[0001] The present invention relates to a process for continuously casting thin slabs, and
particularly to a process for continuously casting thin slabs and carrying out rolling
of the slabs before they are completely solidified, in which the rolling reduction
force can be released during the rolling so that thin slabs free of internal defect
with varied thicknesses can be produced.
[0002] A typical process for making thin plates comprises continuously casting slabs, cooling
the slabs, and then subjecting the once-cooled slabs to hot rolling. According to
this process, however, it is necessary to heat the slabs which have been air-cooled
after casting, and this process is disadvantageous with respect to energy consumption.
[0003] Recently, in view of the advantage that it can reduce energy costs markedly, a direct
rolling process is under development. The direct rolling process is a process for
directly supplying cast slabs from a continuous casting machine to a hot rolling mill
without intentional cooling. When thin cast slabs are used, it is possible to omit
rough hot rolling steps from the direct rolling process. Currently, many attempts
have been made to develop a new and practical continuous casting process for such
thin slabs.
[0004] The direct rolling process using such thin slabs is advantageous because it is possible
to omit rough hot rolling steps and because it is possible to achieve a less energy
consuming, simple process as a whole for making steels in a more efficient manner.
[0005] A recently-proposed process for producing thin slabs is a process for casting slabs
with a mold having the same thickness as is conventional, but not with a mold having
a reduced thickness, and carrying out rolling of the cast slab while a central portion
of the slab is unsolidified to reduce the thickness. This process for carrying out
roll reduction before the slab is solidified is referred to as "squeeze reduction".
[0006] It is now required that the thickness of the cast slab itself be changed during casting
depending on the types of steel, production lots, and the sheet thickness required
in the succeeding steps. For this purpose, a continuous casting operation is carried
out so as to achieve not only squeeze reduction of an unsolidified cast slab to reduce
the thickness of the slab, but also the release of the roll reduction force to increase
or change the thickness of the cast slab. However, in such a case the presence of
a transitional area from a slab having one thickness to another slab having another
thickness, i.e., an unstable area, is unavoidable.
[0007] Usually, in case of squeeze reduction, since the mold has a small thickness, an immersion
nozzle must employ a rather thin refractory wall compared with conventional ones.
Breaking of the immersion nozzle due to corrosive damage to the refractory easily
occurs. Thus, since the service life of the nozzle is short, the number of strands
which can be cast simultaneously is at most 3. In this respect, continuous casting
of 7 or 8 strands is possible for conventional processes. Since the number of strands
is limited, therefore, it is critical how to reduce the unstable area in order to
increase the yield of the product.
[0008] In addition, if internal defects are once formed in a cast slab upon release of the
roll reduction force during casting, portions of the slab where such internal defects
are present must be rejected as unstable areas. Thus, there is a great need for the
development of a casting method which can successfully prevent occurrence of internal
defects in cast slabs at the time when the roll reduction force is released in order
to increase the yield of the product.
[0009] Namely, in order to further improve the yield of the product, it is also advantageous
not only to reduce the length of the unstable area upon release of the roll reduction
force, but also to ensure the quality of the slab.
[0010] However, the prior art does not suggest anything at all about how to reduce the length
of the unstable area, or how to prevent formation of internal defects in the slab
at the time of release of the roll reduction force during squeeze reduction.
[0011] An object, therefore, of the present invention is to provide a process for continuously
casting thin slabs and carrying out squeeze reduction of the slabs, in which the roll
reduction force can be released during casting so as to change the thickness of the
slab while preventing formation of internal defects.
[0012] Another object of the present invention is to provide a process for continuously
casting thin slabs and carrying out squeeze reduction of the slabs, in which the roll
reduction force can be released to decrease the length of an unstable area of the
slab to be as short as possible and to change the thickness of the slab during casting
while preventing formation of internal defects.
[0013] It is to be noted, however, that it is impossible to reduce the length of an unstable
area and to ensure quality of a slab merely by adjusting the roll gap at the time
of release of the roll reduction force during casting. Take for example the case in
which the roll reduction force is released while casting is carried out at a constant
casting speed. An unsolidified slab, i.e., a slab which has not yet been solidified
completely, if it is free from roll reduction pressure, swells again to result in
bulging due to the static pressure of molten steel. The bulging will cause a marked
segregation in a central portion of the slab, as well as internal cracking, resulting
in a further degradation in quality of the unstable area.
[0014] If the operation to release the roll reduction force is called a "release operation",
the release operation starts when the changing point of the slab passes the final
reduction roll. After this point, the roll reduction force is released until a predetermined
slab thickness is obtained. Regarding these features, the inventors of the present
invention found the following.
[0015] First of all, the inventors noted that even when the thickness is increased by releasing
the roll reduction force during squeeze reduction, bulging does not occur under constant
cooling conditions if the solidifying front, i.e., the position where the slab is
solidified completely, is within the squeeze reduction zone where an unsolidified
portion always remains. Thus, the inventors found that if the following conditions
are satisfied when the thickness of the slab is changed, it is possible to change
the thickness of the slab successfully while preventing formation of internal defects,
thereby completing the present invention.
(i) The casting speed is reduced, for example, from a stable normal casting speed
to another casting speed equal to or lower than the casting speed at which the thin
slab can be solidified completely within the squeeze reduction zone, provided that
the thickness of the slab has been reduced to a target thickness under given cooling
conditions. Under these cooling conditions, the roll reduction force is released during
squeeze reduction while the solidifying front is kept at a point upstream from the
end of the roll reduction zone.
(ii) After the target thickness of the slab is achieved, the casting speed is then
increased to the stable normal casting speed for the target thickness of the slab.
[0016] As a result, the present invention is, in a broad sense, a continuous casting and
squeeze reduction process for producing thin slabs in which cast slabs having an unsolidified
portion are reduced in thickness in the roll reduction zone, characterized in that
while the solidifying front is kept at a point upstream of the roll reduction finishing
area, for example, by controlling the casting speed, the roll reduction force is released
during squeeze reduction to change the thickness of the slab to a target thickness.
[0017] In another aspect, the present invention is a continuous casting and squeeze reduction
process for producing thin slabs in which cast slabs having an unsolidified portion
are reduced in thickness in the roll reduction zone, characterized in that the casting
speed is changed to a casting speed which is lower or higher than the casting speed
at which the cast slab having a target thickness after changing the thickness can
be completely solidified within the squeeze reduction zone, then while the solidifying
front is kept at a point upstream of the roll reduction finishing area, simultaneously,
or during or after changing the thickness, the roll reduction force is released until
a target thickness of the slab is achieved, and the casting speed is changed to the
normal casting speed for the target thickness of the slab.
[0018] According to a preferred embodiment of the present invention, it is desirable that
the changing in the casting speed be started at the same time or prior to the time
when the changing point of the cast slab passes the roll reduction finishing area.
[0019] Fig. 1 is a vertical side view in section of a continuous casting machine employed
for carrying out the process of the present invention.
[0020] Fig. 2 is a graph showing relationships between the thickness of a cast slab and
the casting speed, which are obtained when the thickness of slab is changed in accordance
with a process of the present invention.
[0021] Fig. 3 is a graph similar to that of Fig. 2, showing the change of thickness of cast
slabs in a comparative example.
[0022] Fig. 4 is a longitudinal side view of the shape of a cast slab during process in
which the roll reduction force is released in accordance with the present invention.
[0023] Fig. 5 is a longitudinal side view of the shape of a cast slab during the release
of the roll reduction force in a comparative example.
[0024] Fig. 6 is a longitudinal vertical view in section of a cast slab showing the occurrence
of internal defects in the slab during the release of the roll reduction force in
a comparative example.
[0025] Fig. 7 is a graph showing the results of the working examples.
[0026] Fig. 1 is a schematic illustration of the structure of a continuous casting machine
(hereunder referred to merely as "machine") which is preferably used for carrying
out the process of the present invention.
[0027] In the figure, the machine comprises a mold 1, a roller apron zone 2, and pinch roll
zone 3. The machine may be any type of machine, e.g., a conventional curved type or
a VB type. The roller apron zone 2 comprises a series of groups of rolls 4, some of
which may be groups of driving rolls 4'. In the roller apron zone 2 is provided a
squeeze reduction zone 7 which comprises a plurality of segments 6, each having rolls
4 and/or driving rolls 4' provided with a reduction cylinder 5.
[0028] The squeeze reduction zone 7 located within the roller apron zone 2 comprises a total
of 5 segments, as shown in the drawings, and is located within about 6 m from a meniscus
10 of molten steel 9 in the mold 1.
[0029] Mold 1 measures about 90 - 150 mm in thickness and about 1000 - 1800 mm in width.
Cast slabs having these dimensions are reduced to a thickness of about 30 - 70 mm
by squeeze reduction. A preferred squeeze reduction pattern for the machine mentioned
above, therefore, is such that a reduction of about 5 - 35 mm is scheduled for each
of the segments.
[0030] A preferred normal casting speed ranges from 3.0 m/min to 5.0 m/min. Cooling conditions
can be adjusted so that such a casting speed can be ensured. The preferred casting
speed varies depending on the thickness of the slab, and hereunder it will sometimes
be referred to simply as a "predetermined casting speed".
[0031] However, depending on the production schedule, it is sometimes necessary to continue
casting by releasing a roll reduction force to restore the slab to its original thickness
of 100 mm from a thickness of 50 mm during casting based on the relationship between
the type of steel and the casting speed.
[0032] If only the roll reduction force is released without a reduction in the casting speed,
although there will be no re-swelling due to bulging upon release of the roll reduction
force in an area where the solidified shells have been completely bonded with each
other by roll reduction, there will be a re-swelling portion due to bulging upon release
of the roll reduction force in an area where solidification has not yet been completed.
[0033] Namely, if the roll reduction force is released immediately in an area between the
point where the roll reduction starts, the solidifying front moves downstream from
the roll reduction finishing area within the roll reduction zone, and the slab swells
due to bulging, causing possible marked deterioration in internal quality of the slab,
such as formation of internal cracking and a degradation in central segregation.
[0034] It is advisable that the release of the roll reduction force not be carried out immediately
after the changing point of the thin slab passes the roll reduction zone, but that
the release of the roll reduction force be carried out after or at the same time that
the casting speed is lowered to a speed at which the thin slab after roll reduction
can be completely solidified within the squeeze reduction zone. Thus, it is possible
to gradually increase the slab thickness to restore its original thickness while successfully
avoiding occurrence of bulging which inevitably occurs in a transitional period in
the release of the roll reduction force. According to this process of releasing the
roll reduction force, it is possible to produce cast slabs which are free of deterioration
of internal quality even in a transitional area during the thickness changing period
so that continuous casting can be continued efficiently without a reduction in yield.
[0035] The process of the present invention will be described in further detail with reference
to Fig. 2. Fig. 2 is an illustration showing relationships between the thickness of
a cast slab and the casting speed, which are obtained when the thickness of a slab
is changed in accordance with a process of the present invention.
[0036] The following description is based on the case in which squeeze reduction is carried
out under usual conditions so as to reduce the thickness of slabs from 100 mm to 50
mm, and then the thickness is returned to 100 mm. The casting speed is changed at
the same time when the release of the roll reduction force is carried out, i.e., when
the changing point of the slab passes the roll reduction finishing area of the roll
reduction zone.
[0037] In the beginning, the casting of a slab 100 mm thick is started and continued at
a given casting speed of 4.0 m/min, and squeeze reduction is carried out to reduce
the thickness of the slab to 50 mm. It is assumed that it is necessary to change the
thickness of the slab from 50 mm to 100 mm because of a requirement from a production
schedule for example. A shift of operating conditions at this time is started when
the changing point of the slab passes the roll reduction finishing area of the squeeze
reduction zone. Namely, the casting speed is continuously reduced to 2.0 m/min, and
simultaneously the roll reduction force is also continuously released. The target
casting speed mentioned above is equal to or lower than the casting speed at which
a cast slab having a target thickness, 100 mm in this example, is completely solidified
within the roll reduction zone. Thus, the casting speed can be varied depending on
a target thickness of the slab. In other words, although the solidified front moves
upstream or downstream of the roll reduction zone depending on a lowering of the casting
speed and on a release of the roll reduction force, so long as the solidifying front
is essentially located upstream of the roll reduction finishing area within the squeeze
reduction zone, the casting speed as well as the rate of releasing the roll reduction
force are not limited to any specific ones.
[0038] The rate of decreasing the casting speed is not limited to a specific level, and
it is preferable that the casting speed be lowered as quickly as the machine permits
from the viewpoint of avoiding the occurrence of unstable states as completely as
possible. In Figure 2, the length "a" means the length of time required to reduce
the casting speed to a target speed.
[0039] After the casting speed is lowered to a given casting speed, the casting is continued
at the given casting speed. On the other hand, during this period of time, the release
of the roll reduction force is also continued. After the roll reduction force is reduced
to a target level, i.e., after a target thickness of the cast slab is achieved, then
the casting speed begins to return to the normal casting speed. The length "b" up
to this point of time means the length of time required for the solidifying front
located upstream from the roll reduction finishing area of the roll reduction zone
to return to the roll reduction finishing zone.
[0040] Namely, the solidifying front which is once moved upstream of the roll reduction
finishing area due to a reduction in the casting speed continues moving gradually
to downstream of the roll reduction finishing area as the thickness of the slab increases.
The solidifying front returns to the roll reduction finishing area after time b elapses.
After this point of time, the casting speed can be increased by adjusting cooling
conditions while the solidifying front is kept at this position. Alternatively, the
solidifying front may be situated upstream of the roll reduction finishing area after
the elapse of time b, and the solidifying front may be returned to the roll reduction
finishing area by increasing the casting speed.
[0041] The length (a + b) in Figure 2 corresponds to the length of an unstable area, and
it is highly advantageous to decrease this length as much as possible to further improve
the yield. In order to achieve this purpose, according to an embodiment of the present
invention, the length "a" or "b" is decreased as much as possible.
[0042] Thus, according to another embodiment of the present invention, the casting speed
may start to change prior to the time when the changing point of the slab passes the
roll reduction finishing area. This embodiment will be described below.
[0043] The point of time when the casting speed is changed, i.e., the starting point of
a change in thickness is determined on the basis of the point in time when the changing
point passes the roll reduction finishing area. A target casting speed to be reached
is previously determined to be 2.0 m/min at which speed, in this case, a cast slab
100 mm thick can be solidified completely at the roll reduction finishing area.
[0044] Next, the point of time at which the thickness of a slab is required to be changed
to 100 mm under usual conditions due to the requirements of a production schedule
is determined on the basis of the roll reduction finishing area.
[0045] Further, the time required to reduce the casting speed from 4.0 m/min to 2.0 m/min
is determined.
[0046] In the above-mentioned case, for example, if the deceleration rate for the casting
speed is 2.0 m/min
2, the casting speed can be lowered to 2.0 m/min in 1 minute, and at least one minute
is necessary to reduce the casting speed from 4.0 m/min to 2.0 m/min. Three minutes
are necessary for the casting speed to return to a given stable casting speed before
the changing point of the slab passes the roll reduction finishing area which is located
6 m downstream from the meniscus in the mold. Thus, the casting speed may start to
be lowered from the point 4 minutes upstream from the point of time or location when
or where the changing point of the slab passes the roll reduction finishing area.
[0047] According to the present invention, therefore, in order to change the thickness of
a cast slab, first of all, a stable casting speed is changed to a casting speed lower
than the speed at which a thin slab is completely solidified within the squeeze reduction
zone. Provided that the target thickness of a thin slab is 100 mm and the distance
from the molten steel meniscus in the mold to the roll reduction finishing area is
6 m, the above-mentioned casting speed is one at which the thickness of the solidified
shell is 50 mm at the point of the roll reduction finishing area. Thus, in order to
achieve complete solidification, a preferred casting speed is determined depending
on the thickness of the mold and the length of the squeeze reduction zone. In general,
a preferred casting speed is in the range of 1.0 - 2.0 m/min.
[0048] In addition, the rate at which the casting speed is changed, i.e., an acceleration
or deceleration rate preferably is in the range of 1.0 - 4.0 m/min
2.
[0049] Since the casting is carried out continuously, the casting speed in the squeeze reduction
zone is also decreased when the casting speed in the mold is decreased. An unsolidified
slab must be subjected to squeeze reduction when the thickness of a solidified shell
of the unsolidified slab has increased. The roll reduction force, however, is not
large enough to enable so-called rolling to be achieved. As the thickness of the solidified
shell increases, therefore, an increment of the solidified shell thickness cannot
be diminished, and the thickness of the slab inevitably increases to two times the
solidified shell thickness.
[0050] In the embodiment mentioned above, a cast slab 100 mm thick is subjected to squeeze
reduction to form a slab 50 mm thick, and then the thickness of the slab is returned
to 100 mm. Even if the slab is returned to a thickness of 70 mm or 80 mm, the same
procedures as mentioned above can be applied so as to restore the thickness, though
it is necessary not only to install a position sensor in reduction rolls, but also
to control the casting speed and roll gaps so as to change the thickness of the slab
to a target value.
[0051] Next, working examples of the present invention together with its effects will be
described in detail.
Examples
(Example 1)
[0052] Medium carbon, Al-killed steel having the steel composition shown in Table 1 was
cast at a normal casting speed of 5.0 m/min with a machine of the curved type shown
in Figure 1. The mold was 100 mm thick and 1500 mm wide. The cast slab was further
subjected to squeeze reduction to produce a thin slab having target dimensions of
50 mm thick and 1500 mm wide. In the course of the above-mentioned continuous casting,
the thickness of the slab was returned to 100 mm. The casting speed at which a cast
slab was completely solidified before it passed the roll reduction finishing area
was 1.3 m/min for a slab thickness of 100 mm.
[0053] In this example, under normal conditions, a cast slab having an unsolidified portion
in the slab was subjected to squeeze reduction to reduce the thickness to 50 mm. The
roll reduction zone was located in an area 3 m long between the first segment and
the fifth segment in the roller apron zone of the machine. The roll reduction finishing
area was located 4 m down from the molten steel meniscus in the mold. The roll reduction
was carried out at a uniform reduction rate with a reduction of 10 mm for each of
the segments.

[0054] In this example, a 2-strand machine was used. A process for restoring the cast slab
thickness through squeeze reduction in accordance with the present invention, as shown
in Fig. 2, was carried out by using the first strand casting machine. In this case,
since the casting speed at which a slab was completely solidified before it passed
the roll reduction finishing area was 1.3 m/min, the casting speed was once reduced
to 1.3 m/min and the roll reduction force was simultaneously released. After the thickness
was returned to 100 mm, the casting speed was restored to 5.0 m/min, which is the
normal casting speed. During operation, the solidifying front was always located at
a place upstream from the roll reduction finishing area.
[0055] Using the second strand casting machine as a comparative example, restoration of
the cast slab was carried out by releasing the roll reduction force immediately after
the changing point of the slab passed the roll reduction zone while maintaining the
normal casting speed. Fig. 3 is a graph showing a variation in the casting speed and
slab thickness with respect to elapse of the casting period. As is apparent from the
graph, increase in the slab thickness, i.e., opening of the roll gaps at the point
of the roll reduction finishing area proceeded continuously.
[0056] Figs. 4 and 5 illustrate shapes of unstable areas of cast slabs which were obtained
by the thickness restoring operations of an example of the present invention and a
comparative example, respectively. In the drawings, the direction of the arrow indicates
the direction of drawing of a cast slab, i.e., the casting direction.
[0057] As shown in Fig. 4, it is possible in the first strand casting machine to which the
process of the present invention was applied to change the slab thickness from 50
mm to 100 mm smoothly in the transitional area.
[0058] On the other hand, as shown in Fig. 5, according to the comparative example in which
the second strand casting machine was employed, the cast slab in the transitional
area swelled like a drum due to the occurrence of bulging.
[0059] The resulting cast slabs were cut and examined on their cross sections. Cast slabs
from the first strand to which the process of the present invention was applied were
free from internal defects even in a transition area where the slab thickness was
increased gradually. Further rolling following the continuous casting was carried
out successfully, resulting in a coil having good quality. On the other hand, the
cast slabs obtained from the second strand to which an immediate release of the roll
reduction force was applied, as shown in Fig. 6, suffered from internal cracking and
breaking into two pieces in the barrel-like swollen portion of the slab. Regarding
central segregation, heavy normal and inverse segregation was found in scattered places,
resulting in troubles such as formation of internal defects at the time of subsequent
rolling.
[0060] Thus, according to the process of the present invention, in which the roll reduction
force is released during squeeze reduction, it is possible to change the slab thickness
successfully without any degradation in internal quality of the slab, resulting in
a marked improvement in yield.
(Example 2)
[0061] This example was carried out to evaluate the influence of the type of steel. Example
1 was repeated, and low carbon, Al-killed steel having the steel composition shown
in Table 2 was cast at a normal casting speed of 5.0 m/min. In this example, too,
the casting speed at which a cast slab was completely solidified before it passed
the roll reduction finishing area was 1.3 m/min for a slab thickness of 100 mm.

[0062] The results of this example were as follows.
[0063] According to a process of the present invention, changing of the cast slab thickness
was achieved smoothly, and the resulting slab was free from internal cracking and
central segregation in the unstable area and had a good quality.
[0064] On the other hand, in the comparative example, when the unstable area was expanded
from 50 mm to 100 mm upon release of the roll reduction force, as shown in Fig. 5,
swelling like a drum occurred and formation of central segregation and degradation
in porosity were found, although internal cracking did not occur.
[0065] Fig. 7 shows a comparison of the internal quality of the resulting cast slabs of
the example of the present invention and the comparative example. The code number
on the Y-axis is a numerical indication of inner quality of the resulting slabs based
on the following definition.
Code Number |
Porosity area/10 cm2 of horizontal area |
0 |
0 % |
1 |
0 - 10% |
2 |
10 - 30% |
3 |
30 - 50% |
4 |
50 - 70% |
5 |
70% or more |
[0066] Thus, compared with the case of medium carbon steel of Example 1, it is noted that
although there was a little less degradation in inner quality in this comparative
example, the yield was still as low as in the comparative example of Example 1.
(Example 3)
[0067] This example was carried out to evaluate the influence of the casting speed. Example
1 was repeated, and medium carbon, Al-killed steel having the steel composition shown
in Table 1 was cast at a normal casting speed of 5.0 m/min.
[0068] However, in this example, although a target slab thickness to be restored from the
slab thickness of 50 mm was set to be 100 mm, the casting speed was varied to 1.3,
2.0, and 3.0 m/min by adjusting the deceleration rate at the beginning of restoration
of the thickness. In this example, the casting speed at which a cast slab was completely
solidified before it passed the roll reduction finishing area was 1.3 m/min.
[0069] In the case of the present invention, since the casting speed was changed to 1.3
m/min, the thickness of the cast slab was successively changed from 100 mm to 50 mm
and then to 100 mm. The resulting cast slabs were free from internal cracking, and
a degradation in the central segregation was not found.
[0070] On the other hand, in the case of the comparative example, since the casting speed
was lowered to a rather high level of 2.0 m/min or 3.0 m/min, the solidified shell
thickness was 40 mm and 33 mm, respectively, in the roll reduction finishing area,
and an unsolidified portion remained when the slab passed the roll reduction finishing
area. As a result, as shown in Fig. 5, the unstable portion of the slab swelled like
a barrel upon release of the roll reduction force. In the slab, there were occurrence
of internal cracking, degradation in central segregation, and an increase in porosity,
resulting in a reduction in the yield when the casting speed was 2.0 or 3.0 m/min
at the time of release of the roll reduction force.
[0071] According to the present invention, during operation of continuous casting, it is
possible to change the thickness of cast slabs, without a degradation in surface conditions
and inner quality, and a variety of sizes of slabs can be produced efficiently with
a high yield.