La Metallurgia Italiana, n.5 Maggio 2024

La

Metallurgia Italiana

International Journal of the Italian Association for Metallurgy

n. 05 maggio 2024 Organo ufficiale dell’Associazione Italiana di Metallurgia.

Rivista fondata nel 1909

High-quality products and a full control over the process.

GIVA - Italian family-owned group, worldwide leader in the manufacturing of steel products including ingots, forgings, valves and actuators. Thanks to a business-integrated model, we can guarantee full control over quality, timing and cost for the entire value chain.

VALVES & ACTUATORS

MELTING

REMELTING

MACHINING

FORGING

RING ROLLING

CONSOLIDATED EXPERTISE The whole network implements a Quality Management System which meets ISO 9001 and other specific international standards.

corporate social responsibility

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SKILLED ENGINEERS

CUTTING EDGE TECHNOLOGIES

WELL EQUIPPED LABS

ADVANCED SIMULATION SOFTWARES

INTEGRATED IT | OT

La

Metallurgia Italiana

International Journal of the Italian Association for Metallurgy

n. 05 maggio 2024 Organo ufficiale dell’Associazione Italiana di Metallurgia.

Rivista fondata nel 1909

Editoriale / Editorial

A cura di Gabriele Rampinini .............................................................................................................................. pag.05

Memorie scientifiche / Scientific papers Forgiatura / Forging

The 3D model in manufacturing process of the forging products

n.05 maggio 2024

Anno 115 - ISSN 0026-0843

M. Iwaizumi ........................................................................................................................................................ pag.08

Evaluation of deoxidation state in molten steel using image recognition technique of reduction slag by machine learning T. Sowa, Y. Seki, T. Suzuki, S. Tanaka .................................................................................................................. pag.14

Additive billet and FGS forging for large forgings

B. Wang, D. Zhao, Y. Liu, Y. Nie, X. Zhang, R. Wen .......................................................................................................... pag.21

indice

An innovation forging technology for the world's largest austenitic stainless steel ring

F. Wang, W. Yin, Y. Niu, X. Ren, M. Sun, B. Xu, L. Zhao ................................................................................................... pag.28

Smart Forging – Processing ingots by autonomic forging and sustainable heat treatment processes to premium bars

F. Hippenstiel, W. Janz, M. Mueller ...................................................................................................................................... pag.34

Scenari

Acciaio e metalli: dinamiche, cicli e tendenza di mercato / Steel and metals: market dynamics, cycles and trends A. Fornasini ............................................................................................................................................................................. pag.46

Atti e notizie / AIM news

Eventi AIM / AIM events .......................................................................................................... pag.48 Comitati tecnici / Study groups ........................................................................................... pag.50 Normativa / Standards ......................................................................................................... pag.53

La Metallurgia Italiana International Journal of the Italian Association for Metallurgy Organo ufficiale dell’Associazione Italiana di Metallurgia.

House organ of AIM Italian Association for Metallurgy.

Rivista fondata nel 1909

Direttore responsabile/Chief editor: Mario Cusolito Direttore vicario/Deputy director: Gianangelo Camona Comitato scientifico/Editorial panel: Marco Actis Grande, Silvia Barella, Paola Bassani, Christian Bernhard, Massimiliano Bestetti, Wolfgang Bleck, Franco Bonollo, Irene Calliari, Mariano Enrique Castrodeza, Emanuela Cerri, Vlatislav Deev, Andrea Di Schino, Donato Firrao, Bernd Kleimt, Carlo Mapelli, Denis Jean Mithieux, Roberto Montanari, Marco Ormellese, Mariapia Pedeferri, Massimo Pellizzari, Barbara Previtali, Evgeny S. Prusov, Dario Ripamonti, Dieter Senk Segreteria di redazione/Editorial secretary: Marta Verderi Comitato di redazione/Editorial committee: Federica Bassani, Gianangelo Camona, Mario Cusolito, Carlo Mapelli, Federico Mazzolari, Marta Verderi, Silvano Panza Direzione e redazione/Editorial and executive office: AIM - Via F. Turati 8 - 20121 Milano tel. 02 76 02 11 32 - fax 02 76 02 05 51 met@aimnet.it - www.aimnet.it Reg. Trib. Milano n. 499 del 18/9/1948.

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editoriale - editorial

"L'abilità artigianale e l'esperienza accumulata nel corso dei secoli restano pilastri fondamentali su cui si basa l'intero settore."

“The craftsmanship and the experience gained over centuries remain fundamental pillars on which the entire industry is based.”

Ing. Gabriele Rampinini Forgiatura A. Vienna

FORGIARE IL FUTURO

FORGING THE FUTURE

Nel mondo della produzione industriale, la forgia è più

In the world of industrial production, forging is more

di una semplice tecnica: è un'arte intrisa di storia e in-

than just a technique: it is an art full of history and

novazione. Con ogni pressata, si plasmano non solo i

innovation. With each press, not only metals are shaped

metalli, ma anche il destino di intere industrie. In questo

but also the fate of entire industries. In this context

contesto, la tecnologia ha sempre giocato un ruolo cru-

technology has always played a crucial role, constantly

ciale, trasformando e ridefinendo costantemente i limiti

transforming and redefining the limits of what can be

di ciò che è possibile realizzare.

achieved.

Oggi, ci troviamo di fronte a una nuova era di sfide e op-

Today, we are facing a new era of challenges and

portunità nel settore della forgia, e la chiave per affron-

opportunities in the forging industry and the key to

tarle con successo risiede nella fusione armoniosa tra

successfully addressing them lies in the harmonious

tradizione e innovazione tecnologica.

fusion of tradition and technological innovation.

Le tecnologie digitali stanno rivoluzionando ogni

Digital technologies are revolutionizing every aspect

aspetto della produzione industriale, e la forgia non fa

of industrial production and forging in no exception.

eccezione. Dall'intelligenza artificiale che ottimizza i

Starting from artificial intelligence that optimizes

processi di produzione alla stampa 3D che apre nuove

production processes to 3D printing that opens up

possibilità di design, le innovazioni tecnologiche stan-

new design possibilities, technological innovations are

no ridefinendo i confini della forgia moderna.

redefining the boundaries of modern forging.

L'implementazione di sistemi di monitoraggio in tempo

The

reale consente un controllo più preciso dei processi di

systems enables more precise control of production

produzione, garantendo una maggiore qualità e ridu-

processes, ensuring higher quality and reducing waste.

La Metallurgia Italiana - May 2024

implementation

of

real

time

monitoring

pagina 5

editoriale - editorial

cendo gli sprechi. I robot collaborativi, o cobot, lavo-

Collaborative robots also known as cobots, work side by

rano fianco a fianco con gli artigiani, aumentando l'effi-

side with craftsman, increasing efficiency and improving

cienza e migliorando le condizioni di lavoro.

working conditions.

Ma l'innovazione non riguarda solo la produzione. La

Innovation is not just about production. Digitalization

digitalizzazione dei processi di progettazione e simula-

of design and simulation processes enables faster and

zione consente una progettazione più rapida e precisa,

more accurate design, reducing development time and

riducendo i tempi di sviluppo e consentendo la creazio-

ensuring the creation of more complex and up to date

ne di componenti sempre più complessi e performanti.

performing components.

Tuttavia, mentre abbracciamo queste nuove tecnologie,

However, as we embrace these new technologies, it is

è fondamentale non perdere di vista l'essenza stessa

vital not to lose sight of the very essence of the forge.

della forgia. L'abilità artigianale e l'esperienza accumu-

The craftsmanship and the experience gained over

lata nel corso dei secoli restano pilastri fondamentali su

centuries remain fundamental pillars on which the

cui si basa l'intero settore. La tecnologia dovrebbe es-

entire industry is based. Technology should be a tool

sere uno strumento per potenziare queste competen-

for enhancing these skills not replacing them.

ze, non sostituirle.

Furthermore, we cannot overlook the environmental Inoltre, non possiamo trascurare l'impatto ambientale

impact of our industry. Sustainability must become

della nostra industria. La sostenibilità deve diventare un

imperative and technology can play a crucial role

imperativo, e la tecnologia può giocare un ruolo crucia-

in this process. Starting from an optimising energy

le in questo processo. Dall'ottimizzazione dei consumi

consumption to reducing waste, we must ensure that

energetici alla riduzione dei rifiuti, dobbiamo lavorare

our production is also a more eco- sustainable.

per rendere la nostra produzione più eco-sostenibile.

Hence, we must look to the future with confidence Infine, dobbiamo guardare al futuro con fiducia e deter-

and determination. The challenges can be great so

minazione. Le sfide possono essere grandi, ma anche

the opportunities. With a forward-looking vision and

le opportunità. Con una visione lungimirante e un im-

a constant commitment to responsible innovation,

pegno costante verso l'innovazione responsabile, pos-

we can forge a future where technology and art blend

siamo forgiare un futuro in cui la tecnologia e l'arte si

harmoniously to create something truly extraordinary.

fondono armoniosamente per creare qualcosa di veramente straordinario.

Forging is beyond a production technique, it is a symbol of resilience, history creativity and progress. With an

La forgia non è solo una tecnica di produzione: è un

open mind and the courage of the entrepreneurs who

simbolo di resilienza, storia, creatività e progresso. Con

also in Italy have created excellences in this field we can

una mente aperta e con il coraggio degli imprenditori

continue to forge our destiny, shaping a bright future for

che anche in Italia hanno creato eccellenze in questo

the entire industry.

campo, possiamo continuare a forgiare il nostro destino, plasmando un futuro luminoso per l'intera industria.

La Metallurgia Italiana - Maggio 2024

pagina 6

0 CONVEGNO

AIM NAPOLI 11 .13 SETTEMBRE

2024

AIM è lieta di annunciare la 40a edizione del proprio Convegno Nazionale che si terrà dall’11 al 13 settembre 2024 a Napoli.

Organizzato da

Il Convegno Nazionale AIM è un appuntamento irrinunciabile per le Aziende ed i ricercatori che, a vario titolo, sono coinvolti nell’utilizzo e lo studio dei metalli. L’obiettivo dell’iniziativa è fare il punto su materiali, prodotti, processi e tecnologie nei vari settori produttivi e proporre attività innovative. A completamento delle sessioni tecniche, sarà organizzato uno spazio espositivo in cui le aziende dei diversi settori rappresentati nel Convegno potranno far conoscere i loro prodotti e le ultime novità.

La bellissima città di Napoli sarà la sede ideale per ospitare il Convegno, che non solo è un’occasione unica di confronto e di aggiornamento professionale, ma anche un’imperdibile opportunità di incontro, di scambio di idee e di esperienze tra vecchi e nuovi amici.

PRESIDENTE DEL CONVEGNO Tullio Monetta - Università degli Studi di Napoli Federico II

Sponsorizzato da

comitato scientifIco Paola Bassani - Metallurgia Fisica e Scienza dei Materiali Giovanni Bolelli - Rivestimenti e Tribologia Fabio Bolzoni - Corrosione Franco Bonollo - Coord. Univ. per la Didattica e la Ricerca in Metallurgia Ettote Bordon - Ambiente e Sicurezza Giovanni Caironi - Fonderia AIM/Assofond Guido Capoferri - Lavorazioni Plastiche dei Metalli Vincenzo Loconsolo - Metalli e Tecnologie Applicative Gian Luca Garagnani - Storia della Metallurgia Giorgio Gavelli - Materiali per l’Energia Igor Giroletti - Controllo e Caratterizzazione dei Prodotti Carlo Mapelli - Acciaieria Enrico Morgano - Trattamenti Termici e Metallografia Piero Parona - Pressocolata Ilaria Rampin - Metallurgia delle Polveri e Tecnologie Additive Gabriele Rampinini - Forgiatura Giulio Timelli - Metalli Leggeri

ecoils.it

Spazio aziende e sponsorizzazione È previsto uno spazio per l’esposizione di apparecchiature, per la presentazione dei servizi e per la distribuzione di materiale promozionale. Le numerose proposte ideate per le aziende sono disponibili online sul sito dell’evento. Per maggiori informazioni e adesioni contattare la Segreteria organizzativa.

www.aimnet.it/nazionaleaim

Patrocinato da

Memorie scientifiche - Forgiatura

The 3D Model in the Manufacturing Process of Forged Products M. Iwaizumi

In order to assess their dimensions early, forgings have previously been sized after heat treatment with a measuring string in the heat treatment shop. The forgings have then been transported to the machining shop followed by accurate remeasurement for marking, making the original measure pointless. To improve on this inefficient process, we have installed a three-dimensional (3D) laser scanner (Leica Absolute Tracker ATS600) which enables us to measure products quickly and accurately.

Marking and reporting with the ATS600 are essential. Firstly, the data acquired by ATS600 is polygonally-transformed using a computer. Next, the amount of excess material of the forgings is assessed by comparing the polygonal data with the computer-aided design (CAD) model of the product. Finally, according to the optimized dimension data, the product can be marked anywhere using a laser on the surface of the product. Furthermore, the marking instantly provides a paper reporting the maximum and minimum of the excess material at arbitrary points on the product.

Consequently, using this device for measurement and ruling has successfully lessened operation time, resulting in shortening lead times.

KEYWORDS: ATS600, 3D MEASUREMENT, RULED LINE WORK, DIMENSIONAL MEASUREMENT, WFD TECHNOLOGY, THE SURFACE DEVIATION, DIRECT SCANNING CAPABILITY INTRODUCTION We manufacture forgings used in thermal power generation and industrial machinery. The production of steel forgings basically proceeds in the following order: casting, forging, heat treatment, and machining.

In the past, steel forgings were measured on the dirt floor of the heat treatment shop after the heat treatment process. This was done to improve forging procedures for subsequent products through early dimensional confirmation. After that, the forged products were placed on a surface plate at the machine shop to take accurate dimensional measurements for ruled line work prior to machining. In other words, dimensional measurements

Masahiro Iwaizumi

Japan Steel Works M＆E, Inc., Muroran Plant, Japan

were performed on the same product at both the heat treatment shop and the machine shop, wasting time and effort.

To solve this problem, Tokyo Boeki Techno Systems Ltd. introduced the Leica Laser Tracker ATS600 (hereafter ATS600),

a

three-dimensional

measuring

machine

manufactured by Leica Geosystems. This paper reports on a case in which the ATS600 was applied to dimensional measurement, ruled line work, and grading of wrought steel products.

La Metallurgia Italiana - Maggio 2024

pagina 8

Scientific papers - Forging MEASURING METHOD BY THREAD STRETCHING

product is measured with a ruler at each position, and the

In the heat treatment shop, the dimensions of steel

distance A-B [mm] from the shaft center of the product can

forgings after heat treatment were measured by thread

be calculated. This is done at 8 equally spaced positions.

stretching. Figure 1 shows the procedure for thread

However, the measurement method using threads is not

tensioning a shaft-shaped product. First, a temporary

accurate enough to replace the ruled line work in the next

center position is determined at both ends. A thread

process. Therefore, in order to confirm the center of the

tension rod is applied to the center position on both ends,

axis, another measurement is made in the next process,

and the thread is stretched to the same distance A [mm].

and the ruled line work is performed, which duplicates the

Then, the distance B [mm] between the thread and the

previous work.

Fig.1 - The procedure for thread tensioning.

DIMENSIONAL MEASUREMENT WITH ATS600

product's surface topography even in areas that cannot be

The ATS600 is characterized by its direct scanning

touched by humans. Direct scanning is based on Wave-

capability, which enables non-contact, non-marking

Form Digitizer (WFD) technology, which, when combined

measurement of a wide area up to 60 m from the tracker

with reflector measurement, enables measurement work

body in a single scan. This scanning allows taking the

on large products.

coordinates

and

performing

polygonization

of

the

Fig.2 - ATS 600 Main unit.

La Metallurgia Italiana - May 2024

pagina 9

Memorie scientifiche - Forgiatura Tab.1 - Chemical composition (%wt) of the A357 and C355 alloy.

Specifications of ATS 600 Absolute accuracy Reflector measurement (radius)

< ±300 μm

Non-contact measurement Measuring range(radius)

1.5 - 60m

Ambient operating temperature

0 to 40 degrees Celsius

0.8 - 80m

WFD TECHNOLOGY

return after being reflected by the product. The phase-

WFD technology combines the short measurement time

shift method measures distance from the phase shift

of the Time of Flight (ToF) method and the high accuracy

between the emitted and reflected light and from the

of the Phase Shift method to enable quick and highly

wavenumber, or frequency, of the light. The combination

accurate 3D measurements. The ToF method measures

of these two techniques enables quick and highly accurate

three-dimensional information from the time taken

measurement of even large products.

for a light pulse emitted by the measuring machine to

Fig.3 - Illustration of ToF and phase shift methods.

MEASUREMENT METHOD IN ACTUAL OPERATION

this case, it is desirable to install many targets because it

As shown in Figure 4, a target is mounted and reflectors

is necessary to read the coordinates of the reflectors on at

are read before the 3D measurement. The target can be

least three locations. By overlaying the data measured at

mounted on a location other than the product as long as

multiple locations, data for the entire product shape can

the positional relationship with the product is aligned. In

be obtained as shown in Figure 5.

Fig.4 - Work to read reflector position.

La Metallurgia Italiana - Maggio 2024

pagina 10

Scientific papers - Forging

Fig.5 - Overlaying scanned data.

Next, the measured data is compared with the CAD model

6. The alignment of the measurement data and the CAD

of the product shape to determine the amount of excess

model can be adjusted manually. The alignment can be

wall thickness. The measured data can be processed

adjusted by translating or changing the angle. This allows

using PolyWorks|Inspector™ software. By converting the

the user to set the optimum center in consideration of

measurement data into polygons and comparing it with

machining and quality in the next process during the

the CAD model, the surface deviation is automatically

product centering operation.

calculated and output as a color map as shown in Figure

Fig.6 - Matching of measurement data with CAD data.

APPLICATION TO PRE-MACHINING RULED WORK

points with a line, it is possible to create a ruled line. In the

The ATS600 can direct the laser to any location on the

creation of the center position, the laser can be directed

product. This makes it possible to apply the ATS600 to

to the center position by creating a line passing through

pre-machining creasing work. Figure 7 shows the flow of

the axis center of the CAD model. The above operations

creasing work using the ATS600. By selecting a face of the

have greatly improved the efficiency of ruled line work,

CAD model on the PC, the laser can be directed to the end

which was conventionally performed on a surface plate.

face position of the CAD model on the product. By repeating this process and connecting three or more targeted

La Metallurgia Italiana - May 2024

pagina 11

Memorie scientifiche - Forgiatura

Fig.7 - Ruled writing work using ATS600.

EFFECTS OF ATS600 APPLICATION

If the time required for conventional thread tensioning in

At present, 3D measurement is applied to almost all

the heat treatment shop and surface plate ruled lines in the

products for large forgings such as shaft shapes and

machine shop is considered to be 100%, the application of

cylindrical shapes, and dimensional measurement and

the ATS600 eliminates double work and reduces work time

ruled line work are being performed. Therefore, we

by about 65%. In addition, while at least three people were

calculated the work time for each product to investigate

required for each measurement in the conventional yarn

the improvement effect of ATS600. Figure 8 shows the

tensioning operation, the ATS600 enables measurement

average time required for dimensional measurement

and creasing by one person, thus saving manpower in the

and creasing work per product (products of all shapes,

measurement process.

including shaft-shaped products and cylindrical products).

Fig.8 - Change in dimensional measurement and ruled work time.

SUMMARY

confirmed that there were no problems in its operation.

The application of the ATS600 to forging eliminated

The application of 3D measurement to dimensional

the duplication of conventional work. The results are

measurement

summarized below.

conventional duplication of work, resulting in a 65%

The accuracy of the ATS600 was verified, and it was

reduction in work time.

La Metallurgia Italiana - Maggio 2024

and

ruled

line

work

eliminated

the

pagina 12

Scientific papers - Forging

The company plans to improve the processing capacity

the heat treatment process. The company plans to use the

of 3D measurement for further expansion to applicable

ATS600 in a wide range of applications to further reduce

products in the future. The introduction of the ATS600

costs and shorten working times.

has also made it possible to see parts that were previously invisible, such as the amount of deformation caused by

REFERENCES [1]

Hannes Maar and Hans-Martin Zogg: “WFD Wave Form Digitizer Technology”, White Paper, Leica Geosystems AG, Heinrich-WildStrasse CH-9435 Heerbrugg, (2014).

TORNA ALL'INDICE >

La Metallurgia Italiana - May 2024

pagina 13

Memorie scientifiche - Forgiatura

Evaluation of deoxidation state in molten steel using image recognition technique of reduction slag by machine learning T. Sowa, Y. Seki, T. Suzuki, S. Tanaka

Recently, Digital Transformation (DX), promoted by machine learning, Artificial Intelligence (AI), and the Internet of

Things (IoT), has been disseminated in various industrial fields. Steelmaking in Japan Steel Works M&E, Inc., however, still depends on man-powered work and adept persons. One of the processes that require high proficiency is the

projection of progress in deoxidation during secondary refining from the appearance of the reduction slag (hereinafter, referred to as slag) in a ladle furnace. Although up to now, the work has been done visually by operators, the image

recognition technology with machine learning was employed to remove the variability attributed to differences in the

operators’ ability. The technology enabled us to evaluate the state of deoxidation in molten steel during ladle-refining with a consistent accuracy,

-implying that some parts of the steelmaking process can possibly be automated, as well as reducing refining time.

KEYWORDS: SECONDARY REFINING, REDUCTION SLAG, MACHINE LEARNING, COLOR, IMAGE RECOGNITION INTRODUCTION

Our company manufactures forged steel products of

various steel grades in small lots by ingot casting (IC).

In our steel making shop, steel ingots required for these

products are manufactured in a process that consists of an electric furnace, secondary refining (LF: Ladle

Furnace), vacuum casting for steel ingots over 75 tons, and bottom casting for steel ingots of 60 tons or less. In our LF process, reduction refining (hereinafter referred to

as "refining"), vacuum degassing (VD), and composition adjustment are performed using a ladle-refining method.

Slag containing CaO, CaF2 , and SiO2 is used for refining,

and slag deoxidation and desulfurization are carried out by the redox reaction between the slag and molten steel.

The slag is a mixture of colors of low-grade oxides such

Takashi Sowa, Yuta Seki, Tadashi Suzuki, Shinji Tanaka

Muroran Plant, Japan Steel Works M&E, Inc., Japan

as CaO, CaF2 , and SiO2 , and the operator can visually and

empirically judge the deoxidation state from aspects of its

appearance such as color, gloss, and surface roughness.

However, using visual judgment, problems such as poor deoxidation and component defects have occurred due to

variations in skill among operators and errors in judgment.

Therefore, we attempted to improve DX in the steelmaking

process by using image recognition technology, which is used in various fields, to mechanically judge the deoxidation status of slag through machine learning of its image.

La Metallurgia Italiana - Maggio 2024

pagina 14

Scientific papers - Forging Electro furnace (EF)

Secondary refining (LF)

Ingot casting (IC)

Fig.1 - Summary of our steel making shop.

SLAG AND REFINING:

ten steel and reducing lower oxides such as FeO, MnO,

deoxidation using Al as the deoxidant and Si deoxidation

of the lower oxides, and the approximate composition of

oxidation method (Table. 1-1, Table. 1-2). Slag is mainly

the oxygen concentration at the end of primary melt-ing

Deoxidation in our refining is classified into two types, Al using Si, and the slag composition differs for each de-

composed of CaO and CaF2 derived from tailings materials, SiO2 derived from deoxidizers, Al2O3, FeO, MnO, Cr2O3

derived from molten steel elements and MgO derived

from refractory materials. The addition of deoxidizers du-

ring refining causes equilibrium reactions at the slag-metal interface, reduc-ing the oxygen concentration in the mol-

and Cr2O3. The color of the slag is a mixture of the colors

the slag can be estimated from the color (Table. 2). When in an electric arc furnace is approximately 800-1000 ppm, the slag is black in color, mainly FeO, but as deoxidation

progresses and reduction of FeO, MnO, and Cr2O3 proce-

eds, it becomes green to white in color (Fig. 2). Therefore, it is possible to visually determine the deoxidation status of molten steel to some ex-tent.

Table 1-1 - Composition of slag (Si killed steel).

Table 1-2 -Composition of slag (Al killed steel)

Table 2 - Color of slag

La Metallurgia Italiana - May 2024

pagina 15

Memorie scientifiche - Forgiatura

Fig.2 - Condition of slag and oxygen concentration.

One of the roles of the refining process is to deoxidize

in molten steel is measured by a 3 mm x 60 mm dia. quartz

molten steel. The purpose of deoxidation is to prevent the

tube and measuring it with a gas analysis instrument (Fig.

formation of oxidized inclusions such as Al2O3, SiO2, and

3). It takes 15 minutes to ana-lyze the collected sample,

MnO, which are types of sand defects in steel ingots. For

during which time the refiner stands by and compensates

this reason, deoxidation is essential for highly cleanliness

for the temperature drop by energized heating. Sample

steel ingots. Therefore, a cer-tain amount of slag

defects, such as minute cracks or pinholes in the sample,

deoxidation is necessary before VD to prevent deoxidation

occur with some frequency, causing errors in the gas

failure in the VD conducted in the refining process. For

analysis equipment.

general forgings such as reinforcing rolls, the deoxidation

As described above, immediate analysis of the deoxidation

status is determined visually by the refiner. On the other

state of slag during refining by its color is im-portant,

hand, in the case of rotor shafts made of NiCrMoV steel,

but since judgment based on slag color depends on the

which are used for power generation, our main product,

skills of experienced workers, it is neces-sary to develop

control values are set for the oxygen concentration before

a method that does not do so. Therefore, we attempted

and after VD because poor deoxidation and desulfurization

to use machine learning by image recognition as an

after VD can cause the formation of inclusions such as

alternative method to visual judgment.

deoxidation products and MnS. The oxygen concentration

Fig.3 - Sampling instrument of oxygen analysis sample.

IMAGE RECOGNITION AND MACHINE LEARNING:

hidden in them. Machine learning can be used for images

Image recognition is a technique that allows a computer

by converting data into numeric values, and methods such

to recognize objects in an image. (1) However, a computer

as convolutional neural networks have been proposed to

reads an image as a collection of pixel data, and to

better capture features. The Python language was used

recognize "objects" in an image, it needs to learn the

for training, image processing with OpenCV, and machine

characteristics of the surrounding pixel data. Image data is

learning with Keras. The slag for the machine learning was

stored per pixel in the three primary colors (Red, Green,

collected by immersing a steel plate welded to the end of

and Blue) or the HSV (Hue, Saturation, and Value) color

a round bar into molten steel which then adhered to it (Fig.

space as numerical values. Machine learning is an iterative

4). The slag was collected immediately before and after VD

learning using large amounts of data to find patterns

of NiCrMoV steel refining and again at the end of refining.

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pagina 16

Scientific papers - Forging Images were cropped to 256 pixels x 256 pixels to remove

the HSV system. The number of samples used as input

the background. The color of the slag varies from black to

for machine learning and the distribution of oxygen

green to white depending on the oxygen concentration,

concentration are shown below (Table.3, Fig.5).

but the RGB system may be strongly affected by the green color, so the color was preprocessed to be converted to

Fig.4 - Sampling instrument of slag.

Tab.3 - Number of samples.

Fig.5 - Oxygen concentration of samples.

RESULT OF MACHINE LEARNING FOR OXYGEN

in the test data was predicted quantitatively, and in the

CONCENTRATION PREDICTION:

classification, two threshold values were set: 85 ppm,

The oxygen concentration in molten steel was predicted

which is the control value for whether VD can proceed,

from slag images converted to HSV system using two

and 30 ppm, which is the control value for judging whether

types of models: regression and binary classification

the deoxidation status in VD is good or bad.

(hereinafter referred to as classification). Of the teaching

Comparing

data, 5% was used as test data and the remainder as

concentrations

training data. In the regression, the oxygen concentration

difference between the predicted and measured values

La Metallurgia Italiana - May 2024

the

predicted during

and

refining

measured by

oxygen

regression,

the

pagina 17

Memorie scientifiche - Forgiatura was less than 10 ppm, which is lower than the analysis

difference between the predicted and measured values

error of the gas analysis equipment, and there were also

was 40.13 (Fig.6-1,6-2).

data exceeding 80 ppm. The standard deviation of the

Fig.6-1 - Relationship between analysis

Fig.6-2 - Error between analysis and prediction.

The predicted results of the classification are generally

express the results in terms of correctness rate, fit rate,

and prediction.

evaluated in a confusion matrix

(2)

(Table.4-1,4-2). For

reproducibility rate, and F value as evaluation indices.

oxygen concentrations during refining, each region has

The values calculated from the oxygen concentration

the following meaning.

prediction results of this machine learning were more accurate with the threshold value of 85 ppm than with 30

TP (True Positive): Oxygen concentration prediction re-

ppm (Table.5). This suggests that black to green before

sult is below the threshold value and the actual measured

VD is easier to discriminate by machine learning than

value is also below the threshold value.

light green to white after VD. White tends to reflect light,

FP (False Positive): Oxygen concentration prediction re-

so variations in the image are thought to be responsible

sult is below the threshold value, but the measured value

for the lower accuracy.

is higher than the threshold value.

FN (False Negative): Oxygen concentration prediction result is higher than the threshold value, but the actual measured value is below the threshold value.

TN (True Negative): Oxygen concentration prediction result is higher than the threshold value, but the actual measured value is also higher than the threshold value.

The oxygen concentration prediction results of machine learning by classification are shown (Table. 4-1,4-2).

In machine learning by classification, it is common to

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Scientific papers - Forging

Tab. 4-1 - Confusion matrix (85 ppm).

Tab. 4-2 - Confusion matrix (30 ppm).

Tab. 5 - Result of prediction.

USING IN ACTUAL OPERATION:

COST REDUCTION EFFECT:

The following is a discussion of the Process in actual

Using this machine learning model is expected to result

operation. The results of oxygen concentration prediction

in an 8.3% reduction in electricity consumption rate and

by regression have a standard deviation of σ = 40.13, which

an improvement in ladle refractory material consumption

is a 47% variation from the control value of 85ppm for VD

rate by omitting the waiting time for oxygen concentration

progression, and thus have low reliability.

analysis before VD, resulting in a 10% improvement in

For FN and TN, deoxidation is continued in refining and

productivity.

the possibility of VD progress is checked again by oxygen concentration analysis, thus avoiding deoxidation failure.

CONCLUSION:

Deoxidation failure can be avoided. Therefore, FN is

We created a model to determine the deoxidation state

acceptable from the viewpoint of preventing quality

by machine learning the color information using data from

defects in terms of oxygen concentration prediction

images of slag in the refining process. We obtained the

classification, and evaluation by the compliance rate

following findings.

is suitable for predicting oxygen concentration during

1) By machine learning the slag image and outputting it

refining. The accuracy of the prediction of oxygen

as oxygen concentration, it is now possible to mechanize

concentration in the classification is 0.79 at the oxygen

the determination of the deoxidation state of molten steel,

concentration threshold of 30ppm and 0.92 at the oxygen

which until now has depended on human skills.

concentration threshold of 85ppm, the latter of which

2) The model for predicting oxygen concentrations from

can be said to be accurate enough to be utilized in actual

slag images was more accurate in predicting oxygen

operations. In addition, by utilizing machine learning

concentrations by binary classification than by regression,

in actual operations, data will be accumulated as actual

which outputs quantitative prediction results.

results, which will lead to improved accuracy in the future.

REFERENCES [1] [2]

K. He, X. Zhang, S. Ren, J. Sun. CVPR (2016) 770-778.

A. Luque, A. Carrasco, A. Martin, A. Heras. Pattern Recognition 91 (2019) 216-231.

TORNA ALL'INDICE >

La Metallurgia Italiana - May 2024

pagina 19

9th European Coke and Ironmaking Congress COAL, COKE, BIOCOAL, BIOCOKE, BIOCHAR AND IRON REDUCTION

Bardolino . Italy . 16-18 October 2024

2024

AIM is glad to announce the 9th European Coke and Ironmaking Congress (ECIC) to be held in Bardolino, Italy, on 16-18 October 2024.

ECIC 2024 will focus on the newest technologies in coke making, sintering, pelletizing, pyrolizing the biomasses and ironmaking (blast furnaces, direct reduction and carbon-based smelting processes).

The 2025 goal of carbon neutrality and the related intensive efforts of the steel industry will significantly affect the technologies for iron ore reduction. In this perspective, the shortage of iron ores matching the requirement for direct reduction by gas and for melting in electric arc furnace makes important proposal of new technologies and devices that can ensure the carbon neutrality even for the coal based routes.

This Congress will focus on technologies that can achieve such a goal improving the efficiency of the existing process, applying the devices that avoid a net emission of green house gases and to point out new routes based on exploitation of biomasses whose net emission is intrinsically neutral.

9th ECIC European Coke and Ironmaking Congress Bardolino . Italy 16 - 18 October 2024

SCOPE AND TOPICS The 9th ECIC will address both fundamental research work and evaluation and plant operational results and plant construction. The Congress will bring together a wide range of experts, coming from plant operation, plant suppliers, universities and research institutes, who share expertise in: . Cokemaking . Blast furnace ironmaking . Production of Biocoal/biochar . Blast Furnace muds . Industry 4.0 in ironmaking . CCS/CCUS (Carbon Capture, Use and Storage) . Sintering, pelletising, briquette production . Impact of Carbon Border Adjustment Mechanism (CBAM) . Direct reduction and Smelting reduction . H2 and Syngas exploitation The event will provide a forum for best practise and state-of-the-art technology, new developments, new ideas and research results.

BACKGROUND The Coke and Ironmaking events started separately as the European Ironmaking Congress (EIC) in 1986 in Aachen, Germany, and in 1991 in Glasgow, Scotland, and as the International Cokemaking Congress (ICMC) in 1987 in Essen, Germany, and in 1992 in London, England.

The merger of these two events took place in 1996 as the European Coke and Ironmaking Congress (ECIC) in Gent, Belgium.

1st EIC - Aachen, 1986 4th ECIC - Paris, 2000 1st ICMC - Essen, 1987 5th ECIC - Stockholm, 2005 2nd EIC - Glasgow ,1991 6th ECIC - Düsseldorf, 2011 2nd ICMC - London, 1992 7th ECIC - Linz, 2016 3rd ECIC - Gent, 1996 8th ECIC - Bremen, 2022 ORGANIZING SECRETARIAT

SPONSORED BY

Via Filippo Turati 8 - 20121 Milano MI - Italy tel. +39 02 76021132 aim@aimnet.it . www.aimnet.it

CONFERENCE WEBSITE

www.aimnet.it/ecic

Scientific papers - Forging

Additive billet and FGS forging for large forgings B. Wang, D. Zhao, Y. Liu, Y. Nie, X. Zhang, R. Wen

This paper introduces a series of transformative innovation in blank preparation, forming method and facilities development of large forgings carried out by China First Heavy Industries (CFHI) since the Austria Annual Meeting in 2017. In order to promote the high quality development of large forgings, CFHI has set up a research team for transformative innovation in manufacturing technology of heavy and high--end complex forgings, and innovatively proposed new concepts such as additive billet, effective substrate and FGS forging. Through the basic theory research and engineering practice verification, the paper discusses in detail the additive billet which systematically solves the problems of segregation, inclusion and harmful phase and the FGS forging which systematically solves the problems of low material utilization rate, mixed crystal and crack caused by tensile stress. In addition, double super round billet vertical semi-continuous casting machine, innovative application of casting billet and super large multifunctional hydraulic press which are closely related to the full implementation of the two original technological routes of additive billet and FGS forging are described.

KEYWORDS: ADDITIVE BILLET, EFFECTIVE SUBSTRATE, DOUBLE SUPER ROUND BILLET, FGS FORGING, SUPER LARGE MULTIFUNCTIONAL HYDRAULIC PRESS

INTRODUCTION

9th ECIC Euro and Ironmakin

With the continuous development of major equipment, higher requirements have put forward for large forgings.

Not only are the specifications and sections getting bigger

and the internal qualities are improving. For example, the development trend of nuclear power forgings is large-

scale and integrated[1]. The traditional manufacturing method of large forgings is different meet the above

requirements. It is well known, that there are serious problems of segregation, inclusion and harmful phase in the traditional preparation of large ingot. In the traditional

plastic forming process of large forgings, there are same

problems such as low material utilization rate, mixed

Wang Baozhong, Zhao Deli, Liu Ying, Nie Yihong, Zhang Xinjin, Wen Ruijie China First Heavy Industries, Qiqihaer, Heilongjiang, China

crystal and crack caused by tensile stress[2].

In order to systematically solve the above problems, CFHI has set up a research team for transformative innovation in manufacturing technology of heavy and high-end

complex forgings and innovatively proposed new concepts such as additive billet[3], effective substrate

and FGS forging[4]. Through in-depth basic theoretical research and a lot of engineering practice, the connotation and extension of additive billet and FGS forging are expounded. In order to better implement additive billet

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Memorie scientifiche - Forgiatura and FGS forging, a vertical semi-continuous casting

ADDITIVE BILLET

machine with double super round billet for preparing

Additive billet is an original large forging billet preparation

the effective substrate was developed, an innovative idea

technology that uses additive manufacturing model

of preparing super long casting billet into forging billet

to cover the effective substrate with liquid steel or to

then applying it in different sections was put forward, and

compound the effective substrate with each other, and

various preparatory works such as structure selection,

makes binding interface healing and microstructure

technology and construction design, manufacturing

homogenization

process of key parts and installation process of super

explanation of additive billet is shown in Fig.1.

of

composite

billet.

The

pictures

large multifunctional hydraulic press were completed.

Fig.1 - The pictures explanation of additive billet.

As we all know, different material, different preparation

of the composite interface during the heating process

methods of ingot or billet, all correspond to an optimal

before healing. Due to the “liquid-solid” composite under

solidification cross-section. We refer to the ingot or

vacuum, and the composite interface is isolated from the

billet that has no unacceptable casting defects and can

atmosphere after pouring, the composite effect is good,

obtain maximum solidification cross-section as the

and there are no visible defects (see Figure2d). After the

effective substrate. Fig.2 to Fig.4 are typical cases of basic

healing of the composite interface and the microstructure

theoretical research and experimental verification of

homogenization of the composite billet (see Figure2e),

additive billet.

the

Fig.2 shows the scale experiment of additive billet for

Figure2f) can fully meet the conditions for manufacturing

back-up roll. In order to fully cover the round billet (similar

the billet required for back-up rolls.

metallographic

microstructure

test

result

(see

to the effective substrate) with liquid steel, a low melting point support is welded to the round billet (see Figure2a) and the round billet is suspended in the ingot mold (see Figure2b). The low melting point support material is completely melted during the solidification process of the molten steel, which can effectively avoid the oxidation

La Metallurgia Italiana - Maggio 2024

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Scientific papers - Forging

Fig.2 - The scale experiment of additive billet for back-up roll.

Fig.3 shows the engineering practice of increasing the

steel melt the surface of effective substrate (the melting

diameter of back-up roll by means of additive billet making.

layer is generally controlled by 3~5mm), but most of the

Multiple electrodes are distributed in rings around the

melted surface oxides can also be eliminated with the

effective substrate, as shown in Figure3a. The diameter

slag. The compound effect after increased diameter is

of back-up roll billet was increased by ESR, as shown in

very ideal, as shown in Figure3c

Figure3b. In the process of ESR, not only the electroslag

Fig.3 - The engineering practice of increasing the diameter of back-up roll.

FGS FORGING

Fig.4 shows the engineering experiment of FGS forging

FGS forging is an original forging technology which

for cold rolling work roll made of continuous casting

combines forming, grain and stress organically in the

billet with diameter of 600mm. The goal is to replace the

visual state at the same time, and uses a combination

free forging of ESR ingot. There are crack, shrinkage hole

die to make the forging billet near net shape forming

and network carbide in the core of continuous casting

under multidirectional compressive stress, so that the

billet, as shown in Figure4a to 4c. After FGS forging, the

forging can obtain uniform and fine grain. Table1 shows

continuous casting billet containing almost all casting

the research content of FGS forging. Visualization in FGS

defects obtained grade 8 grain and carbide dispersed in

forging includes changes in the external shape and internal

both the roll neck with large extrusion ratio and the roll

structure of the forgings. Visualization technology in FGS

body with small extrusion ratio , as shown in Figure4d

forging is under development. The external shape change

to 4g. Therefore, the cold rolling work roll passes the

of forgings can be displayed by the signal collected by

rigorous surface wave detection very smoothly. This FGS

several sensors mounted on the hydraulic press and

forging method for shaft forging has also achieved very

the die. The internal structure change model of forgings

good results in the application of large section Ni-based

is established based on the numerical simulation of

alloy rotor[5] and super-alloy fine grained bar, as shown

structure evolution repeatedly optimized by the results of

in Fig.5.

forgings anatomical inspection.

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Memorie scientifiche - Forgiatura

Tab.1 - the research content of FGS forging.

THE RESEARCH CONTENT OF FGS FORGING

Research content

Shaft forging extrusion forming

Research approach

Forging with nozzle head integrated forming

Integrated forming of cylinder forging with nozzle

Other forging integrated forming

Lightweight and easy to assemble and disassemble combination mold

Visualization

Numerical simulation;

Numerical simulation;scale test;Industrialization

Anatomical verification

Development target

Rotor roll

Channel head Mono bloc up Head with quick lock

Integrated nozzle shell

Pump shell Main pipe

The inner mold is divided;the outer mold is universal;easy to assemble and disassemble

Guide production and lay the foundation for intelligence

Fig.4 - The engineering experiment of FGS forging for cold rolling work roll.

Fig.5 - The engineering experiment of FGS forging for IN617mod1 and IN718.

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Scientific papers - Forging

Fig.6 shows the combination die used for FGS forging and

6b is the nozzle of CPR100 main pump; Figure 6c is the

the forgings after removing the combination die. Figure 6a

trouser shaped tee for the 600MW fast reactor pressure

is the CAP1000 stainless steel forged pump shell; Figure

pipe.

Fig.6 - The combination die used for FGS forging.

NEW FACILITIES

super round billet is shown in Fig. 7. Because the surface

In order to popularize the original technology of additive

quality of double super round billet is better than that of

billet, CFHI led to development a double super round

die cast ingot, the problem of inclusions being exposed

billet vertical semi-continuous casting machine. Dou-

on the surface of back-up rolls or rotors can be comple-

ble super means that the diameter of 1600mm vertical

tely solved.

semi-continuous casting machine exceeds the largest continuous casting or semi-continuous casting machine diameter in the world, and the length greater than 12500mm exceeds the maximum cutting length of the continuous casting machine. The application of double

Fig.7 - The application of double super round billet.

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pagina 25

Memorie scientifiche - Forgiatura In order to promote the application of the original

(2) FGS forging is an effective way to systematically solve

FGS forging, CFHI intends to build a super large

the problems of low material utilization rate, mixed crystal

multifunctional hydraulic press[6]. After more than five

and cracks caused by tensile stress in the plastic forming

years of in-depth research, has completed the structure

process of hard to deform metal.

selection, technology and construction design, 38 key

(3) The semi-continuous casting machine and super large

parts of the casting, forging, machining and welding

multifunctional hydraulic press are a favorable guarantee

process preparation, developed the installation process

for better implementation of the two original technologies

and commissioning program.

of additive billet and FGS forging.

CONCLUSION (1) Additive billet is an effective way to systematically solve the serious segregation, inclusion and harmful phase of large ingot with hard to deform metal.

REFERENCES [1] [2] [3] [4] [5] [6]

Wang Baozhong, et al. Green Manufacturing Technology and Practice of Super Large Nuclear Power Forgings [M]. Beijing: China Electric Power Press, 2017:12.

Wang Baozhong, Manufacturing defects and countermeasures of large forgings [M]. Beijing: China Machine Press, 2019:1.

Wang Baozhong, et al. Additive Billet for Large Forgings [M]. Beijing: China Machine Press, 2023:1.

Wang Baozhong, et al. FGS Forging for Large Forgings [M]. Beijing: China Machine Press, 2023:1.

Nie Yihong, Zhu Huaishen, Bai Yaguan, Cao Zhiyuan, Xu Shihai, Wang Baozhong, Development of 617 alloy forging for 700°C advanced USC powder plant, 20th international forgemasters Meeting, 2017, 134-141.

Wang Baozhong, et al. Super Large Multifunctional Hydraulic Press [M]. Beijing: China Machine Press, 2023:1.

TORNA ALL'INDICE >

La Metallurgia Italiana - Maggio 2024

pagina 26

PREMIO

Bando Premio Carlo Longaretti - ed. 2024

L’ing. Carlo Longaretti è nato il 17 novembre 1924 e la sua vita professionale rappresenta un’esperienza emblematica di interazione tra mondo della ricerca e produzione industriale. E’ stato ricercatore universitario, rappresentante italiano presso la Comunità Europea del Carbone e dell’Acciaio per la gestione dei progetti di ricerca, fu il primo ad introdurre in Italia la produzione e l’utilizzo delle ghise sferoidali e nel 1952 con il cugino Amanzio è stato fondatore della FGS, la fonderia di acciai e ghise speciali sita in Treviglio, tuttora attiva, che ha amministrato sino alla morte avvenuta il 29 marzo 2019.

Carlo Longaretti è stata una persona determinata e geniale, in grado di integrare nel proprio lavoro le competenze elettrotecniche, strutturali e metallurgiche attraverso le quali ha sviluppato impianti fusori, tecnologie di solidificazione e nuove leghe per la resistenza alle alte temperature.

Grazie alla sua generosità e a quella della famiglia, per ricordare una delle più insigni figure che si sono stagliate nel panorama dell’industria metallurgica italiana del XX e XXI secolo, l’AIM istituisce il Premio Carlo Longaretti. Il Premio, nella sua seconda edizione, verrà conferito l’11 settembre 2024 a Napoli, in occasione dell’apertura del 40° Convegno Nazionale AIM ed include un contributo di €50.000 per sostenere il vincitore nello sviluppo della propria innovazione.

PREM IO

L’oggetto dell’innovazione proposta per il concorso può essere un nuovo materiale di natura metallica, oppure un nuovo materiale anche non metallico che abbia un impatto positivo nella produzione o nell’applicazione delle leghe metalliche oppure una nuova tecnologia metallurgica o a servizio del settore metallurgico.

soci AIM (a titolo personale o Il concorso per il premio è rivolto ai re fatta contestualmente alla aziendale), l’iscrizione ad AIM può esse al premio) e aperto a diplomati presentazione della propria candidatura entando un Istituto Tecnico che abbiano frequentato o stiano frequ ati, laureati magistrali, laure Superiore, studenti di corsi di laurea, a italiana o inglese: lingu in re enta dottori di ricerca che dovranno pres

• curriculum vitae; vazione o di vista tecnico e scientifico dell’inno • una descrizione dettagliata dal punt da: proposta (massimo 15 pagine), che inclu escludano che si tratti di un’idea di che e ione ovaz l’inn ino valid che - elementi rete di sviluppo (es. dati sperimentali carattere teorico senza prospettive conc ti ecc.). anche su scala ridotta, immagini, filma innovazione proposta; dell’ alità rigin o l’ ino - elementi che comprov intenda soddisfare la propria - elementi che indichino quali esigenze o; innovazione e quale è l’impatto attes re di quelle relative all’innovazione delle proprie pubblicazioni, in particola lista • proposta. ande, da trasmettersi per email a Il termine di presentazione delle dom . info@aimnet.it, è fissato al 31 luglio 2024

Via F. Turati 8 . Milano t. +39 0276397770 / +39 0276021132 info@aimnet.it . www.aimnet.it

Memorie scientifiche - Forgiatura

An innovation forging technology for the world's largest austenitic stainless steel ring F. Wang, W. Yin, Y. Niu, X. Ren, M. Sun, B. Xu, L. Zhao

One world record breaking——the world's largest austenitic stainless steel forging ring with a diameter of 15m was successfully forged in China. It have be used as a part of critical support devices for a new generation power plants of China. In order to meet the strict requirements of raw materials and specifications for new energy power equipment, ultra large rings were forged by an innovation process, which combined the metal construction forming technology with the forging & rolling technology. In this paper, based on describing the technical scheme and forging process in details, we analyzed the difficulties and advantages of forging technology of the ultra large austenitic stainless steel ring. Finally, the testing results of the ring indicated that, comparing to traditional ingot forging process, the combination of metal construction forming technology and forging & rolling technology has satisfactory advantages in terms of external dimension control and material performance. This study has created a new forging technology for high-quality and ultra large rings, which is of great significance for the high-quality development of large-scale mechanical equipment in future.

KEYWORDS: 316H, AUSTENITIC STAINLESS STEEL, LARGE FORGING RING, METAL CONSTRUCTION FORMING, FORGING & ROLLING INTRODUCTION Ring is generally used in the key parts of mechanical and engineering equipment of power, chemical industry and other fields[1]. With development of industrial, the ring with larger size and less welded ring are required by customers. Although the diameter of forging ring has reached 12m, it still cannot meet the growing needs of customers[2], that an 316H steel forging ring with a diameter of 15m is required[3,4].

However, there are two problems for production. The first is the manufacturing of stainless steel billet. During the solidification process of large ingot, especially for austenitic stainless steel, will form macro segregation,

Fei Wang1, Wei Yin1, Yugang Niu1 , Xiufeng Ren1, Mingyue Sun2, Bin Xu2, Longzhe Zhao2 1. Iraeta Energy Equipment Co., Ltd, Jinan 250217, China 2. Shenyang National Laboratory for Materials Science,

Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China

the center loose and hollow[5-10], which will cause crack and quality risk of forging[11-13]. The second is the forming of large ring. If free forging is used, with diameter of ring increasing, which means not only more forging time and risk increasing, but also need to increase 30% weight of the billet. So the difficulty and risk of ingot supply are further increased[14].

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pagina 28

Scientific papers - Forging

Fig.1 - World's largest forging ring.

According

with

problems

mentioned

above,

we

MANUFACTURING PROCESS

developed the metal construction forming technology to

Manufacturing of billet

solve the metallurgical quality problems of large billet[15].

Metal construction forming technology (so called MCF) is

meanwhile a forging-rolling technology of 15m-level ring

a type of additive manufacturing with continuous casting

was developed[16]. In May 2022, based on the innovation

slab as the construction units. For one billet, multi-layer

technology and process, we made the world's largest

slabs are interface diffused and integrated by stack-up,

316H steel forging ring with diameter of 15m, as shown

vacuum-package, high temperature, high pressure and

in Fig.1. It was not only reduces the weight of billet, but

large deformation, as shown in Fig.2. Compared with

also decreasing the manufacturing time. Most important,

traditional casting ingot, MCF billet is with no obvious

it could greatly improve the uniform and service safety

solidification problems such as macro segregation and

of the ring, which is the innovation solution for the high-

loose in center area, attributing to the purity and uniformity

quality development of large-scale mechanical equipment

of continuous casting slab[15]. Moreover, MCF could save

in future.

30% raw material for forging, that MCF billet is without bottom and riser, however ingot have to cut them.

Fig.2 - Technical process of metal construction and forming.

For this work, 250 tons MCF billet was made by 200mm

The chemical composition of continuous casting slab as

thick continuous casting slab of 316H steel, which was

shown in Tab.1 and MCF billet forming process as shown

produced through EAF+AOF+LF+CC process with 3 heats.

in Fig.3.

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Memorie scientifiche - Forgiatura

Tab.1 - Chemical composition of 316H steel slab.

C

Si

Mn

Cr

Ni

Mo

1# heat

0.042

0.43

1.63

17.46

11.80

2.52

2# heat

0.043

0.44

1.69

17.32

12.25

2.52

3# heat

0.040

0.47

1.65

17.27

11.80

2.54

Fig.3 - Construction forming process of 316H steel slab.

FORGING & ROLLING OF RING

ring forming process as shown in Fig.4. First of all, the

It was first time to make so large a forging ring. Considering

free forging was used for upsetting and punching with

about disadvantage factors of characteristics of austenitic

13,500 tons forging press, then rolling ring.

stainless steel for forging, we specially designed a large

Fig.4 - Forging-rolling process of ring.

It should be point that the rolling process is in two steps

ring reached 20mm/s and the growth rate was gradually

by ring rolling mill. On the first step, the axial rolling force

reduced to 0.8mm/s. After rolling, the ring was taken to

reached 100%, the growth rate was about 10mm/s, and

water cooling immediately.

the outer diameter was controlled to 7.5m. On the second step, for steady growth, the maximum growth rate of

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pagina 30

Scientific papers - Forging The scratch failure mode of the AlCrN film can be

above the substrate interface. This means that the layer

described, first, as the chipping off the side of the scratch

also possessed rather good adhesion to the substrate,

track of the outer part of the coating. The spalled areas

so that initial failure is of a cohesive nature, and complete

became progressively larger with increasing the load, until

coating removal occurs only at a later stage.

they extended across the entire width of the track. Then,

Thus, it is concluded that, using the L-PBF Ti6Al4V

at the delamination load, the entire coating was spalled

substrates (especially when subjected to the lower-

off and the substrate was detected. Actually, the initial

temperature heat-treatment at 740 °C), the adhesion

chipping failure never occurred at the coating/substrate

strength is comparable to or significantly competitive with

interface. Infact, cracks proceeded transversely along the

the adhesion of conventionally manufactured substrates.

columnar grain boundaries, crossing part of the coating thickness and were deflected along a longitudinal path

Fig.5 - Two steps rolling process of ring.

PERFORMANCE ANALYSIS

casting slabs, and the element contents varied in small-

UT testing

scale along the height. Similarly, the hardness at different

According to the NB/T20003.2-2010 standard, an A-type

heights also fluctuated vary small. It indicated MCF billet

pulse reflection UT detector was used. That the top and

had achieved the result of high-level homogenization. In

bottom sides, outer circle and the inner hole were tested

Fig.6b, all the micro-structure at different heights of the

by straight probe, double crystal probe and oblique

ring were equiaxed grain, the grain size of the top and

probe along circumferential and axial direction of the

bottom of the ring were 4 grade, and the middle height

ring, repeatedly. UT test result demonstrated that, there

is 3 grade. Which implied the forging-rolling process

was no abnormal defect in the ring, and no information

achieved the structure controlling target.

of construction interface of slabs was found, which certainly proved that the MCF billet had reached the goal of integration.

Chemical composition, hardness and micro-structure Chemical composition, hardness and micro-structure along heights of the ring, as shown in Fig.6. In Fig.6a, composition of the ring was consistent with the continuous

La Metallurgia Italiana - May 2024

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Memorie scientifiche - Forgiatura

Fig.6 - Chemical composition, hardness and micro-structure along height of the ring.

Mechanical properties

obvious distinction between the mechanical strength

Mechanical strength data and impact data along the

data of different directions. In Fig.7c, the impact results

height in different directions were shown in Fig.7.

suggested the similar situation, that impact data was

Fig.7a and b showed the tensile and yield strength data

with less fluctuation, relatively stable and no obvious

were relatively stable along the heights, and there is no

differences in different directions.

Fig.7 - The tensile, yield strength and impact of different directions along height of the ring.

Based on the analysis above, it showed that the process

the requirements of customer very well.

of MCF technology and forging-rolling technology had greatly improved the performances of austenitic stainless

SUMMARY

steel forging ring. Meanwhile the performances satisfied

A 316H steel super-large forging ring was manufactured

La Metallurgia Italiana - Maggio 2024

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Scientific papers - Forging by a innovation forming process, which was combined

2. The forging-rolling technology had realized fast

with metal construction forming and forging-rolling

manufacturing of super-large forging ring, and shortened

technologies. It successfully challenged the traditional

the manufacturing time by more than 40%.

process of the large forging ring, which broke the world

3. The test results showed that, performance of the super-

record of diameter of the large forging ring:

large forging ring manufactured by the new process, was

1. Compared with the traditional steel ingot, weight of

gratifying on integration, homogenization, stabilization.

the MCF billet manufacturing was reduced by nearly 30%. And the homogenization of matrix of MCF billet was revolutionized obviously.

REFERENCES [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16]

Sun MY, Lu SP, Li DZ, Li YY, Lang XG, Wang SQ. Three-dimensional finite element method simulation and optimization of shrink fitting process for a large marine crankshaft. Mater. Des.; 2010; 31: 4155.

Pan Y, Qian DS, Hua L, Wu JS, Cui Y, Pan ZH. Simulation and experimental research on the radial- axial rolling of 9 m diameter ultralarge ring. Journal of Plasticity Engineering; 2012; 19: 19-24, 53.

Jin HH, Ryu IS, Kim J, Lim A, Kwon J, Kim S, et al. Investigating helium ion irradiation resistance in additively manufactured austenitic stainless steels. J. Nucl. Mater.; 2024; 588: 154773.

Ziętala M, Durejko T, Polański M, Kunce I, Plocinski T, Zielinski W, et al. The microstructure, mechanical properties and corrosion resistance of 316H stainless steel fabricated using laser engineered net shaping. Mater. Sci. Eng. A; 2016; 677: 1-10.

Mehrabian R, Keane MA, Flemings MC. Experiments on macrosegregation and freckle formation. Metall. Trans.; 1970; 1: 3238–3241.

Kerr RC, Woods AW, Worster MG, Huppert HE. Disequilibrium and macrosegregation during solidification of a binary melt. Nature; 1989; 340: 357-362.

Beckermann C. Modeling of macrosegregation: Applications and future needs. Int. Mater. Rev.; 2002; 47: 243–261.

Flemings MC. Our understanding of macrosegregation: past and present. ISIJ Int.; 2000; 40: 833– 841.

Li DZ, Chen XQ, Fu PX, Ma XP, Liu HW, Chen Y, et al. Inclusion flotation-driven channel segregation in solidifying steels. Nat. Commun.; 2014; 5572: 1-8.

Pickering EJ. Macrosegregation in steel ingots: the applicability of modellingand characterisation techniques. ISIJ Int.; 2013; 53: 935– 949.

Li SJ, Sun MY, Liu HW, Li DZ. Study on void healing behavior during forging process for 25Cr2Ni4MoV steel. Acta Metall. Sin.; 2011; 47(7): 946.

Xu B, Sun MY, Li DZ. The void close behavior of large ingots during hot forging. Acta Metall. Sin.; 2012; 48: 1194.

Feng C, Cui ZS, Liu MX, Shang XQ, Sui DS, Liu J. Investigation on the void closure efficiency in cogging processes of the large ingot by using a 3-D void evolution model. J. Mater. Process Technol.; 2016; 237: 371.

Mi GF, Zhang JQ, Xu B, Sun MY. Physical simulation of internal crack healing in a heavy-forged billet. Chin. J. Eng.; 2017; 39: 16741683.

Sun MY, Xu B, Xie BJ, Li DZ, Li YY. Leading manufacture of the large-scale weldless stainless steel forging ring: Innovative approach by the multilayer hot-compression bonding technology. J. Mater. Sci. Technol.; 2021; 71: 84-86.

Luo SY, Hua L, Qian DS. Evolution behavior of sunking defect in forging rolling process of bearing ring. J. Mech. Technol.; 2014; 50: 118-121.

TORNA ALL'INDICE >

La Metallurgia Italiana - May 2024

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Memorie scientifiche - Forgiatura

Smart Forging – Processing ingots by autonomic forging and sustainable heat treatment processes to premium bars F. Hippenstiel, W. Janz, M. Mueller

The paper provides an overview of the revamping steps to install an autonomous ingot forging process at BGH Edelstahl Siegen. Further the optimization of the complete production process chain from an ingot to a heat-treated bar is shown.

KEYWORDS: FORGING PRESS, AUTOMATIZED FORGING LINE, REPEATABILITY, ENERGY EFFICIENCY, MAINTAINABILITY INTRODUCTION BGH Edelstahl GmbH has a history of forging steel of different grades for more than 550 years. Long products in different dimensions are manufactured at different locations in Germany and Poland, with each factory having its own dimensional range. The Plant in Weidenau of BGH Edelstahl Siegen produces bars with a diameter of 120 – 400 mm. The smart forging line consist of an 20MN open die forging press followed by an GFM forging machine and an in-line heat treatment facility.

This setup allows optimal temperature control through the entire process to ensure highest product quality for the widespread material portfolio, which ranges from low-alloy structural steels, tool steels, duplex and austenitic steels to nickel-based alloys. Monitoring and documentation of all relevant parameters during forging

F. Hippenstiel, W. Janz, M. Mueller

BGH Edelstahl Siegen GmbH, Germany

(e.g., dimensions and temperatures) and heat treatment (temperature and times) guaranty conformity with the most demanding requirements of BGH customers.

Furthermore, all products in the production line are marked with an individual stamping to ensure traceability for every single bar.

The foundation stone for the smart forging line was laid in 2002 with the installation of the GFM RF45 radial forging machine. In the following years, the smart forging line was continually expanded to respond to increasing demands on products, for example the installation of the inductive reheating installation in 2016 [1]. While the final forging process line is fully automatized with including

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Scientific papers - Forging process steps of forging, cropping, marking, inductive re-

was implemented also. Now the complete smart forging

hearing and quenching, therefore, extending automation

line, starting with the pre-forging of the ingot and the final

to pre-forging was the logical consequence for the

forging of the billet and ending with the heat-treatment of

entire forming process. With the last revamp of the key

the produced bar is 100 percent automated.

components of the pre-forging unit autonomous forging

Fig.1 - Process steps of smart forging line.

Besides new software solutions the hardware of the 20 MN

consumption and CO2 emissions could be significantly

open die forging press had to be updated. A new forging

reduced.

manipulator and a turntable for ingots were installed.

repeatability and process stability of a rolling mill with the

The electrical and hydraulically control system was also

advantage of being able to produce flexible diameters.

The

Smart

Forcing

Line

combines

the

partially replaced. In addition, the material transfer to the forging machine was optimized by a second ingot wagon.

DESCRIPTION OF THE FORGING PRESS

With this major upgrade, the pre-forging process of

The components of the 20 MN open die forging press are

ingots can be further optimized based on data mining

the press, Manipulator, Turning table and Ingot waggon.

and analysis. In addition, a more repeatable processes

The Press is a two-column push-down open die forging

guarantees improved product quality in closing porosity

press with a force of 20 MN. The max. speed of the

of ingot, avoidance of segregations and establish a

crosshead is 300 mm/s.

uniform microstructure with fine grain size. Also, energy Tab.1 - Parameters of Press.

Press Type

Push down – 2 columns

Max force

20MN

Drive

Oil hydraulic, 2x 800kW

Nominal pressure

320/160 bar

Height of press stroke

800 mm

Working modus

automatically / manually

Max. forging length

7,5 - 10,5 m

Crosshead speed

300/240/100 mm/s

The rail bound Manipulator has a maximum load of 10 t

Z-Directions, turning and tipping.

and the normal usual possibilities of movement: X-, Y-,

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Memorie scientifiche - Forgiatura Tab.2 - Parameters of Manipulator.

Number

1

Nominal capacity

10 t

Drive

12 m

Clamping with diameters

230 - 950

Weight

48,5 t

Working modus

automatically / manually in combination with the press

With the turntable the ingots could be turned. Because

should be able for a movement in vertical direction very

only one manipulator is available and the gripping end

low above the ground, to reach the given height of the

of the Ingot has been forged also, the ingots should be

roller tables from the GFM forging machine.

turned during forging. Due to the limited space, the turntable cannot move in sideways, so it moves in a

PROCESS DESCRIPTION

vertical direction to move out of the manipulator's travel

The Ingots from in house steel mill, which has been heated

range.

to forging temperature should be pre-forged at the open

The new ingot wagon transports the billets after pre-

die forging press followed by the final forging at the GFM

forging to the GFM forging line using additional existing

RF 45 forging machine.

transportation table. To keep the ingot waggon simple and without an additional movement in high, the manipulator

Fig. 2 - Picture of pre-forging complex.

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Scientific papers - Forging For each Ingot size, output diameter and forming group

the weight of the ingots and the principle of conservation

exists a fixed program. A program includes all required

of mass. Therefore, it is imperative that these parameters

information for the forging process: For the Manipular

are adhered to, which is achieved with defined and fixed

are the required parameter the total ways, step size and

ingot sizes from in-house steel mill. Therefore, automatic

directions in X-axis as well as turning angle and direction

forging

around X-axis. The intermediate and final diameters of the

measuring equipment. Omitting such sensors is cheaper

billet, speed, and oscillation path of the cross head of the

and less prone to failure.

works

completely

without

any

additional

press is also necessary parameters of the press (see Figure 3). The programs are based on the theoretical dimension,

Fig. 3 - Forging Parameters.

The pre-forging process starts with picking the ingots

[2].

from the forging furnace with a crane and take them with

At each time at the automatic forging process the operator

the manipulator. This should be done manually, because

has the possibility to make small corrections without

the operator must ensure that the ingot is completely

interrupting the automatic forging process. So, after the

in the tongs of the manipulator. The stop of the tongs is

correction the program is continued and should not be

the necessary fixed point. Then the operator could start

restarted again which is very user friendly. If there is a

the programme and the automatic forging starts with

main issue, the operator has every time the possibility to

processing the steps of the program. When one side is

interrupt the automatic forging by lifting the crosshead.

forged the manipulator places the billet automatically on

After solving the issue, the automatic can be restated

the upcoming turning table. After turning the billet should

again by choosing the correct program step.

be picked up from the table manually by the operator to

Before the revamping the crane had to place the billet it

ensure a fixed position of the billet in the tongs. Afterwards

on the GFM transportation table first. Only afterwards the

the automatic programme could be continued. After the

crane has the capacity to pick up and the next ingot from

pre forging is finalised, the billet is placed either at the

the forging furnace and transfer this ingot to pre forging

ingot waggon or stays in the tongs of the manipulator,

press. With the new ingot waggon, transferring the billet

depending on if the material getting directly to the GFM

to the forging line and picking up the following ingot from

forging line or should be re-heated in a forging furnace.

the forging furnace could be done at the same time. This

Process steps times and temperatures are automatically

ensures a minimum of off-peak times and a high output.

locked and transferred to the ERP system, so that the

The press is connected to the internal ERP-System. The

important parameter could be checked if an issue appears

program will be chosen by the internal system, dependent

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Memorie scientifiche - Forgiatura from the ingot size, required pre-forged diameter and

intermediate diameter and transfer it to internal system,

the material specific forming group. The press records

so everything is traced.

important

parameters

like

time,

temperature

and

Fig. 4 - Visualisation of Press.

The visualization of the complex is very maintenance

manually. Because each operator has made different

friendly because the status of all valves, pumps and

intermediate diameter, steps in x-Axis and turning angle.

engines are animated and could easily change with a click

Also, the starting point for each forging step is different,

on the symbol. Also, the connections between them are

the process has had high variations. It was not guaranteed

shown and work over several pages of the visualization

that the forging crosses of the forging steps had the

with Hyperlinks. The valve blocks are shown as a 3D clone

necessary offset. Therefore, areas were the porosity

like they are in the reality (see Figure 4). This ensures

isn´t closed while pre-forging could occur and leads to

that the maintenance staff could find the parts easily

indications during ultrasonic testing.

without spending unnecessary time to search for the

The new technology assists the operator so that he can

component based on the designation. This leads to a quick

focus on monitoring functions. Due to the wide range of

troubleshooting and short downtime. Also, the important

materials with a wide variety of forming properties, a lot

parameters of the different tool-sizes could also be easily

of experience is required to be able to accurately assess

chosen by one click.

the material behaviour during forging. It is important to

Due to short off-peak times and quick repair times the

find the optimal path between high productivity and good

average output is 23 t per hour, including off-peak times

temperature control on the one hand and an optimal

and maintenance breaks.

bite ratio and stitch removal on the other hand. Such parameters are stipulated in the programs so that forging

BENEFITS

can be carried out with the correct parameters even for

Before the revamping the Ingots has been forged

non-common materials.

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Scientific papers - Forging In relation to the workforce, the advantage arises that

There are also advantages of the revamping to reducing

even untrained newcomers can quickly gain the necessary

greenhouse gases. On the one hand, increasing quality

experience without the risk of producing material of poor

and minimizing the failure rate always saves energy. At the

quality or, worst case scenario, complete scrap material.

other hand, the specific electricity consumption for the

The required number of highly specialized stuff can be

entire system was reduced by 14% as a result of revamping

significantly reduced. This is a clear advantage, especially

the system components.

given the shortage of skilled workers.

The benefit of the automatized process with the

CONCLUSIONS

programmes is the defined forging operations and

By revamping the system technology of an open die

parameters

process,

forging press and the associated components, forging

independent of operator. The clear parameter could

can be carried out autonomous in a user-controlled

also use to simulate the process (e.g. with QForm) and

mode. Previously pre-forging was the only manual

the porosity of the forged billet to find systematic issue

process step in the fully automated Smart Forging Line.

where the offset of the forging crosses is not optimal.

With the closure of the gap, the process of forming an

With the simulation a solution could be found and being

ingot into the finished heat-treated bar steel for certain

transferred to optimise the programme of autonomous

materials is completely automated. The quality-relevant

forging. This results in a homogenization of the structure

parameters of the forged material and the documentation

and the grain size and other quality-relevant properties.

of the process could be improved and there are further

By recording the process-relevant parameters, every

advantages for personnel availability, maintenance of the

forging can be traced.

system and energy consumption.

which

ensures

a

repeatable

REFERENCES [1] [2]

HIPPENSTIEL, F., JANZ, W., & MÜLLER, M. (2017). 20TH INTERNATIONAL FORGEMASTERS MEETING - IFM 2017. DIRECT QUENCHING AFTER FORGING AND INDUCTIVE REHEATING, (P. 246 - 253). GRAZ, AUSTRIA. Grosse, A., Schoß, H., Weyl, A., & Klaas, P. (2018). Ingot Casting Rolling Forging. Process Integration of a New 20MN Forging Press at BGH Edelstahl Freital, (P. 407-417). Stockholm.

TORNA ALL'INDICE >

La Metallurgia Italiana - May 2024

pagina 39

Acciaio e metalli: dinamiche, cicli e tendenza di mercato

Acciaio e metalli: dinamiche, cicli e tendenze di mercato Rubrica trimestrale a cura di Achille Fornasini

Ha insegnato all’Università Bocconi di Milano, all’Università di Venezia e all’Università di Brescia, dove è responsabile del Laboratorio per lo studio delle Dinamiche dei Sistemi e dei Mercati finanziari.

Coordina l’osservatorio congiunturale di Confindustria Brescia e di ANIMA Confindustria. Partner di Sidewerb, da vent’anni cura rubriche dedicate ai mercati siderurgici e metallurgici. È autore di libri e centinaia di saggi, editoriali e articoli su temi economico-finanziari.

Agli inizi del mese di maggio persistono gli effetti di

tra gli altri, delle tariffe per le rotte Shanghai-Rotterdam

eventi che non giovano né alla crescita economica, né

(-40%), Shanghai-Genova (-43,8%) e Shanghai-New York

alla tranquilla ed equilibrata gestione delle imprese

(-30,3%).

manifatturiere. Mentre si assiste alla cronicizzazione del

Quei ridimensionamenti dimostrano come l’impennata

conflitto russo-ucraino, che mantiene alta la tensione

dei costi sia stata inizialmente orientata dall’ansia e dalla

in Europa, si aggrava e rischia l’escalation lo scontro in

speculazione. Il brusco rialzo di dicembre e il drastico

Medio Oriente. Uno dei sintomi del disordine è colto

calo successivo non hanno tuttavia concorso alla stabi-

dalla figura 1, che aggiorna la dinamica del World Con-

lizzazione dei nuovi livelli di costo conseguenti all’al-

tainer Index: sintesi dei costi del trasporto marittimo di

lungamento delle rotte. Nelle prime settimane di mag-

container sulle principali rotte mondiali rilevati dall’a-

gio, infatti, come conseguenza della forte ripresa della

genzia internazionale Drewry. Come si può osservare,

domanda di spedizioni dalla Cina, le tariffe sono tornate a

dopo gli aumenti straordinari realizzatisi a seguito degli

correre: +16,7% l’indice generale in scia ai rincari, tra gli

attacchi portati dagli yemeniti Houthi al traffico diretto al

altri, per la rotta Shanghai-Rotterdam (+24%), per la rotta

Canale di Suez, e con i conseguenti maggiori costi legati

Shanghai-Genova (+20%) e per la rotta Shanghai-New

alla circumnavigazione dell’Africa, la curva evidenzia

York (+16,4%). Incrementi destinati a proseguire come

una significativa flessione: -31,7% rispetto ai massimi

lascia presagire la difficoltà di trovare spazi in stiva anche

di fine gennaio l’indice generale, che incorpora i cali,

per chi dispone di contratti già sottoscritti con i vettori.

Fig. 1 - Le dinamiche dei noli mercantili.

La Metallurgia Italiana - Maggio 2024

pagina 40

Steel and metals: market dynamics, cycles and trends Accanto agli incerti sviluppi geopolitici, pesano anche

in generale si profila una volatilità crescente dei prezzi

gli alti livelli di inflazione che impediscono il tanto atteso

delle materie prime ed una maggiore opacità dei mer-

ribasso dei tassi d’interesse, i cui livelli correnti seguita-

cati conseguente all’affermarsi di cluster commerciali e

no a frenare investimenti e consumi. Il Fondo Monetario

all’incertezza sulla tenuta delle catene di approvvigiona-

Internazionale ha sintetizzato nel suo rapporto di aprile

mento globali.

la situazione generale, prospettando per il 2024 e per il

Come si evince dalla figura 2 - dedicata agli andamenti

2025 una crescita del PIL globale al 3,2%: una performan-

dei principali sottoinsiemi di materie prime - da inizio

ce che si pone al disotto della media annua storica del

anno si nota un significativo cambio di direzione delle

3,8%. Per quanto riguarda il nostro Paese, il FMI stima

commodities: al recupero delle Hard Commodities - me-

una crescita dello 0,7% per il prossimo biennio, limando

talli +13,9% e fonti energetiche +15,3% - si affianca infatti

al ribasso le proiezioni precedenti, a differenza delle at-

l’ascesa del paniere delle Soft Commodities iniziata

tese dell’Ocse poco più ottimistiche: +1,2% nel 2025. Più

peraltro già nell’ottobre 2022.

Fig. 2 - L’evoluzione generale delle materie prime.

LE PRODUZIONI DI ACCIAIO A CICLO INTEGRALE

Fig.3 - Gli elementi basilari del ciclo integrale dell’acciaio.

La Metallurgia Italiana - May 2024

pagina 41

Acciaio e metalli: dinamiche, cicli e tendenza di mercato La figura 3 illustra gli andamenti dei prezzi medi setti-

opposta (+11,5%) frenando la loro ascesa a fine quadri-

manali in dollari/tonnellata del minerale di ferro (scala

mestre. La dinamica del valore “core” della carica d’al-

di destra) e del carbone metallurgico (scala di sinistra):

toforno, cioè limitato ai soli contributi ponderati dei due

all’inizio di quest’anno, i prezzi del minerale hanno

elementi basilari del ciclo integrale dell’acciaio, inter-

raggiunto il picco di 143,50 dollari/tonnellata per flettere

cetta le inclinazioni ribassiste, esprimendo dapprima un

durante l’intero primo trimestre (-29,8%) e chiudere con

corposo un cedimento (-29%) e successivamente un re-

un rimbalzo il mese di aprile (+17%). Mentre il calo è da

cupero (+12,4%) in via di affievolimento. Dopo il raggiun-

ascrivere alla crisi immobiliare cinese, il recente recu-

gimento dei minimi fissati nel 2022 e nel 2023, la frenata

pero appare motivato dall’avvento di nuova domanda,

degli aumenti registrata a fine aprile lascia presagire il

che non prospetta peraltro la prosecuzione immediata

consolidamento laterale dei prezzi relativi agli ingredienti

della fase ascendente. I prezzi del carbone metallurgico

basilari dell’acciaio prima di un’eventuale ripresa nella

si muovono in alta concordanza con quelli del minerale:

seconda parte dell’anno.

dopo il ribasso iniziale (-32,5%), si orientano in direzione

Fig. 4 - I mercati internazionali dei coils.

Nell’ambito delle produzioni a ciclo integrale, si con-

Le evoluzioni dei principali prodotti piani nazionali rileva-

sideri la figura 4, comprendente le curve di prezzo in

ti settimanalmente da Siderweb in euro/tonnellata sono

dollari/tonnellata dei coils a caldo per rese FOB Shan-

illustrate nella figura 5: qui si osservano gli andamenti

ghai, FOB Black Sea e CIF Houston: il benchmark cinese

altamente concordanti di tutte le produzioni, che prose-

registra il suo minimo nella prima settimana di aprile,

guono al ribasso fino alla conclusione del quadrimestre

cedendo il 10% dai livelli di inizio anno. Coerentemen-

per poi consolidarsi sui minimi: -15% i coils, -14,7% le

te con la contestuale evoluzione del minerale di ferro,

lamiere nere, -14,3% le lamiere zincate, -6,5% le lamie-

segue una reazione (+3%), che tende tuttavia a rallentare.

re da treno. Persiste dunque la depressione dei mercati

Il riferimento europeo cede posizioni per l’intero primo

conseguente al protrarsi della debole domanda prove-

bimestre, per poi stabilizzarsi e chiudere il primo terzo

niente dai comparti degli elettrodomestici e dell’Auto-

dell’anno a -3%. Il mercato nordamericano, infine, si

motive: fluttuazioni destinate a proseguire nell’attuale

mantiene costantemente al ribasso, archiviando il quadri-

orientamento laterale fino a quando non miglioreranno le

mestre a -12,9%. In linea generale, le tre curve di prezzo

condizioni finanziarie di contesto.

riflettono una condizione di domanda asfittica, che profila la prosecuzione della fase stazionaria.

La Metallurgia Italiana - Maggio 2024

pagina 42

Steel and metals: market dynamics, cycles and trends

Fig. 5 - Il mercato nazionale dei prodotti piani.

LE PRODUZIONI A FORNO ELETTRICO

Fig. 6 - Le quotazioni dei rottami ferrosi.

In campo elettro-siderurgico l’analisi non può che ini-

poi risollevarsi (+4%). Ancorché sfasati temporalmente

ziare dal mercato del rottame ferroso il cui andamento

di una settimana, i prezzi dei rottami nazionali seguono

orienta tradizionalmente l’intera filiera. Si consideri al

le medesime traiettorie: all’iniziale recupero (+8,2%),

riguardo la figura 6, che propone le dinamiche in euro/

seguono un contenuto ritracciamento (-3,6%) e un

tonnellata del rottame per resa CFR Turkey e della media

successivo rialzo (+2%). Si coglie un calo della volatilità

delle quotazioni di varie tipologie di rottame - frantu-

di entrambi mercati, che evidenziano inoltre una direzio-

mato, da demolizioni, torniture e lamierino - rilevate

nalità poco spiccata come conseguenza di una domanda

da Siderweb a livello nazionale: dopo aver fissato un

ancora debole generata dal comparto dei prodotti lunghi

massimo in febbraio (+4% da inizio anno), i prezzi del

(figura 7): il grafico - dedicato alle dinamiche dei prezzi

materiale turco stornano fino a metà marzo (-11%) per

in euro/tonnellata delle principali produzioni rilevate da

La Metallurgia Italiana - May 2024

pagina 43

Acciaio e metalli: dinamiche, cicli e tendenza di mercato Siderweb - evidenzia dinamiche differenziate. Alla fine

prezzi dei laminati mercantili e delle travi, che per l’intero

del primo trimestre si esauriscono i ridimensionamenti

primo quadrimestre si mantengono al ribasso: -7,7% i

del tondo per cemento armato (-11,7%), della vergella

primi, -6,4% le seconde. Tenuto conto degli andamenti

da rete (-9,8%) e della vergella da trafila (-7,3%), che

dei prezzi del rottame ferroso e dei prodotti lunghi si può

nel mese di aprile recuperano rispettivamente il 3,1%,

cogliere la progressiva erosione dei margini industriali

il 6,7% e il 5%: rialzi che lasciano peraltro presagire un

delle acciaierie a forno elettrico: una situazione che non

consolidamento laterale delle quotazioni anziché l’avvio

può reggere a lungo ed è dunque destinata ad essere

di trend ascendenti. Si confermano dunque quei sintomi

corretta dai mercati, iniziando proprio dalle quotazioni di

di debolezza già segnalati nella puntata precedente di

travi e laminati mercantili.

questa rubrica. Ne è prova la persistenza dei ribassi dei

Fig. 7 - Il mercato nazionale dei prodotti lunghi.

METALLI NON FERROSI

Fig. 8 - I metalli non ferrosi quotati al London Metal Exchange.

La Metallurgia Italiana - Maggio 2024

pagina 44

Steel and metals: market dynamics, cycles and trends Il primo quadrimestre dell’anno si chiude in deciso rialzo

record del biennio 2021-2022 sull’onda di previsioni di

per tutti i metalli non ferrosi come conseguenza della

un’offerta insufficiente, nel prossimo futuro, a far fronte

progressiva contrazione dell’offerta da parte di diversi

alle necessità legate allo sviluppo della decarbonizza-

Paesi produttori, ma anche per effetto di sanzioni e di

zione e delle infrastrutture elettriche ed elettroniche.

vischiosità logistiche internazionali. Si veda al riguardo

L’aumento dell’Alluminio, pur approssimandosi ai massi-

la figura 8, che presenta l’andamento della media delle

mi del 2023, è meno vistoso (+12%) e tende a indebolirsi

quotazioni medie settimanali dei prezzi in dollari/tonnel-

nella seconda metà di aprile (-2,3%). Recupera anche il

lata dei principali metalli non ferrosi - Alluminio, Rame,

Nickel (+16%) che rientra tra gli elementi chiave delle

Nickel, Zinco, Piombo e Stagno - quotati al London Me-

batterie di nuova generazione per i veicoli elettrici. Dopo

tal Exchange (scala di destra) e la contestuale evoluzione

i massimi storici del 2022, il calo dei costi energetici ha

delle loro scorte fisiche detenute presso i magazzini

accompagnato la discesa dei prezzi dello Zinco culmina-

ufficiali dello stesso mercato (scala di sinistra). La curva

to a febbraio. Il successivo aumento (+24,7%), pur zavor-

sintetica dei prezzi si impenna all’inizio dell’anno per

rato dall’incremento degli stock, prefigura ulteriori rialzi.

proseguire al rialzo, violando le resistenze opposte dai

L’incremento del Piombo è stato il più lento (+5,7%) per

massimi risalenti a un anno fa, fino a metà aprile (+21,6%)

effetto di un’offerta più che sufficiente per far fronte alle

sull’onda dell’accumulazione iniziata nel 2023 per poi

richieste generate dal comparto Automotive. Straordina-

stornare (-1,8%). Nel contempo, l’entità degli stock sale

rio, infine, il balzo dello Stagno (+33%), che risale oltre

per l’intero primo trimestre (+14%) per poi diminuire

i massimi dello scorso anno a causa della contrazione

nell’ultimo mese (-5,9%).

dell’offerta da parte di Congo e Myanmar: una crisi che

Tra i metalli non ferrosi, peraltro, si distinguono evo-

appare rientrata, considerando che i prezzi iniziano a

luzioni differenziate: nei primi quattro mesi dell’anno il

flettere già nella seconda metà di aprile (-4,7%).

Rame ha registrato un rialzo repentino (+15,4%), sfondando quota 10.000 dollari/tonnellata e avvicinando i

COMPARTO INOX

Fig. 9 - I prezzi delle principali ferroleghe.

In continuità con la descrizione dei mercati delle ferrole-

scorsi anni, il primo quadrimestre 2024 vede i timidi rialzi

ghe, l’aggiornamento sugli elementi basilari della colata

del Ferro-Cromo (+3,3%) e del Ferro-Molibdeno (+5%),

inox è favorito dall’analisi della figura 9 dove se ne osser-

mentre il Nickel segna un aumento più deciso (+18,6%).

vano le evoluzioni dei prezzi medi settimanali in euro/

Gli andamenti delle ferroleghe accompagnano le evolu-

tonnellata. Dopo gli eccessi rialzisti e ribassisti degli

zioni dei prezzi delle lamiere inox riferite alle tipologie di

La Metallurgia Italiana - May 2024

pagina 45

Acciaio e metalli: dinamiche, cicli e tendenza di mercato acciaio AISI (American Iron & Steel Institute) specificate

domanda specifica in persistente contrazione.

nella figura 10. Per comprenderne appieno i movimenti,

Le prospettive dei tre mercati sono legate anche alle cre-

si consideri innanzitutto che le lamiere di natura austeni-

scenti difficoltà logistiche determinate dalle tensioni sul

tica come le categorie 304 e 316 sono guidate dai mercati

Mar Rosso, che stanno provocando la rimodulazione del-

del Nickel e del Molibdeno, mentre le lamiere di natura

le consegne e conseguenti maggiori oneri che si faranno

ferritica come la categoria 430 sono influenzate dalla

presumibilmente sentire sui prezzi finali dei laminati inox

dinamica del Ferro-Cromo.

nei prossimi mesi.

Il grafico evidenzia evoluzioni differenziate nel quadro di un mercato inox particolarmente depresso fino a

Lo scenario congiunturale in chiusura del primo qua-

febbraio e in moderata ripresa nei due mesi successivi. I

drimestre conferma le avvisaglie di ripresa registrate

moderati rialzi, peraltro, hanno riguardato solo le lamie-

già all’inizio dell’anno sull’onda di un cauto ottimismo:

re AISI 304 (+7,7%) e AISI 316 (+3,1%), sostenute anche

timidi segnali positivi, che sono peraltro tuttora deboli

dall’aumento del prezzo del rottame e da una domanda

ed eterogenei. Continueremo dunque a monitorare la

in leggero miglioramento. Ancora in flessione, invece,

situazione dei mercati metallurgici e siderurgici, che

il mercato delle lamiere AISI 430 (-1,8%) a causa di una

aggiorneremo nel numero di agosto.

Fig. 10 - L’evoluzione dei prezzi delle lamiere inox.

La mia rubrica proseguirà anche nel 2024, mantenendo la medesima cadenza temporale - febbraio, maggio, luglio-agosto, dicembre - per aggiornare di volta in volta l’attualità e le immediate prospettive dei mercati metallurgici e siderurgici in continuità con l’ultimo intervento proposto lo scorso anno (Dicembre 2023; pagg. 69-76).

Per le domande e i sempre graditi confronti: achille.fornasini@unibs.it

TORNA ALL'INDICE >

La Metallurgia Italiana - Maggio 2024

pagina 46

ialaura Tocci

nalisa Fortini, Mar Andrea Manente, An

ratici Principi teorici e p a applicata dell’analisi termic inio alle leghe di allum

lications Principles and app of thermal analysis ys for aluminium allo

Un manuale che offre una panoramica su aspetti teorici e pratici dell’analisi termica delle leghe di alluminio, attraverso schede tecniche e casi di studio reali.

Il volume è destinato a ingegneri, tecnici di fonderia, ricercatori e studenti che desiderano comprendere e sfruttare appieno le potenzialità dell’analisi termica per ottimizzare la qualità e le prestazioni delle leghe di alluminio nella pratica industriale.

Indice

Caratteristiche dell’opera

› INTRODUZIONE

Anno di pubblicazione: 2024 ISBN: 9788898990368 Formato: A4 Foliazione indicativa: 300 pagina circa Lingua: Italiano/Inglese Rilegatura: brossura cucita filo refe Prezzo di copertina: Euro 100,00

› SCHEDE TECNICHE › Leghe da fonderia e esempi di modifica › Esempi di affinazione › Leghe speciali › Leghe madri › Leghe da deformazione plastica

› CASI DI STUDIO › Effetto della variazione del Si sulla solidificazione di leghe Al-Si e Al-Mg › Effetto della modifica con Sr e Ca della lega AlSi10Cu1Mg › Effetto della modifica con Na su leghe Al-Si all’aumentare del tenore di Si › Segregazioni di fase eutettica in getti ottenuti mediante colata in bassa pressione o pressocolata › Segregazioni di fase eutettica in componenti realizzati in lega AlCu4 › Confronto tra una lega EN AB 42100 ottenuta da riciclo e la corrispondente lega primaria › Applicazione dell’analisi termica per valutare l’efficacia di maniche esotermiche e isotermiche › Valutazione dell’umidità di stampi in terra › Cricche a caldo su getti fusi in conchiglia › Esempi di affinazione di leghe Al-Mg e Al-Zn › Effetto di una affinazione non ottimale su getti ottenuti con lega Duralite

pre-ordina la tua copia

Atti e notizie - AIM news

Eventi AIM / AIM events

CONVEGNI IFM 2024 - INTERNATIONAL FORGEMASTERS MEETING – Milano, 27-30 maggio 2024 ESOMAT 2024 - 12th European Symposium on Martensitic Transformations – Lecco, 26-30 agosto 2024 40° CONVEGNO NAZIONALE AIM – Napoli, 11-13 settembre 2024 ECIC 2024 - 9TH EUROPEAN COKE AND IRONMAKING CONGRESS – Bardolino, 16-18 ottobre 2024

CORSI E GIORNATE DI STUDIO Corso modulare TRATTAMENTI TERMICI – Milano, 8-9-15-16 maggio, Avigliana TO c/o Motivexlab, 22-23 maggio, Campogalliano MO c/o Tec Eurolab, 5-6 giugno 2024 Corso itinerante METALLURGIA FUORI FORNO – 22-23 maggio, 12-13 giugno 2024 Giornata di Studio ESG: sostenibilità, carbon footprint, energia green per il settore trattamenti termici – Brescia c/o Blu Brixia Hotel e via zoom - 6 giugno 2024 Giornata di Studio SBM – Smart Bean Manufacturing: NUOVO LAMINATOIO PER TRAVI – San Zeno sul Naviglio c/o Duferco, 7 giugno 2024 Corso PROVE MECCANICHE - 12-13-19-20 giugno 2024 Giornata di Studio FUTURO SOSTENIBILE E COMPETITIVO DELLA METALLURGIA DELLE POLVERI – Maerne c/o Pometon, 13 giugno 2024 Corso MICROSCOPIA ELETTRONICA IN SCANSIONE – Milano, 18-19 giugno 2024 Corso RIVESTIMENTI – II MODULO: RIVESTIMENTI SPESSI – Milano, 19-20 giugno 2024 METALLURGY SUMMER SCHOOL ON ADDITIVE METALLURGY – Bertinoro, 30 giugno - 1,2,3 luglio 2024 Corso METALLURGIA PER NON METALLURGISTI – Milano, 15-16-22-23-29-30 ottobre 2024 Giornata di Studio MICROSCOPIA ELETTRONICA APPLICATA ALLA FAILURE ANALYSIS – Milano, 7 novembre 2024 Corso PROVE NON DISTRUTTIVE – Milano, novembre 2024 Giornata di Studio RAGGI X – Milano, 3 dicembre 2024 Giornata di Studio NUOVI SVILUPPI ADDITIVE MANUFACTURING PER BIOMEDICALE – Milano c/o PoliMi, 5 dicembre 2024

La Metallurgia Italiana - Maggio 2024

Per ulteriori informazioni rivolgersi alla Segreteria AIM, e-mail: info@aimnet.it, oppure visitare il sito internet www.aimnet.it

International Meeting on CIRCULAR METALLURGY - Raw Materials, By-products & Recycling – Bergamo, 2829 novembre 2024

pagina 48

Atti e notizie - AIM news

FaReTra (Fair Remote Training) - FORMAZIONE E AGGIORNAMENTO A DISTANZA Modalità Asincrona (registrazioni)

www.aimnet.it

Webinar NORMATIVA NEL CAMPO DEI TRATTAMENTI TERMICI Giornata di Studio STATO DI SERVIZIO DEGLI IMPIANTI, CON PARTICOLARE ATTENZIONE ALLA METALLURGIA E AGLI ESAMI UTILIZZATI Giornata di Studio LA NORMATIVA: GLI ACCIAI E I TRATTAMENTI TERMICI NELL'INDUSTRIA AUTOMOTIVE Corso PROVE NON DISTRUTTIVE Giornata di Studio TRATTAMENTI SUPERFICIALI DELL’ALLUMINIO A SCOPO DECORATIVO E PROTETTIVO Corso Modulare METALLOGRAFIA – I MODULO, II MODULO “METALLI NON FERROSI” Corso modulare FONDERIA PER NON FONDITORI Corso DIFETTOLOGIA NEI GETTI PRESSOCOLATI: METALLIZZAZIONI Corso ADDITIVE METALLURGY Corso METALLURGIA PER NON METALLURGISTI Giornata di Studio PRESSOCOLATA DELLE LEGHE DI ZINCO Giornata di Studio LA SFIDA DELLA NEUTRALITÀ CARBONICA Corso modulare TRATTAMENTI TERMICI Corso modulare I REFRATTARI SIDERURGICI E LE LORO APPLICAZIONI Corso GLI ACCIAI INOSSIDABILI 11ª edizione Corso FAILURE ANALYSIS 11a edizione

L’elenco completo delle iniziative è disponibile sul sito: www.aimnet.it

La Metallurgia Italiana - May 2024

pagina 49

Atti e notizie - AIM news

Comitati tecnici / Study groups

CT MATERIALI PER L’ENERGIA (ME) (riunione del 11 aprile 2024)

Consuntivo di attività svolte •

La GdS “Stesura specifiche dei materiali” (coordinatore Pinciroli) si è tenuta il 25 gennaio scorso con la partecipazione di oltre 50 iscritti.

A parte la tempistica che non è stata rispettata (le sessioni si sono dilungate oltre quanto programmato), i giudizi sono stati positivi, con apprezzamenti alle aziende che hanno partecipato e contribuito. Nel complesso dal questionario di valutazione finale sono emerse

osservazioni interessanti circa la necessità di approfondimenti in particolare per il settore oil and gas ma anche su idrogeno e riduzione CO2. È stata evidenziata la mancanza di esempi pratici circa le richieste restrittive da parte del cliente: l’Azienda che doveva affronta-

re queste tematiche ha fatto invece una presentazione molto generica. I partecipanti hanno chiesto inoltre come valutare la carbon

footprint e gli aspetti ambientali, ma si deve pensare a giornata ad hoc per trattare l’aspetto in termini quantitativi e non solo qualitativi.

•

Sono stati inoltre richiesti un focus sul settore ferroviario e approfondimenti sui rivestimenti anticorrosivi.

GdS “Superleghe base nichel: metallurgia, fabbricazione ed utilizzi del prodotto forgiato” si è svolta il 22 febbraio 2024 presso il Museo della Scienza e della Tecnologia a Milano. Ripamonti, tra i coordinatori, riferisce che la giornata ha avuto molto successo, la location

scelta è stata molto d’effetto; vi sono stati circa 200 partecipanti. Dai questionari sono stati raccolti giudizi positivi, e sono stati richiesti

approfondimenti su temi quali ad esempio: forgiature e trattamenti termici, ricristallizzazione, deformazione a caldo, forgiatura/laminazione delle leghe di titanio e rame, aspetti microstrutturali, proprietà meccaniche in relazione al campo di applicazione. La possibilità di interazione, anche extra evento ufficiale, ha soddisfatto i presenti. La parte della forgiatura è stata preponderante, ma la collaborazione ha dato buoni frutti, l’esperienza è da ripetere.

Iniziative future •

Si discute della possibile manifestazione su “Materiali per il settore energetico/cicli combinati a supporto della transizione ecologica”.

I coordinatori saranno Di Gianfrancesco, Merckling e Pinciroli. Viene evidenziata la difficoltà a contattare chi opera sugli impianti e che possa presentare soluzioni tecniche e tecnologiche per materiali e impianti a causa di problemi di riservatezza dei dati. Vengono fatti nominativi di aziende che potrebbero essere interpellate per la partecipazione. La giornata è da pensare focalizzata sui materiali per i

diversi impianti (cicli combinati, idrogeno o altro tipo) accomunati dalle alte temperature e dalle possibili problematiche ambientali. Si potrebbero coinvolgere altri CT interessati alla stessa tematica.

CT TRATTAMENTI TERMICI E METALLOGRAFIA (TTM) (riunione del 14 marzo 2024)

Notizie dal Comitato •

Partecipa come ospite Daniele Piccardo di Q8, che lavora nel settore dei fluidi di tempra. In effetti si tratta di un rientro nel comitato dopo alcuni anni di assenza. Il Presidente e il CT lo accettano come membro effettivo.

Manifestazioni in corso di organizzazione •

•

Il seminario webinar “Normativa nel campo dei trattamenti termici”, ormai diventato un appuntamento annuale ricorrente, si svolgerà

online nella mattinata del 15 marzo, con una trentina di partecipanti. L’obiettivo dell’evento è quello di monitorare e stimolare l’aggior-

namento continuo dei vari standard, in concerto tra clienti e fornitori.

GdS “Evoluzione degli acciai nella storia dell'automobile” (Università di Ferrara, 22 marzo 2024, coordinatori Merlin e Garagnani, in

compartecipazione con il CT Storia della Metallurgia): si tratta del terzo appuntamento su questo argomento; ci sarà anche una espo-

sizione di vetture storiche. Il programma prevede un excursus storico, in particolare sulla carrozzeria, sino ad arrivare all’auto elettrica, •

trattando aspetti di sostenibilità e corrosione. Al momento ci sono circa 50 iscritti.

Il Corso Modulare Trattamenti Termici si svolgerà tra l’8 maggio e il 6 giugno suddiviso in sei moduli oltre al modulo introduttivo. Le

giornate dei moduli 3 e 4 si svolgeranno presso Motivexlab di Avigliana (TO), quelle dei moduli 5 e 6 invece presso Tec Eurolab di Cam-

La Metallurgia Italiana - Maggio 2024

pagina 50

Atti e notizie - AIM news

pogalliano (MO): in entrambi i casi sono previste visite ai laboratori. I contenuti delle lezioni sono quelli classici potenziati sulla parte applicativa, anche in funzione dell’esito dei vari sondaggi degli ultimi anni.

Iniziative future •

La GdS per stampatori e forgiatori, storicamente organizzata presso Confindustria Canavese, si svolgerà tra ottobre e novembre 2024

•

Vicario, sulla base di discussioni sorte nel CT Sviluppo Trattamenti Termici, propone la tematica relativa alle certificazioni ISO 50001,

•

con coordinatore Trombetta. Saranno coinvolti stampatori e trattamentisti, con l’appoggio dell’UNISA che rappresenta gli stampatori. carbon-free, bilancio energetico ecc. I CT Fonderia e Pressocolata e tutte le aziende energivore sarebbero certamente interessate ad una giornata trasversale. Il CT STT spinge per fissare una data entro giugno, visto l’alto interesse per il tema.

La GdS sullo stato dell’arte ed evoluzione dei trattamenti termici (coordinatore Prof. Valentini), già prevista per luglio 2023 in Piaggio,

è stata più volte rimandata per indisponibilità dell’azienda. Si decide di tenere vivo l’argomento ma di rimandare la manifestazione alla primavera 2025.

CENTRO RIVESTIMENTI E TRIBOLOGIA (R) (riunione del 11 aprile 2024)

Notizie dal Comitato •

Il presidente comunica che è presente come ospite Alex Lanzutti (Università di Udine), che ha chiesto di far parte del CT Rivestimenti. I partecipanti al CT accolgono la sua domanda di partecipazione.

Manifestazioni in corso di organizzazione •

Corso “Rivestimenti” – 2° modulo: “Rivestimenti spessi”: il corso è stato fissato per il 19 e 20 giugno al Politecnico di Milano. Ci sono

ancora alcuni dettagli da definire, soprattutto per la prima giornata, quando alcuni oratori non sono stati trovati o non sono disponibili nelle date richieste. Per la seconda giornata mancano solo due conferme da parte degli oratori.

Iniziative future •

GdS sulla Tribocorrosione: al momento la scaletta prevede un intervento di introduzione generale e uno sulla tribocorrosione di film

sottili in ambiente marino e/o biologico. Occorre ora trovare altri interventi e oratori: durante la discussione vengono fatti diversi nomi

da contattare per verifiche. La segreteria manderà il link ad un foglio Excel condiviso per fare proposte e condividere considerazioni sul programma.

La Metallurgia Italiana - May 2024

pagina 51

Corso di base

IV edizione

Microscopia elettronica CS2417

in scansione per metallurgisti MILANO | 18-19 GIUGNO 2024 La microscopia elettronica in scansione, oltre ad essere una tecnica di microscopia con elevato potere risolutivo, fornisce un’ampia gamma di possibili informazioni microanalitiche grazie all’accoppiamento della colonna elettronica del microscopio elettronico in scansione (Scanning Electron Microscope – SEM) con rilevatori di vari segnali che emergono dall’interazione del fascio elettronico con la materia. È così possibile indagare la morfologia nella micro- e nano-scala di superfici piane o variamente strutturate di campioni massivi, e valutarne qualitativamente la composizione chimica mediante il segnale degli elettroni retrodiffusi (BackScattered Electrons – BSE) o quantitativamente mediante la spettroscopia a dispersione di energia (Energy Dispersion Spectroscopy - EDS) e di lunghezza d’onda (Wavelength Dispersion Energy - WDS), ed anche analizzare la struttura cristallografica superficiale di campioni massivi con l’analisi della diffrazione da elettroni retrodiffusi (Electron Back-Scattered Diffraction - EBSD).

Inoltre, l’evoluzione tecnologica ha ampliato la gamma delle soluzioni operative, rendendo possibile l’osservazione di campioni sottili in trasmissione in scansione (Scanning Transmission Electron Microscopy - STEM), o l’osservazione di campioni non conduttivi a pressioni prossime a quelle ambiente o in atmosfere controllate.

Tuttavia, le potenzialità di un SEM possono non essere sfruttate pienamente, qualora non si abbia una adeguata conoscenza della struttura di questo strumento, dei fenomeni di interazione degli elettroni primari con la materia, e dei limiti delle varie tecniche di osservazione. Di fatto, la mancanza di conoscenza dei fondamenti della fisica dell’interazione degli elettroni con la materia e delle tecniche di acquisizione dei vari segnali può portare ad una errata interpretazione dei risultati, o limitare la piena fruizione delle potenzialità dello strumento, mentre l’importanza di un corretto allineamento dello strumento che non è avulsa dalla conoscenza della struttura del SEM, è spesso sottovalutata.

Giunto alla quarta edizione, il corso “Microscopia elettronica in scansione per metallurgisti”, vuole riconfermare i contenuti che hanno caratterizzato le precedenti edizioni. Il Comitato Tecnico di Metallurgia Fisica e Scienza dei Materiali dell’AIM organizza un Corso in cui si forniscono le basi teoriche e pratiche di un corretto utilizzo del SEM, e l’introduzione alle molteplici tecniche microanalitiche ad esso integrate. L’iniziativa si rivolge a quanti, nel mondo industriale e nella ricerca, vogliono affrontare la microscopia elettronica in scansione con maggior consapevolezza, in quanto operatori del SEM, oppure perché fruitori dei risultati da esso prodotti. Il Corso si svolgerà in due giornate dove verranno affrontati gli aspetti teorici dello strumento SEM e delle varie tecniche microanalitiche, e le applicazioni pratiche a casi studio affrontati con differenti tipologie di strumenti. L’elemento caratterizzante del corso, ovvero la parte pratica, è stato confermato, ma con una veste del tutto nuova e speriamo gradita ai partecipanti: alle lezioni teoriche e alle dimostrazioni sui SEM da banco presenti all’evento, saranno infatti affiancate dimostrazioni in collegamento da laboratori all’avanguardia, grazie alla disponibilità di primarie aziende. Una tavola rotonda tenuta da rappresentanti delle principali case costruttrici di SEM a termine del Corso permetterà di individuare le novità nella futura diffusione commerciale del SEM e di nuove tendenze microanalitiche ad esso correlate.

Programma completo e iscrizioni su

www.aimnet.it

Organizzato dal Centro di Studio Metallurgia Fisica e Scienza dei Materiali della

con la collaborazione di

Sponsor dell’evento

Coordinatori del Corso

Giuliano Angella CNR ICMATE, Milano

Paola Bassani CNR ICMATE, Lecco

Atti e notizie - AIM news

Normativa / Standards carbon energy — Cathodic protection

Norme pubblicate e progetti in inchiesta (aggiornamento al 30 aprile 2024)

Progetti UNSIDER messi allo studio

Testing of ceramic materials - Determi-

ISO/DIS 13503-2

Norme UNSIDER pubblicate da UNI

nation of sulfur in non-oxidic ceramic

Oil and gas industries including lower

raw materials and ceramic materials ” Part

carbon energy — Completion fluids

2: inductively coupled plasma optical

and materials — Part 2: Measurement of

emission spectrometry (ICP-OES) or iron

properties of proppants used in hydraulic

chromatography (IC) after burning in the

fracturing and gravel-packing operations

nel mese di aprile 2024 UNI EN 10348:2024

Acciaio per calcestruzzo armato - Prodotti in acciaio zincato per calcestruzzo armato

dal CEN (Stage 10.99) – maggio 2024

of pipeline systems — Part 1: On-land pipelines

prEN ISO 14720-2 rev

oxygen flow ISO/DIS 5002 prEN ISO 14720-1 rev

Hot-rolled and cold-reduced electrolytic

Norme UNSIDER ritirate con sosti-

Testing of ceramic materials - Determina-

zinc-coated carbon steel sheet of com-

tion of sulfur in non-oxidic ceramic raw

mercial and drawing qualities

2024

materials and ceramic materials ” Part 1:

tuzione da UNI nel mese di aprile

UNI EN 10348-2:2019 Acciaio per calcestruzzo armato - Acciaio per calcestruzzo armato zincato - Parte 2: Prodotti in acciaio zincato per calcestruzzo armato

Norme UNSIDER pubblicate da CEN e ISO nel mese di aprile 2024 EN 10051:2024 Continuously hot-rolled strip and plate/ sheet cut from wide strip of non-alloy and alloy steels - Tolerances on dimensions and shape ISO 24476:2024 Steel — Determination of oxygen — Infrared absorption method after fusion under inert gas (Routine method) ISO 9042:2024 Steels — Point counting method for statistically estimating the volume fraction of a constituent with a point grid ISO 6435:2024 Stainless steel bars for the reinforcement of concrete

La Metallurgia Italiana - May 2024

Infrared measurement methods

ISO/DIS 4997 Cold-reduced carbon steel sheet of

EN ISO 377:2017/prA1

structural quality

Steel and steel products - Location and preparation of samples and test pieces for

ISO/DIS 3575

mechanical testing - Amendment 1

Continuous hot-dip zinc-coated and zinc-iron alloy-coated carbon steel sheet

Progetti UNSIDER in inchiesta prEN e ISO/DIS – maggio 2024

of commercial and drawing qualities

Progetti UNSIDER al voto FprEN e

prEN – progetti di norma europei

ISO/FDIS – maggio 2024

prEN ISO19901-5

ISO/FDIS – progetti di norma inter-

Petroleum and natural gas industries

nazionali

- Specific requirements for offshore structures - Part 3: Topsides structure

ISO/FDIS 15590-1

(ISO/DIS 19901-3:2022)

Oil and gas industries including lower carbon energy — Factory bends, fittings

ISO/DIS – progetti di norma interna-

and flanges for pipeline transportation

zionali

systems — Part 1: Induction bends

ISO/DIS 24204

ISO/FDIS 10714

Oil and gas industries including lower

Steel and iron — Determination of

carbon energy — Bulk material for offsho-

phosphorus content — Phosphovanado-

re projects — Design for architectural

molybdate spectrophotometric method

supports ISO/FDIS 4954-1 ISO/DIS 15589-1

Steels for cold heading and cold extru-

Oil and gas industries including lower

ding — Technical delivery conditions —

pagina 53

Atti e notizie - AIM news

Part 1: Non-alloy and alloy steels ISO/FDIS 4954-2 Steels for cold heading and cold extruding — Technical delivery conditions — Part 2: Stainless steels

La Metallurgia Italiana - Maggio 2024

pagina 54

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CIRCULAR

METALLURGY RAW MATERIALS, BY-PRODUCTS & RECYCLING

BERGAMO

28-29 NOVEMBER

2024

CALL FOR PAPERS Prospective authors wishing to present are invited to submit a tentative title and an abstract of about 400 words (in English) to the Organising Secretariat. The abstract should provide sufficient information for a fair assessment.

Two ways to submit papers will be available: • to fill in the form on the International Meeting website at www.aimnet.it • to send the title and the abstract, together with the requested information (Name and Surname, Affiliation, Mailing Address, Phone and e-mail) by e-mail to: aim@aimnet.it

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