Production of hot strip by the
conventional continuous casting route requires reheating and
roughing of continuously cast slabs (150-250mm) by 2-high roughing
mills into sheet bar (30-60mm) followed by hot rolling of the
sheet bar by a tandem strip mill or steckel mill into strip of
the aimed thickness. Recent thin slab casting technology has
made it possible to eliminate the roughing mills and reduce the
number of roll stands in the tandem strip mill. If the steel
melt is directly cast into strip, as originally conceptualized
by Henry Bessemer in 1856, substantial reductions in investment
and operational costs would be expected. This idea has attracted
the attention of a number of investigators, but without any success
in industrialization.
In the last decade, however, attempts were made in Japan, Europe,
and the U.S.A. at the pilot plant scale to overcome the inherent
difficulties of sustaining mold containment, controlling the
melt meniscus level in the mold containment, adjusting the strip
tension and roll gap, and improving the profile and thickness
of the strip. Successful performance has been reported in several
of the pilot plant investigations on a few tons per cast basis.
Nippon Steel Corporation has announced the first commercialization
of the twin-drum type strip caster, which is to come onstream
in 1997, and will be used to cast austenitic stainless steel
strip 2.0-5.0mm in thickness and 760-1,330mm in width at the
60 tons per cast scale.
A schematic of the twin-drum type strip caster is shown in the
figure. This process casts steel from the ladle to the tundish
and from the tundish via nozzle into a mold containment comprising
twin-drum rolls and side dams. The drum rolls are made of steel,
water cooled inside, and ceramic coated outside for heat transfer
control and lubrication. The side dams are made of ceramics
and preheated to prevent the formation of a steel shell.
The productivity of a twin drum type strip caster is given in
the figure in comparison with that of a thin slab caster and
conventional slab caster. At present, the strip caster can only
produce 0.5 million ton/year, and variable cost of strip casting
is not substantially lower due to the cost of the nozzle, side
dams and rolls. Accordingly, the strip caster is not in a position
to replace existing conventional casters for casting commodity
carbon steels in mass, but is rather suited to cast speciality
steels in small lots.
The through-thickness structure of the cast strip is largely
the same as the surface layer of conventional continuous cast
slabs, i.e., chilled crystals at the surface are followed by
fine columnar dendrites, but the central equiaxed zone is very
thin and center segregation much less.
Some grades of steels require texture control by applying reduction
in excess of a threshold value which cannot be met if the starting
material thickness is as thin as the cast strip thickness. Commodity
carbon steels might fall in this category. Further exploration
of such relations as those between the reduction ratio, texture,
and properties is, therefore, needed before extensive use of
strip casting will be possible. |
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