Product Uniformity Control (PUC)

Transcription

1 RESEARCH AND INNOVATION Research Fund for Coal and Steel Frenk van den Berg Product Uniformity Control (PUC) A Joint Approach of European Steel Industries to Non-Destructive Evaluation of Mechanical Properties Industrial Technologies 2016 Conference, RAI Amsterdam, The Netherlands June 23, 2016 PUC - Product Uniformity Control 1

2 FULL AUTHOR LIST Industrial Technologies 2016 Amsterdam Slide 2 Frenk VAN DEN BERG 1, Piet KOK 1, Haibing YANG 1, Maxim AARNTS 1, Jan-Jaap VINK 1, Willem BEUGELING 1, Philip MEILLAND 2, Thomas KEBE 3, Mathias STOLZENBERG 4, David KRIX 5, Anthony PEYTON 6, Wenqian ZHU 6, Ane MARTINEZ-DE-GUERENU 7, Isabel GUTIERREZ 7, Denis JORGE-BADIOLA 7, Kizkitza GURRUCHAGA 7, Peter LUNDIN 8, Arno VOLKER 9, Mariana MOTA 9, Johan MONSTER 9, Håkan WIRDELIUS 10, Claudio MOCCI 11, Gianluca NASTASI 11, Valentina COLLA 11, Claire DAVIS 12, Lei ZHOU 12, René SCHMIDT 13, Stéphane LABBÉ 14, Christophe REBOUD 15, Anastassios SKARLATOS 15, Tomas SVATON 15, Vincent LECONTE 16, Patrick LOMBARD 16 1 Tata Steel, IJmuiden, Netherlands 2 ArcelorMittal Global Research and Development Maizières Process, Maizières-lès-Metz Cedex, France 3 thyssenkrupp Steel Europe AG, Duisburg, Germany 4 Salzgitter Mannesmann Forschung GmbH, Salzgitter, Germany 5 Salzgitter Mannesmann Forschung GmbH, Duisburg, Germany 6 University of Manchester, Manchester, UK 7 CEIT, San Sebastián, Spain 8 Swerea KIMAB AB, Kista, Sweden 9 TNO, Delft, Netherlands 10 Chalmers University of Technology, Göteborg, Sweden 11 Scuola Superiore Sant'Anna, Ghezzano, Pisa, Italy 12 University of Warwick, Warwick Manufacturing Group (WMG), Coventry, UK 13 ArcelorMittal, Eisenhüttenstadt, Germany 14 Université Grenoble Alpes, Grenoble, France 15 CEA Commissariat à l'energie Atomique, Gif-sur-Yvette, France 16 CEDRAT, Meylan, France

3 Partners: Industrial Technologies 2016 Amsterdam Slide 3 Coordinator:

4 Industrial Technologies 2016 Amsterdam Slide 4 Project Scope Main topic: Non-Destructive Evaluation of: Microstructure & Texture Mechanical Properties (Rp, Rm,..) Partners (see previous sheet): 4 Steel manufacturers 10 Research institutes Project period: July 2013 Dec 2017 (4 ½ yrs) Collaboration meetings: every 6 months during 3 days

5 Industrial Technologies 2016 Amsterdam Slide 5 Agenda 1 Project scope and partners 2 Project background, objectives & approach 3 Modeling chain and experimental validation chain 4 Generation of microstructures 5 Modeling of fundamental properties and measuring instruments 6 Outlook

6 Industrial Technologies 2016 Amsterdam Slide 6 Agenda 1 Project scope and partners 2 Project background, objectives & approach 3 Modeling chain and experimental validation chain 4 Generation of microstructures 5 Modeling of fundamental properties and measuring instruments 6 Outlook

7 PUC Background: Industrial Technologies 2016 Amsterdam Slide 7 Traditionally, in steel manufacturing, the microstructure & mechanical properties of the product are derived from samples, typically taken at head or tail of coils: Specimen for tensile testing: Automated tensile testing: Mechanical Properties (Rp, Rm,..)

8 Industrial Technologies 2016 Amsterdam Slide 8 PUC Background: Microstructure analysis: Microscopic analysis Microstructure (EBSD image of micro-alloyed steel) 2º SEM EBSD analysis Ambition: Obtain microstructure and mechanical property information not only from head or tail, but over full length of coil, and with much faster response time (inline).

9 Magnetic Measurement PUC - Product Uniformity Control PUC Main objective: Industrial Technologies 2016 Amsterdam Slide 9 Improve online measurement methods for characterisation of uniformity in microstructure & mechanical properties, to create opportunities for improved process control. Interstitial-free steel (IF) Strip length

10 Background Industrial Technologies 2016 Amsterdam Slide 10

11 PUC Main NDE techniques: Industrial Technologies 2016 Amsterdam Slide 11

12 PUC Model Development Industrial Technologies 2016 Amsterdam Slide 12 Process Process Models Metallurgical Models Mechanical Properties Microstructure Product Uniformity Control Improved Process Models, using Online Product Data Online Measured EM / US Parameters Fundamental Property Models Instrument Models EM / US Properties Instrument Models Novel Sensor Developments & Deployments

13 Industrial Technologies 2016 Amsterdam Slide 13 Agenda 1 Project scope and partners 2 Project background, objectives & approach 3 Modeling chain and experimental validation chain 4 Generation of microstructures 5 Modeling of fundamental properties and measuring instruments 6 Outlook

14 Industrial Technologies 2016 Amsterdam Slide 14 Microstructure Generator & Descriptor Language Microstructure design tool: developed at Tata Steel covers a broad range of single and multi phase steel grades based on advanced Voronoi Tessellation techniques Example: IF steel with elongated coarse ferrite grains Light microscopy image: Microstructure generator:

15 Industrial Technologies 2016 Amsterdam Slide 15 Microstructure Generator & Descriptor Language Features covered in microstructure and micro texture parameters: Grain size distributions Interface densities Grain shape distributions Aspect ratio, perimeter/area Anisotropy: crystallographic texture, directionality of grains, grain boundary misorientation Volume fractions (V V ) of metallurgical phases Spatial distributions: nearest neighbour distance distribution, mean free path, banding quantification Dual Phase steel, 18% second phase, concentrated near grain boundaries of main phase

16 Industrial Technologies 2016 Amsterdam Slide 16 Virtual microstructures Parameter studies A huge advantage of the numerically modelled microstructures, compared to real microstructures, is the ability to explore the microstructure parameter space for each dimension individually. Change grain size Change texture

17 Industrial Technologies 2016 Amsterdam Slide 17 Agenda 1 Project scope and partners 2 Project background, objectives & approach 3 Modeling chain and experimental validation chain 4 Generation of microstructures 5 Modeling of fundamental properties and measuring instruments 6 Outlook

18 Industrial Technologies 2016 Amsterdam Slide 18 PUC Modelling of Fundamental properties:

19 Industrial Technologies 2016 Amsterdam Slide 19 Example: 3-D Micromagnetic modelling at University Grenoble Modelled and Experimental BH curves for steel with 20 mm grain size Grid 10 nm! Here: 16 E 3 DOF Future: 100 E 6 DOF for ~10 x 10 x 10 um 3 10 min calc. time per point on cluster of 3000 CPU nodes

20 Industrial Technologies 2016 Amsterdam Slide 20 PUC Instrument models (EM):

21 Industrial Technologies 2016 Amsterdam Slide 21 PUC Example of result for inline mechanical property monitoring DP grade Continuous monitoring of the mechanical properties Rp and Rm derived from the inline electromagnetic measurement HACOM, from Salzgitter Mannesmann Forschung

22 Industrial Technologies 2016 Amsterdam Slide 22 PUC Recent Publications on World Conference on Non-Destructive Testing (Münich, June 2016):

23 Industrial Technologies 2016 Amsterdam Slide 23 Outlook