Hesham Saad Elsherbeny’s Post

What is electroslag remelting(ESR)? Electroslag remelting (ESR) is a special metallurgical method mainly used for refining various alloy structural steels, heat-resistant steels, bearing steels, die steels, high-temperature alloys, etc. The basic principle is to use the resistance heat generated by the current passing through the molten slag to remelt and refine metals or alloys, and to sequentially solidify into steel ingots or castings. During the electroslag remelting process, metal droplets come into full contact with high-temperature, high-basicity molten slag, resulting in strong metallurgical chemical reactions that refine the metal. The main functions of electroslag remelting include: 1. Improving metal purity, enhancing ingot crystallization, and removing inclusions. 2. The slag system of the electroslag remelting furnace plays a significant role in heat source, protection, shaping, and metallurgical chemistry, greatly affecting product quality and technical-economic indicators. 3. Products from electroslag remelting have characteristics such as metal purity, dense organization, uniform composition, good shaping, smooth surface, and excellent service performance. 4. Electroslag remelting technology can save energy, improve production efficiency, and reduce production costs. The key technology of the electroslag remelting furnace is the slag system, and the chemical composition of the slag has a significant impact on product quality. The characteristics of the slag include: - Having a higher resistivity to generate sufficient heat during melting. - Having a certain basicity for good deoxidation and desulfurization effects. - Not containing stable oxides, such as MnO, FeO, etc. - Having good fluidity to ensure full convection heat exchange and liquid physical chemical reactions at high temperatures. The application range of electroslag remelting furnaces is extensive, not only can it produce various steel grades but also can be used to produce large high-quality alloy steel ingots, special-shaped castings, etc. Through electroslag remelting technology, high-strength, plastic and tough steel can be produced, which is used in high-end equipment manufacturing fields such as aerospace and military industries.

ABCD of Metallurgy... 🔠🔥 Alloy: is a mixture of two or more metals. Alloys have different properties than the individual metals that make them up. Brittle: is a term used to describe a material that breaks easily without bending or stretching. Corrosion: is the process of a metal reacting with its environment and breaking down. Ductility: is a term used to describe a material that can be stretched or drawn out without breaking. Extractive Metallurgy: is the process of extracting metals from their ores. Forging: is a process of shaping metal by hammering it hot. Heat Treatment: is a process of heating and cooling metal to change its properties. Hydrometallurgy: is a process of extracting metals from their ores using water. Ingot: is a large, solid piece of metal that is cast from molten metal. Joining: is the process of connecting two pieces of metal together. Kneading: is a process of mixing metal powders together to form a solid mass. Lamination: is the process of forming metal into thin sheets. Machining: is the process of removing material from metal to create a desired shape. Nemesis: is a metal that is very difficult to extract from its ore. Ores: are rocks that contain metals. Physical Metallurgy: is the study of the physical properties of metals, such as their structure, strength, and ductility. Quenching: is a process of rapidly cooling metal to change its properties. Recrystallization: is the process of forming new crystals in a metal. Smelting: is a process of extracting metals from their ores by heating them in a furnace. Tempering: is a process of heating and cooling metal to change its properties. Ultrasonic Machining: is a process of removing material from metal using ultrasonic vibrations. Vacuum Metallurgy: is a process of extracting metals from their ores in a vacuum. Welding: is a process of joining two pieces of metal together by melting them together. X-Ray Metallography: is a technique used to study the microstructure of metals. Yield Strength: is the stress at which a metal begins to deform plastically. Zinc: is a metal that is often used to protect other metals from corrosion.

The quenching process is a heat treatment technique used in metallurgy to alter the properties of metals, most commonly steel. It involves heating the metal to a high temperature and then rapidly cooling it by immersing it in a cooling medium like water, oil, or air. The purpose of quenching is to harden the metal by creating a more uniform and controlled microstructure Steps in the Quenching Process: 1.Heating: The metal is heated to a specific temperature, usually above its critical temperature, to a point where its crystal structure becomes austenitic (a phase where carbon is dissolved in the iron). 2.Holding: The metal is kept at this temperature for a certain amount of time, allowing the temperature to become uniform throughout the material. 3. Quenching (Cooling): The metal is then rapidly cooled in a quenching medium (water, oil, air, or brine). The rapid cooling transforms the austenite into martensite, a much harder and more brittle phase. 4. Tempering (Optional): After quenching, the metal is sometimes reheated at a lower temperature to reduce brittleness and improve toughness. This step softens the martensite slightly and improves the overall mechanical properties of the material. Quenching Media: - Water: Commonly used for rapid cooling, but it can cause cracking due to uneven cooling and stress. - Oil: Slower than water, oil quenching reduces the risk of cracking and distortion. - Air: Used for slower cooling, often for metals that do not require extreme hardness. Benefits: - Increases hardness and strength of the metal. - Refines the grain structure. - Enhances wear resistance. Drawbacks: - May lead to increased brittleness. - Risk of cracking or distortion if the process is not controlled properly.

The application of boron carbide (B₄C) in refractory materials is mainly due to its excellent high temperature performance, corrosion resistance and wear resistance. As a high-performance ceramic material, boron carbide has the following advantages, which makes it widely used in the field of refractory materials: High melting point: The melting point of boron carbide is about 2,350°C. It can withstand high temperature environments and is widely used in refractory materials in metallurgy, glass, ceramics and other industries. Excellent thermal stability: Boron carbide has strong stability at high temperatures, can maintain its structure and performance at high temperatures for a long time, and is not easy to deform or degrade. Corrosion resistance: Boron carbide has strong corrosion resistance to chemical media such as acids and alkalis, and can be used for a long time in harsh chemical environments. It is particularly suitable for refractory linings in metallurgy, chemical industry and other industries. Thermal shock resistance: Boron carbide materials have strong thermal shock resistance and can withstand temperature changes caused by rapid heating and cooling. They are suitable for high-temperature equipment and furnaces that need to withstand temperature fluctuations. Wear resistance: Boron carbide has extremely high hardness, making it an ideal wear-resistant material for refractory equipment that requires wear resistance, such as metallurgical furnace materials, casting molds, etc. Application areas: Metallurgical industry: Boron carbide can be used for smelting furnace linings, casting molds, etc., and can effectively resist high temperature, high pressure and chemical corrosion. High-temperature furnaces: Boron carbide materials are often used in high-temperature furnaces to play the role of fire resistance, heat insulation and heat preservation. Electronic ceramics: Boron carbide is also used in electronic ceramics, especially in some high temperature and high pressure environments. Development trend: With the increasing demand for high-temperature, wear-resistant and corrosion-resistant materials, the application prospects of boron carbide materials are very broad. Especially in the field of high-performance materials, boron carbide, as an important refractory, antioxidant and corrosion-resistant material, is expected to grow gradually in market demand. In future technological development, the production process, processing performance and performance of boron carbide in special applications will still be the focus of research and development.

Study of metals, a crucial component of materials such as polymers, ceramics, glasses, and metals. Most metals are found in ores, which are mixtures of metals and non-metals. Thus, mineral exploration, mining, ore dressing, ore extraction, ore concentration, and ore beneficiation Ore to metal conversion: extractive metallurgy Examining different furnaces and their inside lining to endure the high temperatures required for metal extraction and purification - Refractories several methods of producing metal, such as wire drawing, extrusion, forging, rolling, and foundry practice. Metals can be heat-treated to change and acquire different characteristics. Physical metallurgy is the study of metals' internal structures. investigation of metals' and alloys' resistance to corrosion Manufacturing technology includes machining, welding, punching, stamping, riveting, and other processes to form metals and alloys into a variety of practical goods. Use of metals and alloys raises environmental issues related to safety, waste management, and disposal, among other things. Metallurgists study the disciplines and topics listed above.

What defines an "advanced" material in powder metallurgy? PickPM is about as official as it gets here, so check out its guide to superalloys, tool steels, refractory metals, and more: https://hubs.li/Q02wS25Z0

𝐎𝐩𝐭𝐢𝐦𝐢𝐳𝐢𝐧𝐠 𝐒𝐭𝐞𝐞𝐥 𝐐𝐮𝐚𝐥𝐢𝐭𝐲: 𝐈𝐧𝐬𝐢𝐠𝐡𝐭𝐬 𝐢𝐧𝐭𝐨 𝐒𝐞𝐜𝐨𝐧𝐝𝐚𝐫𝐲 𝐌𝐞𝐭𝐚𝐥𝐥𝐮𝐫𝐠𝐲 𝐓𝐞𝐜𝐡𝐧𝐢𝐪𝐮𝐞𝐬 𝗜𝗻𝘁𝗿𝗼𝗱𝘂𝗰𝘁𝗶𝗼𝗻 Steel is a fundamental material in various industries, from construction to automotive manufacturing. The quality of steel directly impacts product performance and durability. Secondary metallurgy plays a crucial role in optimizing steel quality, enhancing its properties, and meeting stringent industry standards. This article explores key insights into secondary metallurgy techniques and their impact on steel quality. 𝟭. 𝗨𝗻𝗱𝗲𝗿𝘀𝘁𝗮𝗻𝗱𝗶𝗻𝗴 𝗦𝗲𝗰𝗼𝗻𝗱𝗮𝗿𝘆 𝗠𝗲𝘁𝗮𝗹𝗹𝘂𝗿𝗴𝘆 Secondary metallurgy refers to refining processes that occur after the primary steelmaking stage. It involves precise control over chemical composition, temperature, and inclusion content to achieve desired steel properties. Secondary metallurgy techniques are essential for achieving high-quality steel with specific characteristics such as strength, toughness, and corrosion resistance. 𝟮. 𝗞𝗲𝘆 𝗦𝗲𝗰𝗼𝗻𝗱𝗮𝗿𝘆 𝗠𝗲𝘁𝗮𝗹𝗹𝘂𝗿𝗴𝘆 𝗧𝗲𝗰𝗵𝗻𝗶𝗾𝘂𝗲𝘀 ➡ Ladle Refining: Ladle refining is a common secondary metallurgy technique where the steel undergoes additional refining in a ladle before casting. Processes like degassing, desulfurization, and alloying are carried out to remove impurities and adjust composition. ➡ Vacuum Degassing: Vacuum degassing removes gases such as hydrogen and oxygen from molten steel, improving its cleanliness and reducing the risk of defects like porosity. This technique enhances steel properties such as toughness and ductility. ➡ Argon Oxygen Decarburization (AOD): AOD is a refining process that reduces carbon content in stainless steel while adjusting alloy elements. It enhances steel cleanliness, minimizes non-metallic inclusions, and improves corrosion resistance. ➡ Electroslag Remelting (ESR): ESR is used for producing high-quality specialty steels. It involves melting a consumable electrode in a water-cooled copper mold under a slag layer, resulting in refined steel with reduced segregation and improved homogeneity. 𝐑𝐞𝐚𝐝 𝐌𝐨𝐫𝐞: https://lnkd.in/gaQW5Mch #steelindustry #qualitycontrol #steelmanufacturing #steelproduction #steelperformance #metallurgicalengineering #IndustryStandards #SteelTechnology #highqualitysteel #aodprocess

FERRO ALLOYS SUMBARGED ARC FURNACE (SAF) ELECTRODE PASTE STANDARD ANALYSIS... Paste 1 is suitable for low-to-medium power furnaces . Because Lower ash content (2.1%), Moderate plasticity (53%), Good flexural strength (3.7 MPa) and compressive strength (9.4 MPa) & Moderate resistivity (104 micro ohm m) Ideal for applications requiring better electrical conductivity due to its lower ash content and moderate resistivity. Paste 2 is suitable for medium-to-high power furnaces. Because Higher ash content (3.9%),Lower plasticity (45%),Moderate flexural strength (4.1 MPa) and compressive strength (9.9 MPa) & Lower resistivity (84 micro ohm m) Works well in conditions requiring higher mechanical strength, such as ferromanganese or silicon manganese furnaces, given its improved compressive properties. Paste 3 is ideal for high-power furnaces , such as those used in ferrosilicon or high-carbon ferrochrome production. Because Low ash content (1.9%),Lowest plasticity (31%) but highest flexural (5.2 MPa) and compressive strength (12.5 MPa) & Highest resistivity (89 micro ohm m) Its superior mechanical and thermal properties make it suitable for demanding conditions where high structural integrity is needed. Metallurgical Engineering Metallurgy Daily

Glossary of metallurgy terms starting with the letter "D": 1. Damping: The ability of a material to dissipate energy, often related to how well a material can reduce vibrations or noise. 2. Decarburization: The process in which carbon is removed from the surface layer of steel during heating, leading to a reduction in hardness and strength in that area. 3. Deformation: The change in shape or size of a material under the influence of applied forces, which can be elastic (reversible) or plastic (permanent). 4. Delta Ferrite: A high-temperature phase of iron with a body-centered cubic (BCC) structure, stable at very high temperatures in some stainless steels. 5. Dendrite: A tree-like crystal structure that forms during the solidification of metals, commonly seen in cast metals. 6. Density: The mass of a substance per unit volume, typically measured in grams per cubic centimeter (g/cm³) for metals. 7. Descaling: The removal of oxide layers (scale) from the surface of a metal, often done using acid baths or mechanical means after hot working processes like forging or rolling. 8. Dew Point: The temperature at which moisture begins to condense out of air, relevant in metallurgical processes where moisture can cause oxidation or other surface issues. 9. Ductile Fracture: A type of fracture characterized by extensive plastic deformation before breaking, typically seen in materials that have high ductility. 10. Ductility: The ability of a material to undergo significant plastic deformation before failure, allowing it to be drawn into thin wires or stretched. 11. Dynamic Recrystallization: The process in which new grains form in a material during deformation at elevated temperatures, leading to improved grain structure and mechanical properties. 12. Drawing: A metalworking process used to reduce the cross-sectional area of a metal by pulling it through a die, increasing its length (as in wire drawing). 13. Double Tempering: A heat treatment process involving two tempering cycles, which enhances toughness and refines the microstructure of hardened steels. 14. Drop Forging: A process in which a heated metal is shaped by repeated blows from a hammer or die, often used to produce high-strength parts like gears and shafts.