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Documenti di Professioni
Documenti di Cultura
of
9 Cr Mo Steels
Overview on 9Cr Mo
Steels
P11 and P22
P11 /P12
Performance
P5 and P9
These
P5/P9
Increased
Applications
P91
P91
The
microstructure is
medium carbon
martensite with little or no retained ferrite.
This is developed combining the advantages
of the existing
9%Cr and 12%Cr steels
with improved weldability.
P91
Performance
Modified
9%
chromium,
1%
molybdenum
creep-resisting steel with tungsten
Also known generically as Grade
92/NF616 and E911
These
Modified 9Cr Mo
The microstructure is tempered martensite with little
or no retained ferrite.
Background
Performance
Properties of P91
High Hardness
issues in Moulding
Quality issues in Melting
Quality issues in Refining
Quality issues in HT
Quality issues in Weld repair of casting
Definition
Process in which molten metal flows by
gravity or other force into a mold where it
solidifies in the shape of the mold cavity
Steps
Disadvantages of Casting
Different
Overview of Casting
Technology
Casting
cavity
whose
determines part shape
geometry
2.
Melting
and Pouring
4.
5.
Advantages
Disadvantages
Examples
Sand
engine blocks,
cylinder heads
Shell mold
Expendable
pattern
Plaster mold
prototypes of
mechanical parts
Ceramic mold
small sizes
impellers, injection
mold tooling
Investment
jewellery
Permanent
mold
Die
Centrifugal
pipes, boilers,
flywheels
Steel castings-Molding
Green
Sand molding
Resin sand molding
(Two part ,three part ,Air set etc)
Investment casting
Shell molding
Ceramic molding
Sand Casting
Sand Casting
(Expandable-mould,
Permanent-pattern Casting)
In
Centrifugal Casting
Shell Molding
Steel casting-Types
Plain
C steel
Low alloy steel
Cr-Mo, Ni-Mo ,Cr-Ni-Mo ,Ni-Cr-Mo
steels
High alloy steel
SS 304,316 ,Duplex, Martensitic
grades
Heat resistant grades
ASTM
Steel casting
-Specification
steels
ASTM A 351, ASTM A 352
S.Steels
ASTM A 487- Alloy steel
ASTM A 787
ASTM A 800
ASTM A 801
Steel-Specification
WCB
Specification
Mechanical properties of
GP91 cast steel
Applications
Steam turbines
Turbine bodies
Cylinders
T-Pipes
Valve Chambers
HRSG
Materials for Headers
X20CrMoV11-1
X10CrMoVNb9-1(P91)
X11CrMoWVNb9-1-1 (P911/E911)
X10CrWMoVNb9-2 (P92)
Alloy 617
and Piping
Molding Issues
Sand
Molding Issues
Placing
of core,sleeves
Proper closing
Correct size of chills
Correct composition of Internal
chills
Proper clamping
Top weights
Parting line check
Lab sample and Test bar mold
Melting Furnaces
EAF
EIF
Refining
vessels
Induction Furnace
A current
Induction Furnace
Pouring Vessel
Pouring vessels
returns
M.S. Scrap/S.S. scrap
Borings
HSIB
Fe alloys
Flux
Slag remover
Deoxidants
Melting issues
Charge
composition
Furnace lining
Melting time
Deoxidation
Furnace and ladle deoxidation
Pouring temperature
Cleanliness
Melting issues
Raw
Melting-contd
Slag
Metal Treatment
Ladle
Injection treatment
LRF
Desulfurisation
Dephosporisation
Graded
scrap
Proper Cr addition
Vaccum degassing
Ladle -Issues
Ladle
Pouring-Issues
Ladle
deoxidation
Clean spout
No oxygen lancing of ladle
Pouring without turbulence
Temperature drop
Correct pouring plan-Load cell
Sprinkling of Exothermic powder
Heat Number Tag
Fettling Issues-Inspection
Visual
Inspection
Removal of Defective castings
Off composition melts
Shot blasting
Shot blasting m/c- maintenance
Heat no punching
House keeping
Fettling-Issues-cutting
Gas
cutting- C steel
Arc cutting- S.S
Abrasive wheel cut
Water Jet cutting
undercut on casting
Proper color coding of risers and gates
Placing in bins
House Keeping
Fettling Issues-Heat
Treatment
H.T. furnace
refractory
Correct batch size
Checking on Burners
Calibration of Thermocouples
Water tank circulation
Fan circulation
Temperature, soak time ,Atmosphere
Fettling Issues-Heat
Treatment
Homogenize
castings
Q/T , Normalizing and tempering +SR
HT cracks- Forced air cooling
Intermediate SR for crack prone alloys
Abrasive wheel cutting/Water jet
Fettling-Casting repair
Weld
Fettling-NDT
Radiography
Design-Issues
Correct
methoding
Development of castings
Issues in development- clearly
Brain storming
Remedial measures
Economical design
High yield
Casting Defects
Defects
Casting defects
Internal Defect
Blow holes
Porosity
Pin holes
Inclusions
Dross
Visible defects
Wash
Rat tail
Swell
Misrun
Cold shut
Hot tear
Shrinkage/Shift
Internal Defects
Visible Defects
Casting Design:
guidelines
Use of chills
Casting Design:
guidelines
Casting Design:
guidelines
Casting Design:
guidelines
of
Introduction
A metal
Bolts
Rivets
Connecting rods
Gears
billets
Open Die forging
Closed die forging
Trimming
HT
Inspection
Grain Structure
Parts
Fig : A part made by three different procedures, showing grain flow (a) casting (b) machining (c) forging
Open-Die Forging
Is
Open-Die Forging
Upsetting or flat-die forging
a solid workpiece is
placed between flat dies and is compressed
Barreling
The
material
Fullering material is distributed away from an area
Edging material is gathered into an area
Blocking
Impression
Precision Forging
Used
Formability
Selection
Advantages of forging
There
is an
improvement in
properties take place because
forging:
Breaks up segregation, heals
porosity, and aids homogenization
Produces a fibrous grain structure
that
enhances
mechanical
properties parallel to the grain flow
Reduces as-cast grain size
Thank You