Reprint from "MPT-Metallurgical P(ant and Technology International" issue No. 2/1990, pages Optimization of. Tempcore installations for

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1 Reprnt from "MPT-Metallurgcal P(ant and Technology nternatonal" ssue No. 2/990, pages 6-69 (Ç 990, Verlag StahlesenmbH, Düsseldorf Optmzaton of. Tempcore nstallatons for rebars Perre Smon, Centre de Recherches Metallurgques (C.R.M.), Lége/Belgum. Summary. The model used for optmzaton of the Tempcore nstallatons s descrbed. t s based on the results obtaned n more than plants and gves the quenchng tme as a functon of the parameters of the coolng treatment and of the mechancal propertes requred. For the optmzaton procedure, a great number of parameters are taken nto account: total water flow rate, overall lenght, number of sets of coolng devces, controllablty of the coolng power, straghtness of the rebars, safety margns. The dfferent aspects of the optmzaton are dscussed n the case of a typcal mll. t s clearly shown that, when an nstallaton s desgned, two cases can occur: a) there s no specfc constrant and the lne can be easly optmzed; b) a specfc crteron has an outstandng mportance and the lne s desgned n order to satsfy that crteron. t has to be kept n mnd that such a way of workng can result n an nstallaton whch s not optmal from all ponts of vew. ntroducton. Durng the past ten years quench and self-temperng has become a very popular soluton for producng weldable renforcng bars. n vew of ts advantages compared to mcro alloyng or cold twstng, more than 50 companes n the world have adopted ths technque. t often happens that the problem of choosng a coolng technology for a quenchng and self-temperng nstallaton n a bar ml s not correctly studed: only one crteron (such as overall length, or total water flow rate, or...) s chosen and the coolng technology s selected on the bass of that sngle crteron. As a consequence, the equpment and operatng condtons can be far from optmal wth regard to other crtera. t s very mportant to keep n mnd that there are a lot of dfferent crtera to be consdered, wth respect to the ndustral operaton of the coolng process and to the coolng equpment tself. The present paper shows that the flexblty of the Tempcore process s such that t can be adapted to very dfferent stuatons and the dfferent aspects of the optmzaton procedure are dscussed. As the techncal and economcal aspects of the Tempcore process have been descrbed elsewherel)2), only ts prncple wl be summarzed. Afterwards, the optmzaton procedure wl be detaled. ngéneur Cvl Perre Smon, Chef de Servce adjont, Centre de Recherches Metallurgques (C.R.M.), Lége/Belgum Fgure shows a schematc representaton of the Tempcore process. The rebar leavng the last stand of the hot rollng ml passes through a specal water coolng secton. The coolng effcency of ths nstallaton s such that a surface layer of the bar s quenched nto martenste, the core remanng austentc. The quenchng treatment s stopped when a determned thckness of martenste has been formed under the skn....'.:::~~~~:~r:\,...:~".,... ~,',;,'" ' ", 0 ~-.Ln, ~, '.,, '.. t! ~...,. C 0~ ! t Temperng : : temperature, Ms pont 0 00 Tme (s) Fgure. Schematc representaton of the Tempcore process When the rebar leaves the drastc coolng secton, the temperature gradent establshed n ts cross secton causes heat to flow from the center to the surface. Ths ncrease of the surface layer temperature results n the self-temperng of the martenste. The name Tempcore has been chosen to lustrate the fact that the martenstc layer s TEMPered by the heat left n the CORE at the end of the quenchng stage. Fnally, durng the slow coolng of the rebar on the coolng bed, the austentc core transforms nto ferrte and perlte or nto bante, ferrte and perlte. The temperature-tme hstory of the rebar s also gven n fgure. The three stages of Tempcore process clearly appear: - quenchng of the surface layer; - self-temperng of the martenste; - transfurmatun uf the cure.

2 65 q = m3/h.m ø = mm To = 050 'C 0 55 f(s) ø = mm To = 050 'C ds) YS = 550 APa 'r (5) = 35 mm YS = 550 MPa = m3/h.m t.4.4 t q (m3/h.m) D (mm) (mm) ø (mm) YS (MPa) Fgure 2. - = f(ld,q) Fgure 3. - = f(d,cp) Fgure 4. - =. f(to, YS).36 TS/YS (-).28 """ ", Mn = " " Fgure 5. TS/YS = f(ys,cp,c)... '.. '... ø = 32_C = 0.28 ø = 8 _ C = YS (MPa) Properly appled, the process leads to an ncrease n the yeld strength of 50 to 0 MPa, dependng on the coolng condtons. Crtera for optmaton. Typcal crtera to be consdered for the optmzaton of an nstallaton are: - total coolng water flow rate (and pressure); - overall length of the equpment; - number of sets (or ranges) of coolng nozzles requred to cover the whole range of rebars dameters. n addton, other factors have also to be taken nto account: - controllablty,.e. the ablty to adapt the coolng power of the equpment to large varatons n entry condtons (rollng speed, bar entry temperature, water temperature, etc.); - straghtness of the rebars; - necessty of safety margns,.e. the possblty to cope wth hgh temperature of the coolng water and the fact that the amed yeld strength s well above the guaranteed one (e.g. 550 MPa for 500 MPa n the case of DN 488-V S). t s clear that, to be n a poston to optmze quenchng nstallatons, t s more than helpful to have a model accurately descrbng the process. After a short descrpton of the model of the Tempcore process, the way t s used to optmze nstallatons wl be dscussed. 2 Tempcore model. The model s based on the experence accumulated durng the commssonng of more than Tempcore nstallatons. More than 3000 ndvdual results have been analysed. For each result, the dfferent data taken nto account are the followng: - rebar dameters: 8 to 32 mm; - carbon content: 0.3 to 0.29%; - manganese content: 0.52 to 0.95%; - yeld strength: 4 to 6 MPa; - tensle strength: 500 to 760 MPa; - bar entry temperatures: 950 to 50 c; - bar self-temperng temperatures: 540 to 750 c~ - lnear water flow rate: 0 to 60 m3/h per m of lne; - nternal dameter of coolng nozzles: 5 to 65 mm. From all the above results, two relatonshps have been establshed. The frst one s used for the desgn of nstallatons and gves the quenchng tme as a functon of the requred yeld strength and of the characterstcs of the coolng treatment. The second lnks the mechancal propertes to the chemcal composton of the steel. These two relatonshps can be wrtten n the followng way: and or wth - cj To YS TS TS/YS = q F pa. Tg. YSc r = K Z. d F" t 0 q. TS = K. C. MnfJ. YSY. cpo TS/YS = Kz' C. MnfJ. YSY-. cp (2) quenchng tme (s) rebar dameter (mm) rebar entry temperature ec) yeld strength (MPa) tensle strength (MPa) () tensle to yeld rato (-) as specfed n some standards such as BS 4449 lnear water flow rate (m3/h per m of lne) fllng coeffcent,.e. cpz fry where fd = nternal dameter of the coolng nozzle C carbon content of the steel (%) Mn manganese content of the steel (%) (K, Kz, a, b, c, d, e, ex, ß, y, ; = constants).

3 '" The above relatonshps are lustrated n fgures 2 to 5:.' Fgure 2 gves the quenchng tme r as a functon of the nternal dameter of the coolng nozzles D and of the lnear water flow rate q for a mm rebar. Experence has shown that, for each rebar dameter, there s a mnmum and a maxmum nternal dameter for the coolng nozzles: rsk of cobble and ncreased wear wth too small nozzles, problem of rebar straghtness wth too large nozzles. On the other hand, for each nternal dameter of coolng nozzle and for each rebar dameter, there s a mnmum and a maxmum lnear water flow rate: rsk of heterogenety of coolng for too low water flows, hydraulcal problems wth too hgh flows. These practcal lmts have been ndcated n the fgure. Fgure 3 also gves the quenchng tme r; but as a functon of the rebar dameter cp and of the nternal dameter of the coolng nozzles D. Smlarly to fgure, practcal lmts have been ndcated n the fgure. Fgure 4 shows the nfluence of the rebar entry temperature To and of the yeld strength YS on the quenchng tme r, n the case of a mm rebar; qute logcally, the requred quenchng tme ncreases wth the entry temperature and the amed yeld strength. Fgure 5 shows how the relatonshp between the tensle to yeld rato TS/YSand the yeld strength YSs nfluenced by the rebar dameter cp and the carbon content of the steel c: the hgher are the carbon content and the dameter, the hgher s the tensle to yeld rato. Ths fgure explans why, n the case of standards such as BS 4449 whch requre a rather hgh tensle to yeld rato, there s a mnmum carbon content to be observed. Optmzaton. The dfferent aspects of the optmzaton wl be dscussed n the case of a typcal bar ml wth the followng characterstcs. Rollng condtons as gven n table : slt rollng for dameters 8 to 2 mm and sngle strand for dameters 4 to 32 mm (the rollng speed has been lmted to m/s). The furnace capacty s 80 t/h (whch has been supposed to correspond to a maxmum nstantaneous mass flow of 00 t/h). The fnshng temperature s 050 0c. The mechancal propertes to be acheved are those of DN 488-V S (amed yeld strength of 550 MPa for a guaranteed value of 500 MPa). Fgure 6 shows how the relatonshp () s used n the desgn: n the case of the mm dameter (whch, n the theoretcal ml, s rolled at.5 m/s), the overall length and the total water flow rate Q (m3/h) are gven as 32 / ( 8 ~ \ \ f (mm) ) \ 4 Ranges Table. Rollng condtons Dameter Number of Rollng nstantaneous' strands speed mass flow (mm) (-) (m/s) (t/h) x x x 'On the bass of the nomnal dameter r- 60 q (m3,a.m) ø = mm To = 050 'C YS = 550 MPa Vo =.5 m/s Q(m3 h Fgure 6. val = f(d,q) 0 (m) a functon of the nternal dameter of the coolng nozzles D and of the lnear water flow rate q. The practcal lmts defned n fgure 2 have also been ndcated n fgure 6. f an nternal dameter of 40 mm and a lnear water flow rate of m3/h.m are choosen, fgure 6 shows that the overall length s 7.5 m and the total water flow rate 380 m3/h. Fgure 7 gves the man characterstcs of the optmal lne,.e. of the lne presentng the best compromse between the overall length, the total water flow rate and the number of ranges of coolng nozzles. The overall length s 7.2 m for slt rollng and 7.8 m for sngle strand rollng. The maxmum total water flow rate s 430 m3/h and there are 4.ranges of coolng nozzles. Ths lne s used as a reference ~ / 0 ( ì ~l 30 m3/h o ø (mm) 0 : J ~ \ 0\ 6 Ranges 0t (m3jh) 0 o 0 0t (m3jh) 0 o 0 Fgure 7. Optmal lne Fgure 8. Mnmum water flow 3

4 \! q 32 ø (mm) ø (mm) 0 / 28 a 28 0 l r/ 0 22 J \ 22 ( \ 4- ~), Ronges 2.9 m -l ~~ ; Qt (m3 h 0 o 0 Qt (m3 h ) ~ \\ 3 Ronges 0 o 0 Fgure 9. Mnmum length Fgure 0. Mnmum number of ranges to dscuss what happens when a specfc crteron s gven a prevalent mportance. Total water flow rate. The stuaton wth a mnmzed water flow rate s descrbed n fgure 8. The total water flow s reduced to 30 m3/h. The 'lengths are almost unchanged (8. m/7.2 m) but 6 ranges of coolng nozzles are necessary tò' obtan a hgh fllng coeffcent for all dameters. Overall length. Fgure 9 shows the man characterstcs n the case of mnmzed lengths. The lengths are reduced to 6.8 m (slt rollng) and 2.9 m (sngle strand) but the maxmum total water ncreases to 5 m3/h and 7 ranges are requred to mantan hgh fllng coeffcents. By ncreasng the total flow to 600 m3/h, t s possble to further reduce the lengths down to 6.3 m/2.0 m. Ranges of coolng nozzles. f a reduced number of ranges Table 2. Optmal lne Dameter Number of Rollng speed nstantaneous*) nternal Lnear water Overall length Total strands mass flow dameter flow rate water flow rate (mm) (-) (m/s) (t/h) (mm) (m3/h.m) (m) (m3/h) x x x x x x *) On the bass of the nomnal dameter 4 Table 3. Mnfmum water flow Dameter. Number of Rollng speed nstantaneous*) nternal Lnear water Overall length Total slrands mass flow dameter flow rate water flow rate (mm) (-) (m/s) (t/h) (mm) (m3/h.m) (m) (m3/h) x x x x x x ' *) On the bass of the nomnal dameter

5 Table 4. Mnmum length Dameter Number of Rollng speed nstantaneous*) nternal Lnear water Overall length Total strands mass flow dameter flow rate water flow rate (mm) (-) (m/s) (h) (mm) (m3/h.m) (m) (m3/h) x x x x ' x x *) On the bass of the nomnal dameter Table 5. Mnmum number of ranges Dameter Number of ROlng speed nstantaneous*) nternal Lnear water Overall length Total strands mass flow dameter flow rate water flow rate (mm) (-) (m/s) (t/h) (mm) (m3t.m) (m) (m3/h) x x x x x x ~- *) On the bass of the nomnal dameter of coolng nozzles s requred, t s possble to reduce t to 3 ranges: fgure 0. However, that. reducton s accompaned by an ncrease of the overall length to.0 m. The detals of the desgn data n the dfferent cases s gven n tables 2, 3, 4 and 5. The man characterstcs are gathered n the table hereunder: Length (m) Water flow Ranges (-) (m3/h) Optmal lne 7.2/ Mnmum water flow 8./ Mnmum length 6.8/ Mnmum number 0 ranges 7.2/ Ths table doesn't emphasze some very mportant aspects. Straghtness of the rebars. n the case of mnmum number of ranges or water flow, there could be a problem of rebar straghtness due to the hgh rato nternal dameter to rebar dameter or to the very low lnear water flow rates. Controllablty of the coolng power. For the optmal lne, as well as for the three other cases, the maxmum water pressure s 2.0 bar. Ths pressure provdes flexblty n the control of the process,.e. the possblty to adapt the coolng power of the equpment to varatons n entry cumlluns. However, n case of large varatons n entry condtons, t can be necessary to sgnfcantly reduce the water flow rates (and correspondngly, the pressures) and, n the cases of mnmum water flow and number of ranges, these reduced water flows and pressures could create problems of heterogenety of coolng or rebar straghtness. t has to be noted that such problems wl not occur n the case of the optmal lne. n addton, t s mportant that a good desgn ncludes some safety margns wth respect to the coolng water temperature or the dfference between the amed and the guaranteed yeld strengths. For example, a reducton of the maxmum coolng water temperature from 35 to 30 C brngs a reducton of 0% n water flow rate. On the other hand, a reducton of MPa n yeld strength (amng 530 MPa nstead of 550 MPa when 500 MPa has to be guaranteed) corresponds to another reducton of % n w.ater flow rate. Concluson. When the dfferent coolng technologes for a quenchng and self-temperng nstallaton are examned, t s mportant to avod reducng the dscusson to the comparson of a sngle characterstc such as the overall length or the total water flow rate. The above has clearly shown that, when a Tempcore nstallaton s desgned, there are two man ways to proceed. 5

6 There s no specfc constrant and the lne can be optmzed as descrbed above (best compromse between overall length, total water flow rate and number of ranges of coolng nozzles plus good controllablty of the coolng power). A specfc crteron has an outstandng mportance and the lne s desgned n order to satsfy that crteron. t has to be kept n mnd that ths way of workng can result n an nstallaton far from optmal from other ponts of vew. t must not be forgotten that such a choce s only possble thanks to the flexblty of the Tempcore process. _ References ) Smon, P.; Economopoulos, M.; Nlles, p,: ron Steel Engneer 6 (984), No.3. 2) Smon, P.; Economopoulos, M.; Nlles, P.: Metallurgcal Plant Technology, No. 3/84, p. 80/93. 6

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