U.S. patent number 3,875,989 [Application Number 05/464,979] was granted by the patent office on 1975-04-08 for method of monitoring effervescence of a steel.
This patent grant is currently assigned to Centre de Recherches Metallurgiques-Centrum voor Research in de. Invention is credited to Robert Alfred Pirlet.
United States Patent |
3,875,989 |
Pirlet |
April 8, 1975 |
Method of monitoring effervescence of a steel
Abstract
The sound emitted by steel being teemed into an ingot mould and
by the steel solidifying in the ingot mould is detected. The
acoustic energy of emitted sound of at least one frequency in a
frequency range from 0 to 100 kHz is measured and recorded as a
function of time. For instance the acoustic energy at one frequency
may be recorded during teeming and acoustic energy at two other
frequencies may be recorded during subsequent effervescence. The
energy measurement record is compared with results obtained by
statistical analysis if similar records resulting from monitoring
of a large number of previous ingots. This comparison reveals one
or more characteristics of the sound emitted which give an
indication of the quality of the effervescence of the steel. If the
quality indicated is inferior, it is possible to correct the
composition of the steel in the ingot mould during teeming or soon
after.
Inventors: |
Pirlet; Robert Alfred (Embourg,
BE) |
Assignee: |
Centre de Recherches
Metallurgiques-Centrum voor Research in de (Brussels,
BE)
|
Family
ID: |
3874443 |
Appl.
No.: |
05/464,979 |
Filed: |
April 26, 1974 |
Foreign Application Priority Data
Current U.S.
Class: |
164/4.1;
346/33R |
Current CPC
Class: |
G01N
33/2025 (20190101); B22D 27/00 (20130101); G01N
29/11 (20130101); C21C 5/4673 (20130101); B22D
7/00 (20130101); B22D 2/00 (20130101) |
Current International
Class: |
C21C
5/46 (20060101); G01N 29/04 (20060101); B22D
27/00 (20060101); G01N 29/11 (20060101); B22D
2/00 (20060101); B22D 7/00 (20060101); G01N
33/20 (20060101); B22d 025/06 () |
Field of
Search: |
;73/61LM ;164/4,154 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
1,280,985 |
|
Nov 1961 |
|
FR |
|
1,579,628 |
|
Aug 1969 |
|
FR |
|
Primary Examiner: Husar; Francis S.
Assistant Examiner: Roethel; John E.
Attorney, Agent or Firm: Holman & Stern
Claims
I claim:
1. A method of monitoring the effervescence of steel teemed into an
ingot mould, comprising the steps of:
a. detecting the sound emitted by the steel being teemed and by the
steel solidifying in the ingot mould;
b. measuring the acoustic energy of emitted sound of at least one
frequency in a frequency range from 0 to 100 kHz;
c. recording the energy measurement as a function of time; and
d. comparing the energy measurement record with results obtained by
statistical analysis of similar records resulting from monitoring
of a large number of previous ingots, the comparison revealing at
least one characteristic of the sound emitted, the characteristic
giving an indication of the quality of the effervescence of the
steel.
2. A method as claimed in claim 1, in which the said emitted sound
of at least one frequency is in a frequency range from 0 to 40
kHz.
3. A method as claimed in claim 1, in which the said at least one
characteristic is selected from the group consisting of the form of
the spectrum of the emitted sound, the evolution of the acoustic
energy of emitted sound of at least one given frequency, the
absolute or relative acoustic energy level of emitted sound of at
least one given frequency, and the amplitude of fluctuations in the
acoustic energy of emitted sound of at least one given
frequency.
4. A method as claimed in claim 1, in which the measuring step
comprises measuring the acoustic energy of emitted sound of at
least one given frequency during teeming, the characteristic of the
sound being the average level of the acoustic energy during
teeming.
5. A method as claimed in claim 4, in which a higher average level
represents a better quality of effervescence than a lower average
level.
6. A method as claimed in claim 4, in which the said given
frequency is 8 kHz approximately.
7. A method as claimed in claim 1, in which the measuring step
comprises measuring the acoustic energy of emitted sound of at
least one frequency, during teeming, the characteristic of the
sound being the rapidity of the increase in the acoustic energy
during teeming.
8. A method as claimed in claim 7, in which the said given
frequency is 18 kHz approximately.
9. A method as claimed in claim 1, in which the measuring step
comprises, during teeming, measuring the acoustic energy of sound
of a first frequency between 1 kHz and a frequency f.sub.1, where
f.sub.1 is between 2 and 8 kHz, measuring the acoustic energy of
sound of a second frequency between the frequency f.sub.2 and 10
kHz, and comparing the two measurements with predetermined
values.
10. A method as claimed in claim 9, in which the said first
frequency is 1 kHz.
11. A method as claimed in claim 9, in which the said second
frequency is 8 kHz.
12. A method as claimed in claim 1, in which the measuring step
comprises, during effervescence, measuring the acoustic energy of
emitted sound of a first frequency between 1 and a frequency
f.sub.2, where f.sub.2 is between 5 and 15 kHz, measuring the
acoustic energy of emitted sound of a second frequency between
f.sub.2 and 40 kHz, and comparing the measurements with
predetermined values.
13. A method as claimed in claim 12, in which the said first
frequency is 5 KHz.
14. A method as claimed in claim 12, in which the said second
frequency is 18 kHz.
15. A method as claimed in claim 12, in which a substantially
constant level of the two energy measurements represents a
satisfactory quality of effervescence, an unsatisfactory quality
being represented by a variable level.
16. A method as claimed in claim 12, further comprising the step of
comparing the long term evolution of the energy measurement at the
first frequency with that at the second frequency.
Description
The present invention relates to a method of monitoring the
effervescence (rimming) of a steel during teeming and
solidification in an ingot mould.
Deoxidation by the carbon of unkilled (rimming or balanced) steel
results in the well known phenomenon of rimming (effervescence)
during solidification of the steel in ingot moulds. This phenomenon
occurs as boiling of the molten upper surface of the steel ingot,
due to violent evolution of gas substantially consisting of CO.
This boil is also accompanied by projection of sparks (incandescent
metal particles).
Many factors influence the phenomenon of rimming, such as the
temperature of the steel and the ingot mould, the solidification
rate of the metal, its composition, the proportion of any
deoxidizing elements (e.g., manganese and silicon) and the shape
and dimensions of the ingot mould.
For a long time assessment of rimming was left to the experience of
the observer, who used to classify the ingots in various categories
on the basis of a general evaluation of the effervescence, and who
of course could rely only upon his own substantially subjective
impressions.
It should be noted that such a method has remarkable drawbacks,
particularly in view of the risk of errors in assessment,
variations in assessment depending on the tiredness of the
observer, and the non-reproducibility of the results because of the
substantially subjective nature of the observation means, i.e., the
eye of the observer, and the observation method, i.e., data of
personal experience stored in his memory.
In order to evaluate the gas evolution rate more objectively, a
measuring method has been suggested comprising recording all or a
part of the sound spectrum (sonic and ultrasonic) emitted by the
steel in the ingot mould.
It has actually been noted that a relation exists between the
evolution of the phenomenon observed and the evolution of its sound
spectrum, which allows some indications to be obtained with regard
to such a phenomenon by means of measurements taken on its
spectrum.
Such a method, although it has led to satisfactory results, has the
drawback of obtaining an assessment of the effervescence only at
the end of teeming, which provides the possibility of only tardy
corrections.
The present invention concerns a method which in particular allows
this drawback to be avoided.
The invention is based on the remarkable observation that the
teeming noise of rimming steels already contains indications of
effervescence, which makes it possible to get information from the
very first beginning of the teeming operation and to make any
necessary corrections very rapidly and efficiently.
Another observation is that the solidification process of steel
produces two noises of different frequencies: one noise has
frequencies lower than 10 kHz due to vortices in the molten metal,
and another noise has frequencies higher than 10 kHz due to
bursting of bubbles of gas evolving from the molten metal and to
projection of sparks. These two phenomena occur during
solidification of steel and as a result of its effervescence.
Experience has suggested that it is important to monitor both of
them, preferably at the same time, in order to better assess the
quality of the process taking place.
In the method according to the present invention the acoustic
energy (sonic and ultrasonic) from the steel while being teemed
into ingot mounds and while solidifying into an ingot is recorded
as a function of time and within a frequency range from 0 to 100
kHz (preferably from 0 to 40 kHz) and the effervescence rate and
possibly the materials to be added, for correcting this
effervescence as a function of specific characteristics of the
acoustic energy, are determined by comparison with results obtained
from a statistic study based on a large number of ingots. Acoustic
energy can be picked up by an acoustic transducer or an
accelerometer.
If the characteristics indicate an inferior quality of
effervescence, this can be corrected during teeming or soon after,
by adding oxidising agents or deoxidants.
Suitable characteristics of the emitted sound can comprise the form
of the spectrum and/or development of the frequency components of
the spectrum and/or the relative or absolute level of these
components and/or the amplitude of their fluctuations.
For example, when picking up the sonic energy during teeming of
steel, the quality of the effervescence (and possible the materials
to be added for correcting this effervescence) is determined as a
function of the average level and/or the rate of increase of the
time curve of the evolution of the sonic energy filtered at at
least one given frequency.
It has been observed in fact that at a high average level of the
sonic energy a good start of the effervescence occurs, while at a
not very high average level effervescence starts badly.
In the case in which the quality of the effervescence is determined
as a function of the average level of the sonic energy, it has been
found to be particularly advantageous to observe the time evolution
of the sonic energy filtered to a frequency of 8 kHz
approximately.
When the quality of the effervescence is determined as a function
of the rate of increase of the sonic energy, the time evolution of
the sonic energy filtered in respect of a frequency of 18 kHz
advantageously observed.
The picked up sonic energy not only depends upon the metallurgic
process (appearance of effervescence during casting) but also upon
external factors such as the form and dimensions of the ingot
mould, and the position of the picking up device. In order to
eliminate the influence of these other factors, the picked up sonic
energy is filtered at a first frequency which is affected by the
effervescence and the external factors, such as at 8 kHz, and also
at a second frequency mainly affected by the external factors, at 1
kHz example, and the ratio between the two sonic energies thus
filtered is determined to obtain a purely representative index of
the quality of the effervescence in the steel being tested.
In the case in which the acoustic energy during teeming is picked
up, the quality of rimming (and possibly the materials to be added
for correcting (effervescence) can be determined by filtering the
acoustic energy to a first frequency between 1 kHz and f.sub.1
(where f.sub.1 is betwen 2 and 8 kHz) and to a second frequency
between f.sub.1 and 10 kHz, measuring the acoustic intensity at
these two frequencies, and comparing the data at these two
frequencies with predetermined values.
The indications thus obtained are employed to forsee the behaviour
during rimming and to decide in a very rapid manner on the possible
corrections to be made (e.g., addition of oxidizing powder if
rimming is to be increased, or addition of deoxidants if rimming is
to be decreased).
In the case in which the sonic energy from the effervescence during
rimming of the steel in the ingot mould is picked up, the
effervescence quality (and possibly the materials to be added for
correcting this effervescence) is determined by filtering the sonic
energy to a first frequency between 1 kHz and f.sub.2 (f.sub.2
being between 5 kHz and 15 kHz) and to a second frequency between
f.sub.2 and 40 kHz, measuring the acoustic intensity at these two
frequencies, and comparing the data at these two frequencies with
predetermined values.
It has been found to be advantageous to record the time evolution
of the sonic energy filtered to a first frequency of 5 kHz and a
second frequency of 18 kHz.
Frequencies have to be chosen in accordance with the equipment used
and the environment, in order to avoid the room noise and
particular noise such as metallic impact and bridge crane
noise.
In this case there is observed that a regular time evolution (that
is an evolution at a relatively uniform level) shown by the curves
of the sonic energy filtered to 5 kHz and to 18 kHz, corresponds to
satisfactory effervescence while a deficient effervescence occurs
as a result of an irregular evolution, i.e., an evolution at a
variable level.
It should also be noted that the long term evolutions of the sonic
energy filtered to these two frequencies are different from one
another and characteristic of the effervescence. Thus when the boil
of the metal bath becomes irregular (wild) which gives an
indication of a deficient effervescence, the level of the noise due
to vortices in the metal bath (low frequency) changes by undergoing
an increase, while the level of noise due to the bubble burst and
the projection of sparks (high frequency) varies by undergoing a
decrease.
On the other hand, when the boil of the metal bath is slow, which
is another indication of a deficient effervescence, the level of
noise due to vortices in the metal bath and to the bursting of the
gas bubbles decreases.
EXAMPLES
The invention will be described further, by way of example only,
with reference to the accompanying drawings, in which:
FIGS. 1 to 4 are graphs of acoustic energy against time, at various
frequencies.
The graphs show the evolutions as a function of the time
selectively filtered components (at 5 kHz, 8 kHz and 18 kHz) of the
noise emitted by steel while being teemed (FIGS. 1 and 2) and
during effervescence (FIGS. 3 and 4). The amplitudes of these
components are shown in a logarithmic scale on the vertical axes
(y). Time from the beginning of teeming is recorded linearly on the
abscissa axis (t).
The observations described below relate to two rimming steel ingots
obtained from two different heats. The first was an ingot of 16.5
tonnes, case in size 1,200 (analysis: carbon 0.064% and manganese
0.300%; temperature of the steel in ladle: 1,550.degree.C). The
second ingot was an ingot of 18 tonnes, case in size 1,400
(analysis: carbon 0.075% and manganese 0.300%; temperature in the
ladle: 1,542,20 C).
The solidification process of the first ingot is an example of good
behaviour: quick commencement of rimming after teeming, no
immediate rise or reboil, good and regular rimming until the ingot
is hardened at its surface; and horizontal closing of the head.
In contrast, the second ingot is an example of bad behaviour: slow
starting and steel reboiling in the first few minutes after
teeming; slow and disorderly boiling; and bad closing.
FIG. 1 shows the evolution of the component at 8 kHz of the noise
emitted, during teeming and for 40 seconds after teeming, by the
first ingot (curve 1) and by the second ingot (curve 2).
The origin of the time axis corresponds to the beginning of
teeming. The end of the teeming is indicated in the graph by a drop
3 in the two curves; the remaining part of the graph shows the
noise emitted by the rimming metal bath during the first period
immediately after teeming. Three short returns of the jet during
the second ingot correspond to peaks 4 in the curve 2.
It should be noted that the level of curve 1 for the first ingot
is, from the beginning, higher than the curve 2 for the second
ingot; the average difference between the two curves is 15
decibels. This difference is due to a more substantial
effervescence occurring during teeming of the first ingot than that
appearing during teeming of the second ingot. This allows one to
foresee from the very first minutes of teeming that rimming will
commence rapidly and will be lively, in the case of the first
ingot, and that it will start slowly and will be sluggish in the
case of the second ingot.
The first ingot does not need any correction, while the second
ingot has to be corrected by addition of an oxidising powder.
The same conclusions are reached by examination of FIG. 2, showing
the evolution of the component at 18 kHz of the teeming noise on
the same scale of coordinates as in FIG. 1. The shape of the two
curves is different: the most important appearances of
effervescence correspond to a steeper rise and a higher level of
the curve 1 in connection with the first ingot.
FIGS. 3 and 4 show the evolution of the effervescence noise,
selectively filtered at 5 kHz (curve 1) and at 18 kHz (curve 2),
during a 20 minute period from teeming to covering of the ingot.
The origin of the time axis corresponds to the beginning of
teeming; the end of teeming is indicated at 3. FIG. 3 relates to
the first ingot. In this graph the two curves have a regular shape.
They show short-term fluctuations around a relatively constant
average level; such curves indicates a good lively and regular
effervescence. FIG. 4 relates to the second ingot. The two curves
have an irregular average level, which indicates disorderly
effervescence. After the fourth minute, the curve 1 rises in a
remarkable way, while the curve 2 passes through a minimum. Such a
curve indicates a phase of wild effervescence during which the
eddies or vortices become violent and disorientated, while spark
projection decreases. This behaviour is accompanied by rising and
sloping and results in bad solidification.
* * * * *