Current projects
Optimising of secondary metallurgy in respect of non-metallic inclusions to achieve improved steel properties, quality and production efficiency with focus on special and high alloy steel.
(JK 23045)
Advanced products with optimal material properties have been the key to success for the Swedish steel industry. In order to operate at the leading edge so far as material properties are concerned, however, there is a requirement for continuous investment in enhancing the purity of the steel. This project studies how inclusions of non-metallic compounds that contaminate the steel arise during ladle treatment. The goal is to optimise the ladle process to achieve the maximum possible purity at all the participating steelworks.
The project lies within technical area 23.
Development of calculation models for scale-up of moulds taking account of the flux powder’s properties.
(JK 24051)
Continuous casting of advanced steels can be a difficult process giving rise to possible surface defects and - in the worst case - to operating interruptions. With a greater knowledge of how mould, flux and molten steel exchange heat during solidification the continuous casting process could be improved. Within this project, models are developed for scale-up during casting and are validated in industrial trials. The models are intended to constitute basic data for analysing the casting process and identifying critical process parameters in order to enhance the quality of the cast material, increase productivity and not least enable the continuous casting of more types of steel.
The project lies within technical area 24.
Feasibility of welding and cutting of stainless steel tubes with fiber laser ("FIBERTUBE")
(JK 34012)
With the introduction of laser welding in the production of stainless steel tubes there has been an increase in productivity and downward pressure on prices. To continue to be competitive there is a requirement for Swedish tube manufacturers to keep up with this development. The fiber laser has a superior beam focus which enables cutting and welding with narrower and deeper geometry at higher speeds. However, more research is required before this method can be implemented. Within the project’s first phase ("FIBERTUBE") a systematic experimental survey of different applications for the fiber laser was carried out.
The project lies within technical area 34.
Advanced welding and cutting of stainless steel tubes with fiber laser ("FIBERTUBE ADVANCED")
(JK 34013)
Both quality and productivity in the manufacturing of stainless steel tubes has great potential for improvement through laser processing. The new fiber laser facilitates excellent precision and high speed in welding and cutting which has become evident in the pilot project “FIBERTUBE”. This technology, however, requires further development; the instability phenomenon needs to be overcome while process and application techniques must also be adapted. Tube manufacturers, end users and institutes are participating in order to achieve best possible understanding of the process and its implementation in the industry.
The project lies within technical area 34.
Improved follow-up and control of metallurgical processes through reliable determination of incorporated elements and non-metallic inclusions in steel samples Phase 1 ("INNESTYR 1")
(JK 45016)
Nordic steel companies are frequently market leaders within a narrow market segment. This development has been made possible as a result of highly developed know-how of the processes and material properties that are demanded by customers. This presupposes trustworthy information from the samples that are removed for process and product control. Within the project, work is being carried out on the development of new sampling techniques for inclusion characteristics and analysis of samples with the aid of the modern PDA technique.
The project lies within technical area 45.
Improved follow-up and control of metallurgical processes through reliable determination of incorporated elements and non-metallic inclusions in steel samples Phase 2 ("INNESTYR 2")
(JK 45017)
Within this project, a new sampling methodology is being prepared for inclusion characteristics and analysis of the samples. Within Phase 1, samplers and sampling methodology have been successfully developed as has testing of the PDA technique on samples from ladle. In Phase 2 the focus will be on testing the technique that has been developed on a number of different applications in an operating environment.
The project lies within technical area 45.
Improved process technology for continuous casting of steel especially sensitive to clogging ("IGENSÄTTNING")
(JK 23052)
Clogging i.e. the process whereby non-metallic elements accumulate and become stuck in the equipment is the single largest process interruption in continuous casting. The problem cannot be solved without a holistic view that comprehends both the casting and the metallurgical process stages that precede it. In the project a study shall be made of how the composition of the non-metallic inclusions and the casting machine design and ceramic materials affect the tendency to clog. The goal is to come up with concrete proposals for changes in alloy order and improvements in the casting equipment that can reduce the problems.
This is a collaborative project between technical area 23 and technical area 24.
On-line control of temperature and decarburisation in the converter process ("LD AOD Direktmätning")
(JK 21066)
An effective process control in AOD and LD converters is dependent on a reliable prediction of temperature and carbon content. Precision in temperature and carbon content determination could be increased if the gas temperature and the ratio between CO and CO2 could be measured directly and continuously in the converters which is not possible at present. This project encompasses the development of new technology based on fibre optics to transfer data between the measurement point in the loaded converter environment for analysis. It is hoped that this shall enable a continuous and direct measuring of temperature and the CO/CO2 ratio.
This is a collaborative project between technical area 21 and technical area 23.
LOWWEAR hot WP1 och WP2
(JK 31053 och JK 31053)
In the rolling process, the rollers become worn and must be replaced subsequently in order for the quality of the strip not to be affected. This project attempts to find an accurate method to enable assessment of when roller replacement needs to take place. The project is divided into one part that concerns hot rolling (WP1) and the other part that concerns cold rolling (WP2). Within the sub-project for hot rolling, measurement methods are developed for measuring roller wear so that the state of each one of the rollers is measured and not merely the roller gap as at present. The sub-project for cold rolling includes development of a measuring roller with measurement sensor mounted on the roller surface for direct measurements of normal pressure, friction stress and contact length.
The project lies within technical area 31.
Automation, measuring and control of quality determining parameters in wire drawing
(JK 33015)
The development of wire drawing technology has reached an ‘uneven’ technical level. Certain parts of the process are very technically advanced whereas other parts have undergone very little development. This project attempts to take the entire wire drawing process to the frontline of technology through identifying and introducing new technology to those parts where developments have lagged. The idea is that this shall reduce or eliminate the requirement for quality controls or processing stages before and after wire drawing and, moreover, reduce the need for manual operations.
The project lies within technical area 33.
Temperature determination for optimal annealing
(JK 51055)
For both stainless steel products and advanced high-strength carbon steel, monitoring temperatures is essential for achieving the right mechanical properties in the end product. Today’s conventional methods for measuring and calculating the temperature of the steel do not meet the standards for precision and reproducibility that will be demanded in future. This project evaluates conventional and new temperature measuring techniques and develops statistical and physical models for temperature prediction. The goal is enhanced product quality with increased profit and reduced rejections as a consequence. In the longer term, the increased reliability of temperature determination and control increases the possibilities of reducing the utilisation of alloying elements in the steel.
The project lies within technical area 51.
Construction products based on slag Phase 1 and Phase 2
(JK 55011 and JK 55012)
From every steelworks and from each separate process stage in steel production different types of slag arise. All of these have unique characteristics that e.g. depend on their mineralogical composition. The overall purpose of this project is to increase the underlying knowledge of the mineralogical composition of the slags and the contribution of the individual minerals to the characteristics of the slags with the object of creating expanded and new possibilities for their sale.
The project lies within technical area 55.
Next generation of ingot casting system
(JK 24053)
A relatively large proportion of Swedish steel (just over 10%) is cast as ingots. The reason for this is that certain niche steels cannot be continuously cast. This project attempts to reduce the quantity of non-metallic inclusions through a new injection methodology for flux powder as well as a so-called swirl blade to reduce the turbulence at the start of casting. Advanced calculations are also carried out that shall form the basis for the next generation of ingot casting system.
The project lies within technical area 24.
Multiscale modelling of steel deformation processes
(JK 31054)
Current models of deformation properties in steel are calibrated with the aid of experiments. Through combining atomic models with macroscopic models in so-called multiscale models it is possible to end the dependence on experimental data and, in the longer term, design steel and steel processes directly in the computer. The project shall form the basis for the development of such models in Sweden which already has a leading position in respect of macroscopic models of deformation.
The project lies within technical area 31.
Development of pickling process to meet demand for pickling of new, difficult to pickle, special steels
(JK 31056)
The synthetic resins used as construction material in pickling plants are exposed to very large stresses from the strong acids that are used in pickling process. Since at present methods are lacking for assessing the condition and useful life of pickling plants maintenance is carried out at frequent intervals which leads to costly operating stoppages. The project shall develop a methodology for assessing the maintenance requirement in pickling plants and increase knowledge of the behaviour of different resins in aggressive acid environments.
The project lies within technical area 31.
Optimisation of costly alloying agents in high strength steel
(JK 32076)
The alloying elements are costly but are of decisive importance for the properties of steel. Though optimising the treatment process it is possible to change the composition of steel without the material quality being changed. Within the project an attempt is made in this way to reduce the use of alloying agents with new effective processes during heat treatment for the production of high-strength, microregulated steel without the properties being affected negatively. Special focus is placed on weldability since this is frequently limited by the steel composition.
The project lies within technical area 32.
N-CORINOX - Limits for localised corrosion of stainless steel
(JK 43028)
The use of stainless steel is frequently limited owing to the difficulties of adjudging the risk of localised corrosion (e.g. at a point or fissure). Within the project a methodology is used that has been developed in previous projects to map out how point corrosion, crevice corrosion, stress corrosion and the interaction between these forms of corrosion depend on various environmental variables for four steel grades of strategic Swedish/Nordic importance. The results are structured in a user-friendly database that can be used in the design of new products.
The project lies within technical area 43.
Production concept for growth of powder metallurgy
(JK 80097)
There are applications, frequently in products subject to high loading pressures, where powder metallurgy could be used but until now this has not been done. This is partly due to there being insufficient theoretical data to describe the influence of porosity on bearing resistance and wear and tear characteristics. The project seeks to demonstrate practicable powder metallurgy production concepts for two target objects (gear selector and sprocket).
The project lies within technical area 80.
Development of flux powder for niche steel
(JK 24052)
Continuous casting of advanced steel grades, so-called niche steel, places heavy demands on continuous casting machines and casting technology. The flux powder is a complex material that pays a multifaceted role during casting. The optimisation of the flux powder use and composition is a precondition for any casting of these advanced steel grades. Within the project a survey is carried out that shall lead to proposals for changes in the flux powder composition. This will then be tested in operating trials after the necessary analyses and calculations are carried out.
The project lies within technical area 24.
Prediction, verification and consequences of duplex microstructures ("PREDUP")
(JK 43029)
For duplex stainless steel the microstructure and thereby the product characteristics are strongly dependent on production pathway. Through utilising thermodynamic databases the structural development can be successfully calculated and modelled. The intention is to use experimental techniques to confirm the evolution and its effects on the properties. By using e.g. image analysis and FEG/SEM/EBSD, the preconditions exist for verifying models with the aid of metallography. The results shall therefore be able to be used for control of the processes.
The project lies within technical area 43.
Model-based process analysis and development
(JK 32075)
In the rolling process the steel undergoes a deformation at the same time as heat is exchanged and the steel’s microstructure is changed. In order to acquire an understanding for the process there is thus a requirement for a combination of different models. In previous projects a “tool box” with a large set of models for stimulating the rolling process has been developed. In this project the tool box is complemented in order to expand its capacity and area of application.
The project lies within technical area 32.
On-line dimension measuring and control of wall thickness in rolling of tubes
(JK 34011)
In the production of certain types of tube a thicker-sized mother tube is rolled down to a smaller dimension. Previously, it has only been possible to measure the average thickness of the tube in a continuous manner. Were it possible to measure the tube’s thickness continuously and locally the control of the rolling process could be enhanced. This project attempts to find a suitable method for measuring the dimension of hot tubes and then adapt the method to the plant and reconnect the measuring data in order to control the rolling process.
The project lies within technical area 34.
Structure and phase stability with steel
(JK 41010)
In the development of new steel grades in future, the use of so-called first-principle models, i.e. models of the steel at the atomic level, will come to play an ever more important role. Such models can subsequently form the basis for a modelling at a rougher level or for multiscale modelling, the purpose of which is the design of new steels and steel technologies directly in the computer. Within the project, models are developed at an atomic level for the most important bulk phases of the steels as well as their surfaces, grain boundaries also including intermediate phase boundaries with special regard being paid to duplex steels.
The project lies within technical area 41.
Non-destructive determination of microstructure, hardness penetration and inner stresses
(JK 44030)
Determination of microstructure, hardness penetration and mechanical properties has until now always meant destructive sampling. This means that produced parts will be discarded and a costly and time-consuming work must be carried out. In recent time several methods to measure different material parameters in a non-destructive manner have been presented. By combining different investigation methods measurement errors should be able to be minimised. Within the project different techniques are evaluated for non-destructive testing, separately and in combination. Apart from the optimisation of the measurement parameters for the respective method the object is also to present the combination of methods that offers the best possible measurement results.
The project lies within technical area 44.
Modelling of loss of flatness on tempering, straightening and cutting ("ModFlat")
(JK 31056)
On manufacturing of plate and strip the intention is naturally to achieve as high degree of flatness as possible. Flatness is affected however in several operations e.g. during tempering. In this project, the effect of different operations and process parameters (e.g. uneven cooling) on the plate/strip properties shall be investigated via modelling and trials. This shall result in concrete recommendations in the case of tempering, straightening and cutting in order to maximise flatness.
The project lies within technical area 31.
Material performance in cold working operations ("COLDMAT")
(JK 41011)
Simulating how steel behaves in different forming operations e.g. bending and wire drawing, is acquiring increasing importance within the industry. However, the results obtained from a simulation depend heavily on the quality of the material model employed. Traditionally, empirical models are used that have little or no connection with the material’s make-up which means that precision is lacking when the conditions are not the same as the test conditions used for development of the model. The project plans to develop models that are based on physical descriptions of the material which enable the models to simulate the steel’s performance over large elongation and elongation rate ranges.
This project lies within technical area 41.
Development of thermodynamic databases for industrial applications ("Legeringsutveckling")
(JK 41012)
Predictions of phase equilibria using calculations is a powerful tool for alloy development. Reliable software and thermodynamic databases are available for many commercial steel types. In composition and temperature ranges that have not previously been investigated, new information and validation of
calculations is needed. The project will provide new experimental information that will be integrated with available thermodynamic databases. The work will be performed in collaboration between Swerea KIMAB, KTH and Swedish industry, and will provide important input to the long term development of
the field.
This project lies within technical area 41.
Rolling at high strain rates and high temperatures
(JK 32077)
At hot rolling of wires the productivity for some steel grades are limited by the final rolling speed since an increased rolling speed is related to a considerable increase in the stock temperature which in turn might cause melting. Hence, an unwanted loss of production and costs due to yield losses arise. The aim of the project is to suggest process improvements based on present hot rolling equipment for increasing the final rolling speed/production volume with preserved quality. Hence, advanced modelling based on finite element analyses of the entire deformation process is suggested. Therefore, accurate material data is needed for precise simulations of the hot rolling process. Material testing at high strain rates will be performed in specially designed equipment suitable for dynamic conditions.
The project lies within technical area 32.
Conducting polymer as a green and smart corrosion protection of steel
(JK 41013)
The research aims at developing an alternate form of corrosion protection of steel based on conducting polymers. It requires a novel combined multi-disciplinary effort where surface chemistry, corrosion science and polymer technology are integrated.The coating is chromate-free, self-repairing, reacts smart on the environment and may be applied in only one step, whereby several environmental benefits are obtained. The overall goal of the project is to produce the surface coating on steel in an industrial lab scale that passes current standard corrosion tests in chloride-solutions.
