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ISIJ International Vol. 64 (2024), No. 12

ISIJ International
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ONLINE ISSN: 1347-5460
PRINT ISSN: 0915-1559
Publisher: The Iron and Steel Institute of Japan

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  1. Vol. 64 (2024)

    1. No.13
    2. No.12
    3. No.11
    4. No.10
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  2. Vol. 63 (2023)

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  3. Vol. 62 (2022)

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  4. Vol. 61 (2021)

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  5. Vol. 60 (2020)

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  6. Vol. 59 (2019)

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  7. Vol. 58 (2018)

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  8. Vol. 57 (2017)

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  9. Vol. 56 (2016)

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  10. Vol. 55 (2015)

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  11. Vol. 54 (2014)

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  12. Vol. 53 (2013)

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  13. Vol. 52 (2012)

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  14. Vol. 51 (2011)

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  15. Vol. 50 (2010)

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  16. Vol. 49 (2009)

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  17. Vol. 48 (2008)

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  18. Vol. 47 (2007)

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  19. Vol. 46 (2006)

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  21. Vol. 44 (2004)

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ISIJ International Vol. 64 (2024), No. 12

CO Reduction Process Technology and Development of Iron Ore Sintering Process

Tingliang Zhong, Xiaohai Li, Xuefeng She, Yanjiang Wang, Peng Liu, Haibin Zuo, Qingguo Xue

pp. 1737-1757

DOI:

10.2355/isijinternational.ISIJINT-2023-318

Abstract

Iron ore sintering is a high-energy-consuming industry, and its high dependence on fossil fuels and the low concentration of CO in the sintering flue gas conceal the truth of the large total amount of CO emissions, which leads to the continuous emission of CO in the sintering flue gas has been harmful to the atmosphere and human health, and it is facing the great pressure of CO emission reduction. On the basis of commercially applied sintering technologies, the mechanism and characteristics of CO emission from sintering flue gas are discussed, and feasible ways to control CO emission in multiple aspects of source control, process emission reduction and end-of-pipe treatment are summarized. The core of source abatement is to reduce the fuel ratio, process abatement is to improve the combustion conditions of fuels to enhance the conversion rate of CO to CO2, and end-of-pipe treatment is to separate or oxidize CO to CO2 by physical or chemical means. Hydrogen sintering technology is the future development direction for source abatement, steam blowing sintering technology is introduced for process control, and catalytic oxidation technology has great prospects for removing CO from flue gas in end-of-pipe treatment. CO has great prospects, but efforts are needed to develop highly active catalysts with anti-poisoning and long-standing stability. Finally, feasible technical routes for sintering flue gas CO reduction and their challenges are analyzed, and a coordinated multifaceted control of source-process-end sintering technologies is proposed to achieve the goal of high-efficiency sintering flue gas CO reduction.

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CO Reduction Process Technology and Development of Iron Ore Sintering Process

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Nucleation-controlled Selection of Metastable Ferrite in Solidification of Fe-22mass%Mn-0.7mass%C Alloy

Taka Narumi, Makoto Ohta, Kengo Fujita, Ryoji Katsube, Hideyuki Yasuda

pp. 1758-1767

DOI:

10.2355/isijinternational.ISIJINT-2024-185

Abstract

The competition between the ferrite and austenite for nucleation in the melt can result in various solidification sequences in the Fe-based alloy. This study demonstrates that the austenite solidification was initiated by metastable ferrite nucleation followed by ferrite-austenite transformation even in Fe-22mass%Mn-0.7mass%C, where the austenite is the primary phase in equilibrium. Time-resolved X-ray diffraction measurements were performed using a time-resolved X-ray tomography apparatus to identify the metastable ferrite nucleation followed by the austenite solidification. X-ray radiography was performed to observe the microstructure evolution through the metastable ferrite nucleation followed by the austenite solidification. The metastable ferrite nucleation was preferably selected when the completely melted specimen was cooled. During subsequent cooling, the ferrite massively transformed to the austenite in the solid state, and multiple austenite grains were produced in a single ferrite grain through ferrite-austenite transformation. The ferrite-austenite transformation was immediately followed by the coarsening of multiple austenite grains. When the ferrite-austenite transformation occurred in a semisolid state consisting of the ferrite and liquid phase, the liquid phase, which isolated the austenite grains, suppressed the coarsening of austenite grain. The typical austenite grain size ranged from 100 to 500 µm. Thus, the present results suggest that the ferrite-austenite transformation following the metastable ferrite nucleation has the potential to control the austenite grain size in as-cast microstructures.

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Nucleation-controlled Selection of Metastable Ferrite in Solidification of Fe-22mass%Mn-0.7mass%C Alloy

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Evaluation for Carbonization Rate of Porous Iron Whisker with CO

Ryota Higashi, Daisuke Maruoka, Yuji Iwami, Taichi Murakami

pp. 1768-1774

DOI:

10.2355/isijinternational.ISIJINT-2024-238

Abstract

Currently, research and developments are underway for steel production using hydrogen-direct reduced iron and large-scale electric arc furnace (EAF). Fe3C has attracted attention as a carburizing agent and clean source of iron for EAF steel production to lower the concentration of impurities. However, production capacity of cementite is low since the carbonization reaction rate of reduced iron pellet is limited by gas diffusion inside micropores in the pellet.

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Evaluation for Carbonization Rate of Porous Iron Whisker with CO

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Effect of Exit Wear Length on the Behavior of Coherent Jet

Fuhai Liu, Bin Tong, Rong Zhu, Guangsheng Wei, Kai Dong

pp. 1775-1782

DOI:

10.2355/isijinternational.ISIJINT-2024-153

Abstract

The copper was the main manufacturing material to produce the coherent lance for enhancing the cooling effect. Due to the low hardness of copper and high-temperature environment, the exit of Laval nozzle would be worn off, resulting in suppressing the impaction ability of supersonic oxygen jet. In order to investigate the effect of wear length on the behavior of coherent jet, both high-temperature experiment and numerical simulation have been carried out, and the axial velocity, total temperature and oxygen fraction were measured in the experimental test to verify the accuracy of simulation model. Based on the result, the overexpand phenomenon was generated due to the Laval nozzle exit wear off, which improved the shock wave intensity at the tip of Laval nozzle, resulting in a lower axial velocity at the velocity potential core. With a longer wear length, the vorticity of the coherent jet periphery is increased, which causes more thermal energy of combustion flame being released prematurely near the coherent lance tip, leading to a shorter velocity potential core.

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Effect of Exit Wear Length on the Behavior of Coherent Jet

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Analysis of Generation Mechanism of Unimodal and Bimodal Waveform Detection Signals of a Whole Roll Flatness Meter

Tongyuan Zhang, Shuang Liao, Juntao Gao, Wenkai Hao, Hongmin Liu

pp. 1783-1794

DOI:

10.2355/isijinternational.ISIJINT-2024-169

Abstract

Under certain conditions, the whole roll flatness meter outputs a bimodal waveform signal, which is clearly different from the conventional unimodal waveform signal. Since detection relies on the extraction of crest values and the values of the two waveforms do not have the same linearity, the presence of the two waveforms of different channels will clearly give rise to errors in the calculated flatness distribution. To develop an effective extraction method, it is necessary to accurately analyze the evolution of the waveforms. In this paper, the finite element method is used to calculate the load of the sensor, the stress distribution of each analysis surface and the deformation of the sensor mounting hole during the real-time detection to analyze the mechanism of the waveforms. The results show that unimodal and bimodal waveforms are produced under different strip tension and wrap angle conditions. In addition, the radial stress of the roll surface always presents two stress wave distributions. With increasing strip tension or wrap angle, the phase difference between the two waves increases. The stress distribution will change the deformation trend of the mounting hole and affect the stress distribution state of the sensor. When the phase difference of the stress waves exceeds the covering range of the sensor, the output signal changes from a unimodal waveform to a bimodal waveform. Finally, by setting up an experimental platform with variable tension and wrap angle, the relationship between the output waveforms and the working conditions in the simulation is reproduced.

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Analysis of Generation Mechanism of Unimodal and Bimodal Waveform Detection Signals of a Whole Roll Flatness Meter

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Friction Stir Welding of 1.4 GPa-Grade Tempered Martensitic Steel

Yasuyuki Miyano, Hiroki Washiya, Hiromu Sato, Yasuhiro Aoki, Mitsuhiko Kimura, Kohsaku Ushioda, Hidetoshi Fujii

pp. 1795-1803

DOI:

10.2355/isijinternational.ISIJINT-2024-175

Abstract

Thermal hysteresis in fusion welding causes significant weld deterioration in medium- and high-carbon steels. Therefore, the development of an effective alternative welding process is required. Friction stir welding (FSW) is a solid-state welding process performed in an atmosphere that reduces the risks associated with melting and solidification of metals, making it an effective alternative method. Furthermore, it facilitates a flexible in-process control of heat input, which can be achieved by controlling the welding parameters. Considering these, the authors conducted a series of studies to elucidate the characteristics of FSW for medium- and high-carbon steels, including high-strength tempered steels.

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Friction Stir Welding of 1.4 GPa-Grade Tempered Martensitic Steel

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In-situ Observation of Sliding Interface in Commercially Pure Titanium Sheet with a TiO2 Film

Ryotaro Miyoshi, Genki Tsukamoto

pp. 1804-1812

DOI:

10.2355/isijinternational.ISIJINT-2024-090

Abstract

To investigate the factor that cause the variation in friction coefficient by sliding conditions in commercially pure titanium coated titanium oxide film, in-situ observation of sliding interface during ball on block test and EBSD analysis of a sliding cross-section were performed. At the vertical load of 0.1 N, the friction coefficient stabilized at a low level of approximately 0.12. However, at 0.5 N, the friction coefficient varying widely in the range of 0.20–0.80. At 2.0 and 4.0 N, the friction coefficient stabilized at a high level, approximately 0.30 and 0.40, respectively. At the vertical load of 0.5 N, the friction coefficient was negatively correlated to the Taylor factor for the uniaxial compression of the titanium grains directly beneath the film. Thus, it can be presumed that the ploughing term of friction coefficient increased due to the enhancement of compressive strain of titanium. On the other hands, at vertical loads of 2.0 and 4.0 N, the ball is always in contact with multiple grains due to the larger contact area. As a result, it is considered that the influence of Taylor factor was equalized and the variation of friction coefficient got smaller.

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In-situ Observation of Sliding Interface in Commercially Pure Titanium Sheet with a TiO2 Film

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Effect of Cu Addition on Localized Corrosion Originating from MnS Inclusions for Low-alloy Steel in a 3% NaCl Solution

Takuya Hara, Hiroyuki Fuji

pp. 1813-1819

DOI:

10.2355/isijinternational.ISIJINT-2024-184

Abstract

The effect of MnS inclusions on the localized corrosion of low-alloy steel in a 0.5 mol/kg (3%) NaCl solution was investigated to propose countermeasures for inhibiting localized corrosion initiated by MnS inclusions. Low alloy steels without MnS inclusions did not corrode in a 0.5 mol/kg (3%) NaCl solution, regardless of the addition of Cu. That is, no matrix improvement effect due to solute Cu was confirmed. Slight corrosion occurred in the Cu containing steel with MnS inclusions; however, the MnS inclusions remained. Cu7.2S4 precipitated on the MnS in contact with a 0.5 mol/kg (3%) NaCl solution. Therefore, Cu7.2S4 precipitates on the MnS inclusions during immersion, which could suppress the localized corrosion initiated by the MnS inclusions because Cu sulfide is not dissolved based on potential-pH diagram. The addition of Cu in a 0.5 mol/kg (3%) NaCl solution does not improve the corrosion resistance of the matrix due to solute Cu but does suppress localized corrosion initiating from MnS by precipitating Cu sulfide on MnS.

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Effect of Cu Addition on Localized Corrosion Originating from MnS Inclusions for Low-alloy Steel in a 3% NaCl Solution

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Effect of P Addition on the Corrosion Resistance of Steels before and after Rust Formation

Chihiro Hayama, Mariko Kadowaki, Yoshiharu Murase, Hideki Katayama, Toru Hara, Yuka Hara, Hikari Watanabe, Isao Shitanda, Masayuki Itagaki

pp. 1820-1828

DOI:

10.2355/isijinternational.ISIJINT-2024-191

Abstract

This study investigates the effect of P addition on the corrosion resistance of steels before and after rust formation. Electrochemical measurements and surface analysis of P-containing steels (Fe-0.5 mass% P, Fe-1.0 mass% P, and Fe-1.5 mass% P) were conducted to analyze the contribution of P to their initial corrosion resistance before rust formation. The results showed that the initial corrosion resistance of the steel worsened with increasing P content. According to the surface analysis conducted by SEM/EDS, more P segregations at the grain boundaries occurred with higher P content. Polarization measurements indicated that these P segregations became initiation sites for localized corrosion, resulting in a decrease in the initial corrosion resistance.

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Effect of P Addition on the Corrosion Resistance of Steels before and after Rust Formation

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Alloying Pre-alloyed Fe–Mo Powders by Silicon Carbide Addition

Nattaya Tosangthum, Thanyaporn Yotkaew, Rungtip Krataitong, Monnapas Morakotjinda, Preeya Nakornkaew, Piyanuch Nakpong, Ruangdaj Tongsri

pp. 1829-1837

DOI:

10.2355/isijinternational.ISIJINT-2024-139

Abstract

This work demonstrated that the silicon carbide addition to pre-alloyed Fe–Mo powder could result either in the formation of steel or iron microstructure depending on the added silicon carbide content. With 1.0 wt.% silicon carbide addition, slowly cooled sintered Fe–Mo–Si–C alloys showed steel microstructures consisting of proeutectoid ferrite and eutectoid transformation product in the form of ferrite + carbide mixture. With 2.0 wt.% silicon carbide addition, slowly cooled sintered Fe–Mo–Si–C alloys with Mo contents of ≥ 0.85 wt.% microstructures comprised ferrite + austenite constituents in the forms of either degenerate upper bainite or ausferrite. With ≥ 3.0 wt.% silicon carbide addition, ductile iron-like microstructures were developed in sintered Fe–Mo–Si–C alloys. The change of microstructures in experimental sintered alloys was attributed to the combined effect of alloying molybdenum, silicon, and carbon elements. Tensile strength and hardness increased with increasing added SiC content while ductility varied with microstructural components.

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Alloying Pre-alloyed Fe–Mo Powders by Silicon Carbide Addition

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Effect of Al Addition on Thermal Fatigue Deformation Morphology in High Heat-resistant Ferritic Stainless Steel SUS444

Tetsuyuki Nakamura, Kyosuke Yoshimi

pp. 1838-1846

DOI:

10.2355/isijinternational.ISIJINT-2024-194

Abstract

Ferritic stainless steels are used for automobile exhaust parts because of their high heat and corrosion resistance. Among them, parts located upstream near the engine, so-called hot-end parts, for example, exhaust manifolds, are required to show excellent heat resistance. Since thermal fatigue is induced by repeating heating and cooling with mechanical strain restriction, thermal fatigue resistance is one of the most important properties of upstream exhaust-parts materials.

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Effect of Al Addition on Thermal Fatigue Deformation Morphology in High Heat-resistant Ferritic Stainless Steel SUS444

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Real-time Observation of Stress-strain Behavior beyond Necking in Martensitic Steel by in-situ Synchrotron X-ray Diffraction

Avala Lavakumar, Sukyoung Hwang, Kazuho Okada, Myeong-heom Park, Atul Haris Chokshi, Nobuhiro Tsuji

pp. 1847-1852

DOI:

10.2355/isijinternational.ISIJINT-2024-093

Abstract

In general, the stress-strain relationship of materials obtained by standard uniaxial tensile test, which can identify the hardening behavior only up to necking. Beyond necking, the material behavior is usually estimated by extrapolating or numerical modelling based on hardening behavior prior to the uniform elongation. This study investigated the post-necking hardening behavior of a fully martensitic steel by in-situ synchrotron X-ray diffraction during tensile deformation. From the in-situ results, the dislocation density, lattice strain and phase stress were calculated within the necked region and outside the necked region. A near steady-state flow with some hardening was observed within the necked region of a martensitic steel. However, beyond uniform elongation, outside the necked region the dislocation density and phase stress decreased slightly, suggesting stress relaxation. Steady-state flow and dislocation densities at large strains suggest dynamic recovery occurs in the martensitic steel at room temperature.

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Real-time Observation of Stress-strain Behavior beyond Necking in Martensitic Steel by in-situ Synchrotron X-ray Diffraction

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Editorial Board, Copyright Page and Announcements

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