International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 11 Issue: 04 | Apr 2024
p-ISSN: 2395-0072
www.irjet.net
A Comprehensive Examination of Defect in Continuous Cast Billet and Analysis Using Quality Control Tool Rinil1, Mijuwad P P2, Adwaith A3, Anaj T4, Jibi R5, Jijo TM6 1234Graduate Student, 5Assistant Professor Department of Mechanical Engineering, AWH Engineering
College Calicut, Kerala, India,6Production Manager KENZA TMT Steel Bar, Palakkad, Kerala, India.
--------------------------------------------------------------------***----------------------------------------------------------------------2 LITERATURE REVIEW Abstract – The steel industry is of paramount importance in the infrastructure development of a nation. Within this industry, the continuous casting method is employed to create semi-finished products such as slabs, blooms, and billets. The quality of steel billets is crucial for the production of superior steel goods. Flawless billets result in the manufacture of highquality steel products, while imperfect ones lead to a decrease in mechanical properties and the overall quality of the rolled product. In a recent project, common defects found in steel plants were identified in steel billets, and the causes of these defects were analyzed through a cause-and-effect diagram.
1. Defects of the steel billet in continuous casting. Author: Anh-Hoa BUI and Van-Hung NGUYEN The primary goal of this research is to identify deficiencies in the continual casting of steel billets, a critical aspect that impacts the quality of rolled products. The study was carried out to explore the flaws in 130×130 mm2 billets and to analyze their causes and preventive measures. The formation of defects and cracks was predominantly influenced by the temperature distribution and cooling process of the casting strand. Notably, caster, rhomboidal billets, and off-corner cracks constituted the major portion of defects observed during production. The chemical composition of the molten metal and the secondary cooling procedure played crucial roles in the development of these defects.
Key Words: Continuous casting, Billet, Cause and effect diagram, Blooms.
1.INTRODUCTION The iron and steel sector has a lot of significance in India, contributing greatly to the country's industrial landscape. Steel, a vital and versatile material, plays a pivotal role in the development of infrastructure. India stands as the world's second-largest steel producer, with this industry accounting for roughly 2.5% of the national GDP, providing employment opportunities for approximately 2.5 million individuals both directly and indirectly. At its core, steel is an alloy of iron and carbon, with carbon levels ranging up to 1.5%. The process of continuous casting serves as a crucial intermediary between steel production and rolling. This method efficiently creates semi-finished products by transforming molten steel into large blocks known as billets. Automation largely drives this process, ensuring a continuous supply of metal through a mold, resulting in the production of billets or blooms that are further utilized in the rolling phase. Defects in a steel billet during continuous casting can significantly impact the quality of the final rolled product. This study delves into the analysis of defects in continuous cast billets, leveraging statistical quality control tools like cause-and-effect diagrams to identify and addressing root causes. The Cause-and-Effect Diagram, also known as the Ishikawa or fishbone diagram, visually represents the relationship between a specific outcome and the various factors influencing it.
2. Reform the Performance of a Billet Quality by Reducing its Defects at SAIL-SCL Kerala Limited Author: Abdul Haseeb NC, Alex P Jacob, Arvind Kumar, Dibin Vincent Explored the different procedures within the industry and successfully executed a project to enhance the quality of billets, resulting in a reduction of significant losses for the company. The primary challenge encountered by the industry pertains to defects arising during the casting of billets. Defective billets can only be repurposed as scrap, leading to substantial losses. Analyzed the underlying causes of these defects and proposed solutions tailored to each scenario. Put forth the idea of utilizing a field mixing technology for blending molten metal in accurate proportions, thereby reducing defects by approximately 75%. Additionally, recommended alternative approaches to enhance the overall quality of billets. 3. Analysis of the Defect of Crack in Casting Author: Vijay Pandey This research delves into the various kinds of internal and external fractures that can persistently emerge during steel casting. Each category of a fracture is analyzed concerning the operational and metallurgical factors that can impact the development of fractures due to the robust high-temperature
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