Alloy steel plate production involves complex processes such as smelting, casting, rolling, heat treatment, and finishing. Due to the high requirements for alloying element control, microstructure uniformity, and mechanical properties, various issues may arise during production. These problems can affect product quality, performance, or usability. Below are common situations/defects that may occur in the production process, categorized by key stages:

1. Smelting & Casting Stage

This stage involves melting raw materials (iron ore, scrap steel, alloying elements like Cr, Ni, Mo, etc.) and casting into slabs (continuous casting or ingot casting). Key issues include:

 

Element composition deviation

Causes: Inaccurate addition of alloying elements, uneven mixing in the molten steel, or loss of volatile elements (e.g., Mn, Si) during smelting.

Impact: Failure to meet standard requirements for alloy content (e.g., Cr content in 4130 steel is too low), leading to insufficient strength, corrosion resistance, or hardenability.

Non-metallic inclusions

Causes: Incomplete removal of slag, reaction between molten steel and refractory materials, or contamination by air (forming oxides like Al₂O₃, SiO₂) or sulfides (e.g., MnS).

Impact: Inclusions act as stress concentration points, reducing the plate's toughness, fatigue resistance, and weldability. Severe inclusions may cause cracking during rolling.

Gas porosity

Causes: Inadequate deoxidation (residual gases like O₂, N₂, H₂ in molten steel) or rapid cooling during casting, trapping gases in the slab.

Impact: Small pores (surface or internal) weaken the material's density. Surface porosity can lead to cracking during rolling, while internal porosity reduces mechanical strength.

Shrinkage &  (Looseness)

Causes: Uneven cooling during solidification, resulting in insufficient molten steel feeding to compensate for volume shrinkage.

Impact: Internal voids or loose structures reduce the plate's compactness, leading to lower tensile strength and impact toughness.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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