Lubricating Composition for Continuous Steel Casting
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Solution Overview
Problem
Current lubricating compositions used in continuous steel casting, particularly in open casting processes, fail to ensure effective lubrication, leading to excessive scaling, cracking, and difficulty in lamination due to their poor manageability and quality limitations.
Innovation Solution
A lubricating composition comprising a dispersion of a specifically formulated lubricating powder in a liquid medium, with the powder including carbon, SiO2, Al2O3, Na2O, CaO, fluorides, and transition metal oxides, dispersed in an oily medium like glyceric esters of fatty acids, optimized for a phase transition at less than 600°C, providing improved manageability and quality standards for both close and open casting processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lubricating oils of mineral, vegetable or synthetic origin are used in open casting, then the cost is reduced compared to submerged entry nozzle, but effective lubrication is not ensured leading to excessive scaling and cracking
Solution Approach 1:
The invention uses a composite lubricating composition containing 20-80 wt% casting powder particles (0.1-5 mm size) dispersed in a lubricating oil medium. This composite structure combines the excellent lubricating properties of casting powder with the ease of application and cost benefits of lubricating oils, thereby achieving both effective lubrication and cost reduction.
Solution Approach 2:
The invention changes the physical state parameters of the lubricating composition by dispersing solid casting powder particles in a liquid oil medium, creating a suspension with specific concentration ranges (20-80 wt%). This parameter optimization allows the composition to provide both the lubricating effectiveness of solid powder and the ease of application of liquid oil.
2Reliability
If casting powders are used in close casting, then steel quality is improved, but manageability and ease of application deteriorate due to complex feeding systems required
Solution Approach 1:
The invention introduces a lubricating oil medium as an intermediary carrier to disperse and deliver casting powder particles. This intermediary allows the powder to be easily applied through conventional lubrication systems while maintaining the quality benefits of casting powder, thus improving manageability without sacrificing steel quality.
Solution Approach 2:
The invention changes the physical form of casting powder from pure solid particles to a liquid suspension containing 20-80 wt% powder in lubricating oil. This parameter change enables the use of simple conventional lubrication feeding systems while maintaining the beneficial effects of casting powder on steel quality.
3Ease of operation
If conventional lubricating oils are used, then application is simple, but lubrication effectiveness is insufficient leading to excessive scaling and difficulty of lamination
Solution Approach 1:
The invention creates a composite lubricating composition by dispersing 20-80 wt% casting powder particles in lubricating oil. This composite maintains the ease of application of conventional oils while incorporating the surface-quality-enhancing properties of casting powder, thereby reducing scaling and improving lamination quality.
Solution Approach 2:
The invention creates an asymmetric structure in the lubricating composition by combining solid powder particles (0.1-5 mm size) with liquid oil medium, where the solid particles provide structural lubrication and surface protection while the liquid provides ease of flow and application. This asymmetric combination achieves both simple application and high surface quality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The lubricating composition effectively reduces scaling and cracking, increases casting speed, and allows for the use of poor-quality scrap steel, while maintaining high quality standards and environmental compatibility, with advantages in manageability and shelf-life compared to traditional casting powders.
Implementation Method 1
The lubricating powder is formulated in such a way as to maximize the rate of phase transition, in order to form the first liquid phase at less than 600°C
Implementation Method 2
forming a sintered layer and a molten one. The latter is distributed over the entire free surface of the steel and, thanks to the oscillations of the mould, infiltrates in the gap between it and the outermost shell of solidified steel. In this way, the liquid layer acts as a lubricant.
Implementation Method 3
The latter is distributed over the entire free surface of the steel and, thanks to the oscillations of the mould, infiltrates in the gap between it and the outermost shell of solidified steel.
Implementation Method 4
The liquid that has infiltrated in turn partially solidifies in contact with the ingot mould, the wall of which is generally water-cooled, forming a layer of solid slag. The role of this layer is to allow an adequate level of heat transfer between the solidified steel shell and the ingot mould.
Data Source
AI summary
The present invention concerns a lubricating composition to be used in the casting of steel, in particular in continuous casting processes. In particular, the present invention concerns a lubricating composition for processes for producing steel in continuous casting comprising a dispersion of a lubricating powder in a liquid medium.