Ultralow-Carbon Shadow Mask Strip Double Cold Reduction Process
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Solution Overview
Problem
Current methods for producing thin and ultralow-carbon double cold reduction strips for shadow masks are costly due to the addition of expensive alloy elements and require high annealing temperatures, which increases energy consumption and cannot produce strips with thicknesses less than 0.15 millimeters.
Innovation Solution
The process involves using ultralow-carbon-and-aluminum killed steel with controlled chemical compositions and optimized production steps, including converter steelmaking, continuous billet casting, hot rolling, pickling, cold rolling, annealing, and double cold reduction, to produce a thin and low-carbon shadow mask strip without the need for expensive alloy elements, reducing production costs and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expensive alloy elements (Ti, Nb) are added to ultralow-carbon steel to improve aging resistance and stamping formation uniformity, then the material performance is improved, but the production cost increases substantially and high annealing temperature is required
Solution Approach 1:
The patent extracts and removes the expensive alloy elements (Ti, Nb) from the steel composition, achieving the same technical effect through a different approach. By using ultralow-carbon steel with controlled composition (C: 0.001-0.005%, Si: 0.01-0.05%, Mn: 0.05-0.50%, Al: 0.01-0.10%) and optimized processing parameters, the patent achieves good aging resistance and stamping formation uniformity without relying on costly alloy additions.
Solution Approach 2:
The patent changes the key parameters of the steel composition, specifically maintaining extremely low carbon content (0.001-0.005%) while controlling other alloying elements within specific ranges. This parameter optimization allows the steel to achieve desired properties through compositional control rather than heavy alloying, reducing both cost and annealing temperature requirements.
2Reliability
If high annealing temperature is used to completely anneal the steel with added alloy elements, then the material performance is improved, but the energy consumption increases
Solution Approach 1:
The patent optimizes the annealing temperature parameter based on the simplified composition. Without expensive alloy elements like Ti and Nb, the steel requires lower annealing temperature to achieve complete annealing and desired material performance. This parameter adjustment significantly reduces energy consumption while maintaining or improving material properties.
3Length of moving object
If conventional double cold reduction process is used with rolling ratio of 20-92%, then the thin strip is produced, but the strip thickness cannot be less than 0.15 millimeters
Solution Approach 1:
The patent optimizes the chemical composition parameters (ultralow carbon, controlled Si, Mn, Al content) to enable the steel to withstand higher cold reduction ratios. This compositional optimization allows the material to maintain sufficient ductility and formability even with rolling ratios exceeding conventional limits, enabling production of strips thinner than 0.15mm.
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
This approach results in a shadow mask strip with improved surface quality and mechanical properties, achieving a suitable thickness and surface roughness while reducing production costs and energy consumption, making it suitable for industrial production.
Implementation Method 1
the decarburization time is 20～25 min
Implementation Method 2
vacuum circulation degassing refine technology is utilized
Implementation Method 3
the billet is subjected to hot rolling
Implementation Method 4
pickling and cold rolling
Implementation Method 5
pickling and cold rolling
Implementation Method 6
further to continuous annealing or box annealing so as to regulate the content of residual C to 0.003 wt. % or less
Implementation Method 7
still further to double cold reduction at a rolling ratio of 20 to 92%
Data Source
AI summary
The present invention discloses a double cold reduction strip for shadow mask and a process for producing the same, comprising the following procedures: converter steelmaking→continuous billet casting→hot rolling→pickling and cold rolling→continuous annealing→double cold reduction→finishing and oiling. The weight percentages of essential elements of the shadow mask strip are: C: ≦0.001%, Mn: 0.10˜0.40%, Al: 0.02˜0.06%, Si: ≦0.025%, P: ≦0.015%, S: ≦0.01%, O: ≦0.004%, with remainders composed of Fe and inevitable impurities. Through the composition design for the elements in steel material according to the present invention, on the one hand, the weight percentage of carbon is controlled at a low level; on the other hand, the middle decarburization annealing process is omitted, the annealing temperature is declined, the production period is shortened and the production cost is reduced; through the optimization for rolling parameters and roller processing in the double cold reduction, procedures for degreasing and finishing are removed, and steels with excellent mechanical property and high surface quality are obtained.