Papers by Author: Mihály Réger

Abstract: ISD DUNAFERR Co. Ltd., formerly named as Dunai Vasmű (Danube Ironworks), has a history of over half a century. Currently it is the only factory in Hungary that is operated by integrated steel-making technology and has a hot metal production capacity of 1.7 million tons (Figure 1). The metallurgical combine includes coke production, hot metal production, steel-making, hot and cold rolling, profiling and manufacturing of galvanized products too. Steel is produced by 2 BOFs with the capacity of 135 tons each.

Abstract: The graphite nodule count and size distribution are important structural parameters in the quantitative characterization of the microstructure of ductile cast irons. In several cases, it is observed that local surface damages (cracks or microchip formations) are generated by the final manufacturing process (superfinishing operation), and these defects are originated basically from the hidden (invisible) graphite nodules located directly below surface. Based on measured data obtained by an image analyzer, a stereological model and a simulation algorithm have been developed to analyse the correspondances between the graphite morphology and the defect formation. This method makes it possible to establish a correlation between the microstructure parameters and the occurrence of local surface defects on ductile cast iron components.

Abstract: The paper deals with the stability of centerline inhomogenity of continuously cast slabs and hot rolled products. The centerline segregation is a disadvantageous failure of slabs which can affect the quality properties of the final products. During hot rolling of the slabs the centerline segregation pattern will become thin and stretched and it can also be detected in the middle part of heavy plates and coils. It is a common experience that the centerline segregation of heavy plates can not be easily decreased by post heat treatment. The pattern of the centerline segregation was modeled physically by preparing a sandwich structure of steel plates with different levels of carbon and alloying elements. Homogenization experiments were performed and the samples were examined metallographically. Diffusional calculations proved the governing role of carbon activity which is influenced by the distribution of alloying elements.

Abstract: Industrial data set with 400 CC (continuous casting) steel slabs were analysed by a statistical method for revealing the real connections between the technological parameters, heat transfer model results and the precisely determined centerline segregation index. Because of the poor correlations a new model was developed in which the shrinkage and deformations of the shells of the slabs can also be taken into account. It has been proved that the stopping of liquid movement below about 30 % liquid ratio plays an important role in the centerline segregation formation. The conclusions of the calculations are in good accordance with the results of the metallographical analysis.

Abstract: A study was carried out on Zr-Cr bearing copper electrodes used for resistance spot welding of galvannealed steel strips. One electrode exhibited a series of well-defined layers in which Zn diffused to form β- and γ-brasses; an external layer containing iron was detected in this electrode. Another electrode that exhibited a high degree of damage did not exhibited continuous Zn-diffusion layers in all places, moreover, the Fe-containing layer was either removed, or had it grown to a high extent in some places; the occurrence of Cu-rich particles embedded within the Fe containing layer was observed. Multiple cracks were observed within the γ brass layer in both electrodes. The difference in the observed behaviour of the electrodes can be attributed to a difference in the characteristics of the galvannealed coating of the strips, as the first electrode was used to weld strips in which the layer corresponding to the  phase was well developed, whereas the second electrode was used to weld strips with only an incipient layer. It can be concluded that growth of the  phase changes the thermophysical properties of the zinc coating, affecting the temperature profile during spot welding.

Abstract: The paper deals with the stability of centerline inhomogenity of continuously cast slabs and hot rolled products. The centerline segregation is a disadvantageous failure of slabs which can affect the quality properties of the final products. During hot rolling of slabs the centerline segregation pattern will become thin and stretch and it can also be detected in the middle part of heavy plates and coils. It is a common experience that the centerline segregation of heavy plates can not be easily decreased by post heat treatment. The pattern of the centerline segregation was modeled physically by preparing a sandwich structure of steel plates with different levels of carbon and alloying elements. Homogenization experiments were performed and the samples were examined metallographically. Diffusional calculations proved the governing role of carbon activity which is influenced by the distribution of alloying elements.

Abstract: Industrial data set with 400 CC steel slabs were analysed by a statistical method for revealing the real connections between the technological parameters, heat transfer model results and the precisely determined centerline segregation index. Because of the poor correlations a new model was developed in which the shrinkage and deformations of the shells of the slabs can also be taken into account. It has been proved that the stopping of liquid movement below about 30 % liquid ratio plays an important role in the centerline segregation formation. The conclusions of the calculations are in good accordance with the results of the metallographical analysis.

Abstract: In spite of speedy development of technical tools for examination, the importance of macro structural investigation has not decreased; on the contrary, these methods are in the state of their revival. One of evident reasons for it is the fact, that the results of macro structural examinations and the conclusions drawn from them are in the closest relation with the parameters of technology, reflect their changes, and the deviations from the specified values. It is expedient from time to time to check the methods proved earlier suitable for macro structural investigation, possibly to develop and implement new methods. We have to take in account that the methods now widely applied were developed when the technology, composition, type and quantity of pollutants were still basically different from those of the present. We mention as an example that in the fundamental work of George F. Vander Voort published in 1984 the examinations of macrostructure of continuously cast semi products occupied hardly one to two pages, while nowadays they produce about 90% of the annual 1.1 billion tonne steel quantity in continuous casting plants, thus the decisive proportion of continuously cast semi products examination can hardly be questioned. Taking in consideration the above points of view, in the frame of a consortium work we examined the macrostructure of samples taken from bloom slabs cast on vertical continuous casting machine from nine consciously chosen charges, with methods known from the literature or personal information.

Abstract: This paper deals with the characterization of solidification, cooling and expected properties of continuously cast slabs. Semi-empirical models based on theoretical consideration and on the results of heat transfer model are used for characterization of the following: surface and inner temperature distribution of the cast semis, liquid sump depth and shape, liquid motion intensity resulting in centerline segregation, parameters of the primary dendritic structure (primary and secondary dendritic spacings, columnar to equiaxed transition position, CET). This method provides an opportunity to make a realistic comparison between the solidification and final properties of semis with different chemical compositions as a function of applied casting technologies. The final goal of this research activity in the future is to define a comprehensive quality function for optimizing continuous casting technology.

Abstract: The final microstructure of DP and TRIP assisted steels can evolve after hot working (hot rolling) or during post heat treatment process. In the formation of the final structure a number of different technological parameters have important role, e.g. finishing temperature of rolling, cooling rates, temperature of intercritical annealing, etc. As a result of the individual factors and their combinations a lot of production technology routes are feasible. The effect of the different combinations of these technological parameters on the microstructure can be mapped by a special Jominy end-quench test (so called intercritical Jominy end-quench test) described in this paper. Unlike the traditional Jominy test, in this case there is a partial austenizing between A1 and A3 temperatures which results in a given amount of ferrite in the microstructure before quenching. The amount of ferrite depends on the temperature. In some cases the quenching process was interrupted for a given period of time in order to model the cooling process on the run-out table. During cooling each point of the Jominy specimen has a different cooling rate, so the effect of cooling rate on the microstructure can be evaluated along the length of the specimen.