Prevention of scaling by means of recycled process waste gases

authored by: Niklas Gerke, Julius Peddinghaus, Daniel Rosenbusch, Johanna Uhe, Kai Brunotte, Bernd Arno Behrens
Abstract: During hot forging of steel materials, the blanks are subjected to various heating processes. During these processes, scale is formed, which can lead to a mass loss of up to 3%. The additional mass required to compensate this material loss for a given forging component has a significant impact on the process emissions, as the production of the billet material has the highest impact on the overall CO₂ footprint of metal forming products [1]. Additionally, descaling operations such as upsetting are required to guarantee forging quality and process stability. At the same time, large quantities of process waste gas are emitted in the production of raw materials and components. These burnt gases have lower oxygen concentration due to the prior chemical combustion reaction. This work addresses the question, whether these burnt gases can be utilized as a forging process atmosphere. This would not only reduce material loss, but would also result in a reuse of the process waste gas. In order to retrofit existing forging infrastructure, a tooling system with a gas-tight enclosure was constructed and realized in a forming press. Defined gas combinations were fed into the enclosure to create an oxygen-reduced atmosphere. First, different gas combinations were investigated in annealing tests. The three most promising ones were then selected for the forging tests. The enclosure contained a heating, transport, forming and collecting unit. The blanks were fed in through a magazine and inductively heated to 1200 °C, formed and cooled under the defined atmosphere. In each atmosphere, 100 components were forged from the material 42CrMo4. Furthermore, it was investigated whether forming under a gas atmosphere has an influence on tool wear as scale can act as an abrasive. The investigations showed that both the surface of the starting material and the oxygen concentration of the atmosphere have a significant influence on scale formation. The amount of scale formed was reduced by up to 74% compared to an oxygen atmosphere. The adhesive layer on the upper dies was reduced with decreasing oxygen concentration. On the lower dies was an increased adhesive build-up.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
Type: Conference contribution
Pages: 861-870
No. of pages: 10
Publication date: 2024
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Materials Science(all)
Electronic version(s): https://doi.org/10.21741/9781644903131-94 (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@inproceedings{56e965b6353f42b6851f9ea689c49c32,
title = "Prevention of scaling by means of recycled process waste gases",
abstract = "During hot forging of steel materials, the blanks are subjected to various heating processes. During these processes, scale is formed, which can lead to a mass loss of up to 3%. The additional mass required to compensate this material loss for a given forging component has a significant impact on the process emissions, as the production of the billet material has the highest impact on the overall CO₂ footprint of metal forming products [1]. Additionally, descaling operations such as upsetting are required to guarantee forging quality and process stability. At the same time, large quantities of process waste gas are emitted in the production of raw materials and components. These burnt gases have lower oxygen concentration due to the prior chemical combustion reaction. This work addresses the question, whether these burnt gases can be utilized as a forging process atmosphere. This would not only reduce material loss, but would also result in a reuse of the process waste gas. In order to retrofit existing forging infrastructure, a tooling system with a gas-tight enclosure was constructed and realized in a forming press. Defined gas combinations were fed into the enclosure to create an oxygen-reduced atmosphere. First, different gas combinations were investigated in annealing tests. The three most promising ones were then selected for the forging tests. The enclosure contained a heating, transport, forming and collecting unit. The blanks were fed in through a magazine and inductively heated to 1200 °C, formed and cooled under the defined atmosphere. In each atmosphere, 100 components were forged from the material 42CrMo4. Furthermore, it was investigated whether forming under a gas atmosphere has an influence on tool wear as scale can act as an abrasive. The investigations showed that both the surface of the starting material and the oxygen concentration of the atmosphere have a significant influence on scale formation. The amount of scale formed was reduced by up to 74% compared to an oxygen atmosphere. The adhesive layer on the upper dies was reduced with decreasing oxygen concentration. On the lower dies was an increased adhesive build-up.",
keywords = "Hot Forming, NoCarb, Retrofit",
author = "Niklas Gerke and Julius Peddinghaus and Daniel Rosenbusch and Johanna Uhe and Kai Brunotte and Behrens, {Bernd Arno}",
note = "Publisher Copyright: {\textcopyright} 2024, Association of American Publishers. All rights reserved.; 27th International ESAFORM Conference on Material Forming, ESAFORM 2024 ; Conference date: 24-04-2024 Through 26-04-2024",
year = "2024",
doi = "10.21741/9781644903131-94",
language = "English",
isbn = "9781644903131",
series = "Materials Research Proceedings",
publisher = "Association of American Publishers",
pages = "861--870",
editor = "Araujo, {Anna Carla} and Arthur Cantarel and France Chabert and Adrian Korycki and Philippe Olivier and Fabrice Schmidt",
booktitle = "Material Forming, ESAFORM 2024",
}