Metallurgical processes

Metallurgical processes

This project aims to study the particle flow and packing in relation to burden distribution and segregation control for BF top charging, specifically, (1) model lump discharge and distribution in blast furnace, (2) study and simulate different discharge options (separately or mixed with sinter), (3) simulate blast furnace burden distributions with different lump ratio, strength and RDI.

Project Leader: Dr Zongyan Zhou, Monash-JITRI

This project aims to (1) numerically examine the flow, heat transfer, ore softening, and the thermal behaviour of particles in reactors related to iron ore sintering bed, (2) conduct parametric study for the control of grain size distribution and bulk density, particularly the sintering properties of low-grade iron ore under different conditions and (3) examine the liquid dispersion in porous media.

Project Leader: Dr Zongyan Zhou, Monash-JITRI

The project involves (1) modelling BF hearth working status under (1a) changing melting properties of sinter and lump ores; (1b) changing thermal properties of slag at different stage in hearth area; (1c) changing dynamic status of gas, molten slag and hot metal and solid particles; (2) modelling tapping dynamics under different slag chemistry.

Project Leader: Prof Aibing Yu & Dr Baoyu Guo, Monash-JITRI

This project aims to develop an integrated BF process model that can aid design and process control, and optimise BF practice under different conditions. This is achieved through: (1) developing an integrated BF process model to describe the phenomena and performance of a BF; (2) investigating the effects of key variables; and (3) formulating optimal operational strategies under different production conditions.

Project Leader: Dr Shibo Kuang, Monash-Baosteel-JITRI

This project aims to: (1) refine the ß grains while improving homogeneity by firstly investigating the forged microstructure under different processing parameters and identifying the cause of the heterogeneities along with recrystallization behaviour; (2) evaluate and identify thermomechanical processing schemes for ß grain refinement; (3) evaluate the mechanical properties of the near-ß Ti alloy with different heat treatment processes and with different thermomechanical history concentrating on the influence of prior grain size and structure on subsequent microstructure evolution and development that affects the final properties; (4) evaluate the HIPping process and seek to incorporate microstructure feature modelling into simulation of the HIPping process.

Project Leader: A/Prof Ruiping Zou & Dr Samuel Lim, Monash-Baosteel

This project aims to study melting properties and viscosity of CaO-Al2O3-based mould fluxes, their crystallisation behaviour and heat transfer, and interaction of these fluxes with high-Al steel to establish a scientific ground for the development of mould fluxes for the continuous casting of high-Al steel.

Project Leader: A/Prof Jianqiang Zhang, UNSW-Baosteel

This project aims to: (1) determine the difference of the inclusion compositions present in the spring steels between Baosteel and other companies through analyses of the products and further analyse the reasons for the difference; (2) determine the formation mechanisms of the inclusions through analyses of the spring steels sampling from different stages of the process in Baosteel; (3) provide suggestions to Baosteel for control of the inclusion size below 15 µm through experimental investigation and theoretical analyses of the effects of refining slag composition and deoxidation process on composition and shape of the inclusions; (4) investigate the effects of refining process, quenching and tempering, number and size distribution of precipitates on steel strength after the additions of V, Nb and Ti.

Project Leader: Prof Baojun Zhao, UQ-Baosteel

This project aims to develop 1) a novel method to capture the randomness of the surface asperities and wear particles; and hence to reveal the mechanism of wear at the contact zone; (2) a multi-field method for analysing the effects of contact stresses and heat transfer from micro-scale to macro-scale, coupling both the properties of the surface materials in contact sliding; and (3) an innovative method to integrate the asperity/asperity-lubricant interaction with the micro wear process; and thereby to explore the mechanism of surface scratching.

Project Leader: Prof Liangchi Zhang, UNSW-Baosteel

This project research aims to reveal the underlying mechanisms behind the challenges and in turn develop practical solutions for overcoming the relevant difficulties encountered in the production lines of Baosteel: (1) clarify how roll elastic deflection, additives/particles in lubricant influence rolling pressure, friction distribution, deformation-induce temperature variation in the rolling bite, and roll-to-strip surface texture transfer in the regime of thin strip rolling; and (2) try to find proper lubricant or lubrication medium to minimize the surface damage to difficult-to-roll metals that are prone to oxidation, spalling, adhesion and damaging by debris particles.

Project Leader: Prof Liangchi Zhang, UNSW-Baosteel

This project aims to (1) optimize refining conditions to improve the quality and productivity of current products; (2) develop new high-end gear steel with sophisticated MnS precipitation control; (3) provide technical support of commercial high-end gear steel products.

Project Leader: Prof Baojun Zhao, UQ-Baosteel

The overall aim of this project is to investigate and understand the actual causes and mechanisms of wire fracture during the manufacturing of the high strength steel cords, and then to design/propose an effective and practical technique/method to reduce or even eliminate the fracture. The objectives/tasks include: (1) Under the support of Baosteel project, to conduct failure analysis using advanced materials characterization technologies, such as TEM, SEM, EBSD, neutron diffraction and nanoindentation, to identify the actual causes of the fractures at both descaling and stranding processes and post-coating annealing in the manufacturing of high grade (3600 MPa and 4000 MPa classes) steel cords; (2) To comprehensively investigate the influence of microalloying the current high grade cord steels with alloying elements, such as Cr, Co, V and others on the formation of non-metallic inclusions, formation of grain boundary cementite and cementite dissolution. Based on the outcomes, a plan for modifying the compositions of the currently used high grade cord steels will be proposed; (3) To study the effects of post-brass coating annealing temperature on the strength and toughness of steel wires; (4) To investigate the causes and mechanism of cementite dissolution during cold drawing and how such dissolution influence the microstructure and mechanical properties of the steel wires; (5) To investigate the effect of heat flow generated during cold drawing on cementite dissolution and fracture of the high strength steel cords through computational simulation; (6) To design/proposal an effective and practical technique/method that can overcome the problem followed by middle scale trial at Baosteel Research Institute.

Project Leader: Prof Han Huang, UQ-Baosteel