centre for advanced steels research, casr · thermodynamics! reaction kinetics! reaction mechanism!...

Centre for Advanced Steels Research, CASR

ADMA Seminar 21.05.2015 Prof. Timo Fabritius

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http://www.oulu.fi/casr/

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Architecture

Mining and mineral

engineering

Steel research

Business and

economy

Research based teacher education

Environment, natural resources

and materials

Cultural identity ���and interaction

Information technology

Biosciences and health

Scientific Profile of University of Oulu

HUMANS TECHNOLOGY ENVIRONMENT

Faculty of Technology – ���Research groups

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Material Engineering Includes Physical Metallurgy and Rolling Technology groups

Center for Advanced Steels Research, CASR

CASR covers the whole chain of steel processing from raw material handling to the mechanical properties of steel and the fabrication of final product:

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-  process control, -  process and physical

metallurgy based design, -  prediction of chemical

compositions, micro-structures and

-  the rolling stage modelling

-  modelling the relationships between industrial processing data and

-  modelling the properties of novel steel grades.

“Virtual Research Unit”, founded 2006

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Organisation of CASR

6 Organization of CASR

Advisory Board

Kari Knuutila Outotec Oyj / Oulu Mining School

Jukka Kömi, SSAB Europe Oy

Mikko Ylitalo, Outokumpu Oyj

Pekka Karvonen, Oy Ovako Ab Imatra

Kalle Kantola, FIMECC Oy

Kari Keskinen, Tekes

NN, Association of Finnish Steel and Metal Producers

Staff for steel research at CASR

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(m-years)

Staff of CASR (currently) 8

Material Engineering Group (Prof. David Porter): Personnel (Total 27)

- 2 professors (JL from 1.2.2015), (1 emeritus), 3 lecturers,

- 4 technical staff,

- 17 researchers incl. 5 postdocs + 2 visiting postdocs

Incl. Rolling Technology Group (Prof. Jari Larkiola) now 4, expanding

to 6 in near future

Process Metallurgy Group (Prof. Timo Fabritius):

Personnel (Total 25)

- 1 prof. + 1 FiDiPro, 2 lectures, 1 technical staff,

- 16 doctoral students plus 4 postdocs

Main inventory of CASR (1/3) 9

Material Engineering Group:

•  Gleeble 3800 thermomechanical simulator

•  Laboratory rolling mill

•  Mechanical testing machines (MTS 810, Zwick 100)

•  Macro- and microhardness

•  Laser and optical microscopes, metallography

•  GDOES (GDA750)

•  STEM, FESEM-EDS-EBSD, EPMA, XPS, FIB+FESEM

+EDS, XRD at MNT center

Main inventory of CASR (2/3) 10

Process Metallurgy Group:

•  High temperature devices

(DSC-TGA-MS, High-T viscometer, Optical dilatometer)

•  BSF, Blast furnace gas phase simulator

•  Water models for fluid simulations

•  Fluent, OpenFOAM, FactSage, ThermoCalc, MiniTab

•  FESEM, EBSD, EDS, XRD at MNT center

http://www.oulu.fi/pyomet/node/2221

Main inventory of CASR (3/3) 11

Future Manufacturing

Group:

•  Lasers •  Water jet cutting machine •  Pilot induction heating plant with accelerated cooling unit

http://www.oulu.fi/fmt/FMT6/indexENG.html

Development of infrastructure of CASR 12

2011: SEM-EDS; GDOES; DSC

2012: 3D Laser scanning microscope; EBSD

2013: ThermoCalc and FactSage

2014: Up-dating the fatigue testing environment (DIC,..)

2015: High-T XRD

2016: (New TEM to MNT Center)

Examples of research projects (1/3)

Material Engineering Group:

•  FIMECC DEMAPP - Production and Properties of New Wear Resistant Materials. UO: 1.0 M€, SSAB Share of the Work 90 %, 2009‐14

•  FIMECC LIGHT- Production and Properties of Breakthrough Materials. UO: 2.6 M€, SSAB 64%, 2009-14

•  FIMECC BSA – Novel Super-High-Strength Steels.

UO: 2.7 M€, SSAB 100%, 2014-2018

•  UKRa, TeOS (2005-11)

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FIMECC (Finnish Metals and Engineering Competence Cluster) is an open innovation R&D company.

Examples of research projects (2/3)

Process Metallurgy, ECE, BISG Groups:

1. FIMECC-ELEMET Energy and Lifecycle Efficient Metal Processes,

- Material Efficient Blast Furnace, UO Budget 645 k€, SSAB share 90%, 2009-14

also attended by ECE 0.30 M€

- Advanced Melt Metallurgy, 1 M€, SSAB 50%, 2009-14

2. SA - Efficient Fuel for a Blast Furnace, 1.03 M€, SSAB 90%, 2011-15

3. FIMECC-SIMP System Integrated Metal Processes

- Dynamic Multiphysics Modelling as Guidance in Progressing Steel Making,

1.25 M€, SSAB 50%, 2014-18

- Decision Support of Metallurgical Processes, 937 k€, SSAB 50%, 2014-18

SIMP is also attended by BISG, 1.45 M€

•  :

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Examples of research projects (3/3)

FMT Group:

° ULLE Ultra high--strength steel workshop usability.

Budget 456 k€, SSAB share 6.6% (30 k€), 2007-09.

° ULLA Local laser heat treatments of ultra-high strength steels.

Budget 600 k€, SSAB share 7.5% (45 k€), 2009-11.

° ROLLE Ultra-high strength steel forming expertise.

Budget 571 k€, SSAB share 5.2% (30 k€), 2009-11.

° KEKERA Robust and light weight structures.

Budget 900 k€, SSAB share 3% (30 k€), 2014-17.

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Doctoral dissertations since 2011 16

•  Suopajärvi Hannu; Bioreducer use in blast furnace ironmaking in Finland. Techno-economic assessment and CO2 emission reduction potential, 2015

•  Kulju Timo: Utilization of phenomena-based modeling in unit operation design, 2014

•  Tamminen Satu; Modelling the rejection probability of a quality test consisting of multiple measurements, 2014

•  Mehtonen Saara; The behavior of stabilized high-chromium ferritic stainless steels in hot deformation, 2014

•  Heikkinen Eetu-Pekka; On the role of computational thermodynamics in research and development of AOD and CRC processes, 2013

•  Paananen Timo; The effect of minor oxide components on reduction of iron ore agglomerates, 2013

•  Sorsa Aki; Prediction of material properties based on non-destructive Barkhausen noise measurement, 2013

•  Ruuska Jari; Special measurements and control models for a basic oxygen furnace (BOF), 2012

•  Martin David; Selected heat conduction problems in thermomechanical treatment of steel, 2011

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MSc degrees since 2008

Publications at CASR in 2008 -14 18

Core competencies:

- Reduction metallurgy (Blast Furnace, Sintering, SAF, coke) - Coke research (reactivity, hot strength, ash) - Refining metallurgy (BOF, AOD, secondary metallurgy)

•  Application areas:

- Metallurgical processes of metal production chains (high temperature chemistry) - Utilisation and modification of dusts, sludges and slags in iron, ferroalloy and nonferrous production

- novel measuring methods in metal production (laser based, emissiospectroscopy)

Research Tools:

- Thermodynamical Modelling (HSC, Fact Sage) - Computational Fluid Dynamics (Fluent, Open Foam, MatLab) - Experimental methods and analysis (DTA-TGA-MS, Blast Furnace Simulator, high temperature furnaces, microscopies)

Process Metallurgy Research Group

FACTS (2014): Staff: 25 1 full professor 1 FiDiPro professor (2014-16) Degrees: 10 M.Sc., 1 Ph.D. a 16 research projects 16 referee publications 2 Spinn-off companies

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Core competencies of Process Metallurgy

Transfer Processes Mass Transfer Heat Transfer Momentum Transfer

Structures Mineralogy Applied petrology

Reactions Thermodynamics Kinetics Mechanisms

HIGH TEMPERATURE CHEMISTRY

Juho Haapakangas Anne Hietava Matti Sakaranaho Mikko Iljana

Stanislav Gornostayev Pekka Tanskanen Olli Peltosaari Jyrki Heino Hannu Suopajärvi Mamdouh Omran

Antti Kemppainen Aleksi Laukka Aki Kärnä Timo Fabritius Petri Sulasalmi Ville-Valtteri Visuri

Tommi Kokkonen Eetu Heikkinen Riku Mattila Teija Sipola Tuomas Alatarvas

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Way to make a research

Fluent Phoenics MatLab

Laboratory experiments

Industrial trials

FactSage ThermoCalc

HSC Chemistry Factory ST

Micro mass transfer Macro mass transfer

Heat transfer

Thermodynamics Reaction kinetics

Reaction mechanism Surface chemistry

Physics Mathematics

Physical chemistry Inorganic chemistry

Basic knowledge

Research results (models, analysies)

Tools and methods

Applied Know-how

Mega-scale (mass and heat balances, circulation processes)

Micro- ja nanoscale (mineralogical-, chemical

analysies)

Macro-scale (fluid flow modelling,

industrial trials)

Multi scale modelling (time

and scale)

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Research topics at Material Engineering