteries and the Gas Treatment Plant developed by Paul Wurth up to the Coke Machines supplied by Schalker Eisenhütte, whose technology is now part of Paul Wurth coke making products portfolio. Present paper describes the plant configuration focusing on Coke Oven Machines and the key factors which are guarantying the success of the project.

Aug 16, 2017

By Lidong Teng

ArcSaveTM is a new generation of electromagnetic stirrer (EMS) from ABB for electric arc furnace (EAF) operation. Its goal is to improve the safety, increase the productivity and reduce costs. Electromagnetic stirring in the melt bath during arc furnace operation will affect the scrap smelting, bath temperature distribution, refining reactions, and also the tapping practice. This paper has summarized the investigation results obtained from the first ArcSaveTM system installed in a 90 ton EBT arc furnace in USA. The hot test results show that ArcSaveTM has enhanced the heat and mass transfer in the arc furnace process. This results in a faster scrap melting rate, lower slag superheat during arcing, more homogenous melt bath, higher decarburization rate and higher EBT free opening frequency. ArcSaveTM has also reduced the tapping temperature and tapping oxygen in the steel. This brings a higher scrap yield and saves ferroalloy consumption in the downstream ladle furnace operation. The lower energy consumption, short tap-to-tap time, and consistent furnace operation bring increased productivity and safety.

Aug 16, 2017

By Andreas Cestonaro

Roll grade evolution in plate mill applications is traditionally following the development in hot strip mills. New grades normally find their way into service only after being successfully implemented in hot strip production. The majority of the plate mills worldwide are using work roll grades that have been invented before the 1980’s. But today the demands in the mills are pushed by sophisticated product mixes and longer rolling campaigns. The result of this development is a higher wear rate on the work rolls and as a consequence roll hardness is increased and advanced roll materials are used. The backup rolls are also affected by this. The wear rate is higher and the mechanical impact in terms of contact pressure and work hardening is increasing. This paper outlines the results of the roll grade development at Gontermann-Peipers and introduces new materials for work and backup rolls for plate mills.

Jul 30, 2018

By Piezanowski Ludivine

With the aim to reduce the hot metal production cost, ArcelorMittal Gent decided to integrate more ores with finer particle size distribution in the raw material mix for the production of blast furnace sinter. As a consequence of such an increase of finer material in the sinter raw mix, the sinter machine productivity and the quality of the sinter are affected. In order to compensate this impact, modern granulation technology can be employed. Within this context, ArcelorMittal Gent has invested in a vertical intensive mixer. The equipment was placed before the existing drums, with a function of “mixer”, whereas the drums are fully optimised for the nodulizing process. The paper presents the results of the industrial operation during the commissioning phase of the new equipment. Gradually increasing the proportion of fine material in the sinter raw mix has made it possible to compare the performances of the old system using drums for mixing and pelletizing with the new system using an intensive mixer combined with a nodulizing.

Aug 1, 2018

By Darina Manova

Plasma assisted surface modification methods have been used to nitride stainless steels in order to enhance hardness and therefore the lifetime of industrial components. Nevertheless, the corrosion resistance is not always preserved since it is very sensitive to the process parameters, either in implantation or in thermochemical diffusion techniques. AISI 316L stainless steel was plasma nitrided using three different techniques: Low Energy Ion Implantation (LEII), Plasma Immersion Implantation (PI3) and conventional DC pulsed plasma nitriding (DCPN). For each method several parameters were tested and some of them were selected to achieve the so called S phase of about 3 µm thickness and no nitrides precipitation. The nitrided layer was characterized with OM and SEM. Hardness was assessed on the surface with Vickers indenter and 25 g load. XRD was performed to characterize the S phase and to detect other phases if present and electrochemical corrosion tests were carried out in 3.5% NaCl solution. Although the S phase thickness in the three groups of samples was comparable, hardness was not and neither was the corrosion resistance. The PI3 samples were the hardest with the best performance in corrosion experiments, resulting in a higher breakdown potential and lower currents.

Aug 8, 2018