Centro de Investigación Industrial
FUDETEC
CINI – 2000
The Center for Industrial Research
The Fundación para el Desarrollo Tecnológico (FUDETEC) is a non-profit
organization, established by the TECHINT group of companies in 1989. FUDETEC
houses the Center for Industrial Research (CINI), which is the R&D center for the
engineering and industrial companies of the TECHINT group.
CINI is located in Campana, Argentina.
Objectives
The CINI objectives are:
• To develop scientific applied research and technological research to support the
engineering and steel companies of the TECHINT group in the fields of:
o Development of new products.
o Development and optimization of production processes.
• To establish a network with institutions performing basic scientific research, such
as universities and national labs, in order to transfer scientific knowledge to
technological applications.
• To provide graduate education and training for young engineers and scientists.
Organization
CINI is organized in four departments. These departments cover the different areas of
technical expertise that constitute the kernel of the Center research activities:
Department of Applied Physics
Department of Computational Mechanics
Department of Materials and Corrosion
Department of Mechanical Technology
The CINI staff includes 47 persons (as of December 1999):
• 9 with doctoral degrees from different universities in Argentina and abroad
•
•
•
University of Buenos Aires (Argentina), University of El Litoral (Argentina), University of Mar
del Plata (Argentina), Balseiro Institute (Argentina), Massachusetts Institute of Technology
(U.S.A.), Washington University (U.S.A.), University of Manchester Institute of Science and
Technology (U.K.)
31 with university degrees in Engineering, Physics and Chemistry.
4 technicians.
2 secretaries and 1 administrative employee.
FUDETEC Steering Board
Honorary President:
Dr. Roberto Rocca
President:
Vice-President:
Dr. Leonardo Stazi
Ing. Reinaldo Castilla
Members:
Ing. Carlos Costamagna
Cont. Fernando Mozzi
Ing. Marcelo Ramos
Ing. Gustavo Bauer
CINI General Director: Dr. Eduardo Dvorkin
Budget
•
•
•
•
The CINI budget is built on the basis of ad hoc agreements, between the research
center and the industrial companies. Each agreement defines a job or research
program.
CINI obtains its financial support mainly from the steel companies in the
TECHINT group.
CINI operational budget in the period of July 1995 to June 2000:
During the period 1998-1999 a total amount of US$ 2,200,000 was invested in the
following items:
o New building in Campana, Argentina.
o Scanning electron-microscope.
o RX difractometer.
o Gleeble 3500 thermo-mechanical simulator of steel production processes.
Graduate Education of Young Engineers and Scientists
•
During the period July 1995 – December 1999 the following theses were
developed under the supervision of CINI researchers:
Doctoral theses
Master in Materials
theses
Graduate theses in
Engineering and Physics
•
•
Universities Giving the Degree
University of El Litoral (Argentina)
Univ. Gral San Mar. (Argentina)
University of Buenos Aires (Argentina)
Instituto Balseiro (Argentina)
Number of Theses
1
8
7
During the period July 1995 – December 1999 approximately twenty young
researchers, trained at CINI, were transferred to the TECHINT group steel
industries to work in the areas of Product and Process Engineering.
During the period July 1995 – December 1999, twenty Research Assistants
working at CINI were awarded fellowships by TECHINT or by other sources to
pursue doctoral degrees at American or European universities.
The CINI new building in Campana, Argentina
Department of Applied Physics
Department Head
Dr. Alberto Pignotti1
api@siderca.com
Objectives
The department of Applied Physics is concerned with the analysis of physical phenomena
that underlie production processes in the steel industry. The ultimate aim is the
development of methodologies and tools that contribute to achieving high standards of
quality for the manufactured goods with an efficient use of the available resources.
Methodology
Even though each one of the tackled problems has characteristic features that may require
special treatment, the general approach to a specific problem proceeds through the
following steps:
• Initially, a simplified numerical model is formulated to provide guidelines and
identify the relevant variables and process parameters, and their inter-dependence.
• A more elaborate model, into which finer details are incorporated, is subsequently
developed.
• Material properties, which are essential ingredients of the models, are obtained
either from the open literature or form laboratory tests performed at CINI or
outside facilities. Collaboration with experts from other research institutions is
sought whenever the required expertise is not found within CINI.
• Validation through plant tests is the decisive criterion to judge the model
reliability.
• The validated model is used either to find ways to improve current practices or to
suggest the implementation of alternative courses of action, such as on-line
model-assisted process control.
• Plant implementation is of course performed in a joint effort with production
lines.
Research Areas
Reheating Gas Furnaces
Reheating gas furnaces play a major role in many manufacturing processes in the steel
industry. Even though such furnaces have been in operation for decades, there is still
room for improving their quality and productivity. The demands of tighter quality
1
Fellow of the Argentine Academy of Exact, Physical and Natural Sciences and of the Third World
Academy of Sciences
standards and the quest for competitiveness in today’s markets are strong incentives for
the introduction of sophisticated tools in furnace operation.
Furnace models that include detailed descriptions of the complex processes that take
place inside an industrial furnace are beyond current modeling capabilities. It is still
possible, however, to use numerical models based on the relevant physical laws to
improve furnace performance, with three objectives in mind: to achieve a consistently
high quality standard of the heated products, to increase process productivity, and to
decrease fuel consumption and oxide generation. At CINI, such models have been
developed for the following four different types of furnaces:
1.
2.
3.
4.
Rotating-hearth furnaces, used to reheat steel billets prior to piercing.
Walking-beam furnaces for reheating steel tubes.
Slab pushing reheating furnaces.
Continuous galvanizing line furnaces.
The approach that has been implemented is based on using the information from
temperature measurements by thermocouples placed inside the furnace, in order to avoid
performing complex fluid-dynamical calculations that are not essential for the
determination of the temperature of the load. In addition, time-consuming calculations
required to take into account radiative exchanges inside the furnace are carried out in
advance, and their results are stored in huge files. In this fashion, a fairly realistic
representation of the load temperatures can be obtained in real time.
An example of these applications is the HEFESTOS on-line control system, based on a
model developed at CINI, that has been in operation at SIDERCA for several years. Not
surprisingly, this model-assisted control system is able to out-perform human operation
because of two reasons:
•
•
it possesses more information on the temperature distribution in the load and
furnace than is available to the furnace operator,
it has a predictive power that allows it to “think ahead,” and avoid pursuing
unfavorable courses of action before their consequences are felt.
Analogous systems are under development for the other types of furnaces mentioned
above.
Isotherms in a billet transverse cross section and upper sole of SIDERCA rotary
reheating furnace, as calculated by the HEFESTOS model: a) at 1.3 m from the furnace
entrance; b) at 42.3 m; c) at 110.5 m (furnace exit). The updated thermal map of the
furnace and the load is used to provide thermocouple and cycle time settings for optimal
furnace operation.
View of the screen that displays information on the thermal state of the load and furnace
calculated by the HEFESTOS model.
Cross sections of other types of furnaces on
which work is performed at CINI:
a) Slab-pushing reheating furnace
b) Walking-beam furnace for
reheating steel tubes
c) Continuous galvanizing line
furnace
Magnetic Nondestructive Inspection
The technique of flaw detection by magnetic flux leakage is widely used in the
nondestructive evaluation of steel pipes, and is based on the detection of the distortion of
an applied magnetic field due to the presence of a flaw. The main problem is to ensure a
high probability of detection of flaws that exceed some specified critical value, while
minimizing productivity losses due to the inevitable presence of false alarms.
The study of this problem has involved several distinct activities:
• numerical modeling of the leaked magnetic field,
• measurement of magnetic properties of various steels,
• laboratory and plant measurements of signals generated by machined and natural
flaws,
•
•
Monte Carlo simulation of the probability of flaw detection, and of occurrence of
false alarms,
model evaluation of the improvement of detection effectiveness using artificial
neural networks.
The objective is to implement an intelligent system to process on-line the signals from
nondestructive magnetic inspection equipment, with an enhanced flaw discrimination
capability.
As a necessary step prior to such a plant implementation, a robust on-line signal
digitizing and processing system called Cerbero was developed in collaboration with
Siderca. This system is currently operating in four Siderca inspection lines. It was
designed and built as a hard real-time software system that runs on standard PC
hardware, using state of the art programming techniques. Thorough testing led to the
conclusion that it is reliable, robust, easy to use, and meets the productivity and quality
requirements of industrial inspection lines. Its modular design will allow us to implement
more elaborate signal processing algorithms in the future.
Monte Carlo simulation of the crack
detection process with the magnetic flux
leakage technique. The four quadrants
exhibited contain:
I (blue): correctly detected craks;
II (magenta): false alarms;
III (green): correctly accepted tubes;
IV (red): erroneously accepted tubes
Monitor screen
displaying results
of the Cerbero
signal digitizing
system from one of
SIDERCA
nondestructive
inspection lines
Electromagnetic Processes
CINI has the capability to develop two- and three-dimensional models of processes that
involve electromagnetic phenomena. The two main applications in which these models
have been used are:
• induction heating of steel tube-ends prior to the upsetting operation,
• electromagnetic stirring of continuous casting of steel (EMS)
In the former one, the model was used to fine-tune process parameters and to design coils
to use with existing power sources and new products. In the latter, a detailed model of
the EMS set up installed at the SIDERCA continuous casting facility was modeled in
detail and validated with measurements of the magnetic field in the absence of liquid
steel. The forces that act during the continuous casting operation were calculated as
functions of the current intensity and frequency, and were used as input to a fluid
dynamical calculation of the liquid steel movement performed by CINI Computational
Mechanics department.
Finite element mesh used to
model the electromagnetic
stirring equipment installed at
the SIDERCA continuous
casting facility.
Horizontal cross section of SIDERCA
mold, showing a color map of the absolute
value of the instantaneous acceleration
generated in the liquid steel by the
electromagnetic forces
Publications in the Open Literature (1994 – 1999)
(a) Refereed Journals
1. E. Altschuler and A. Pignotti, “Nonlinear Model of Flaw Detection in Steel Pipes
by Magnetic Flux Leakage,” NDT&E International, Vol. 28, pp. 35-40, 1995.
2. H. Gavarini, R. P. J. Perazzo, S. L. Reich, E. Altschuler, and A. Pignotti, “Neural
Network Classifier of Cracks in Steel Tubes,” INSIGHT-Non-Destructive Testing
and Condition Monitoring, Vol. 38, pp. 108-111, 1996.
3. E. Altschuler, J. Paiuk, and A. Pignotti, “Monte Carlo Simulation of False Alarms
and Detection Reliability in MFL Inspection of Steel Tubes,” Materials
Evaluation, Vol. 54, pp. 1032-4, 1996.
4. R. K. Shah and A. Pignotti, “Influence of a Finite Number of Baffles on Shelland-Tube Heat Exchanger Performance,” Heat Transfer Engineering, Vol. 18, pp.
82-94, 1997.
5. G. D. Garbulsky, P. Marino, and A. Pignotti, “Numerical Model of Induction
Heating of Steel-Tube Ends,” IEEE Transactions on Magnetics, Vol. 33, pp. 74652, 1997.
6. H. Gavarini, R. P. J. Perazzo, S. L. Reich, E. Altschuler, and A. Pignotti,
“Automatic Assessment of the Severity of Cracks in Steel Tubes Using Neural
Networks,” INSIGHT-Non-Destructive Testing and Condition Monitoring,
Vol.40, pp. 92-100, 1998.
7. P. Sekulic, R. K. Shah, and A. Pignotti, “A Review of Solution Methods for
Determining Effectiveness – Ntu Relationships for Heat Exchanger Complex
Flow Arrangements,” Applied Mechanics Review, Vol. 52, pp. 97-117, 1999.
(b) Conference Proceedings
1. P. Marino and A. Pignotti, “On-Line Modeling and Control System for a
Reheating Gas Furnace,” Proc. 4th Symposium on Low Cost Automation,
International Federation for Automatic Control, pp. 329-334, 1995.
2. E. Altschuler, H. Gavarini, R. Perazzo, A. Pignotti, and S. Reich, “Neural
Network for MFL Inspection of Steel Tubes,” Proc. 14th World Conference on
NDT, New Delhi, India, pp. 1841-44, December 8-13, 1996.
3. P. Marino and A. Pignotti, “On-Line Model for Controlling an Industrial Rotary
Reheating Gas Furnace,” Proc. 4th European Conference on Industrial Furnaces
and Boilers, Espinho, Portugal, 1-4 April 1997.
4. D. Comuzzi, F. Monti, A. Nicolini, and P. Stickar, “Digitized System for the
Inspection of Steel Pipes,” Proc. 26th Annual Review of Progress in Quantitative
Nondestructive Evaluation, Montreal, Canada, July 26-30, 1999 (to be published).
5. E. Altschuler, P. Marino, A. Pignotti, D. Migliorino, and A. Jacobsen, “Numerical
Model of #1CGL Furnace at SIDERAR,” Proc. 91st Galvanizer’s Conference,
Jackson, MS, USA, October 24-27, 1999 (to be published).
6. F. Robiglio, A. Campos, J. Paiuk, M. Maldovan, J. Príncipe, A. Pignotti, and M.
Goldschmit, “Design and Numerical Modeling of Siderca’s EMS” (in Spanish),
Proc. 12th Steelmaking Seminar and 2nd Iron and Steel Society Argentina Section
Meeting, pp. 410-419, Buenos Aires, Argentina, November 2-5, 1999.
7. E. Altschuler, P. Marino, and A. Pignotti, “Numerical Models of Reheating Gas
Furnaces in the Steel Industry,” Proc. Fourth ISHMT/ASME Heat and Mass
Transfer Conference, Pune, India, January 12-15, 2000 (to be published).
Department of Computational Mechanics
Department Head
Eduardo N. Dvorkin, Ph.D.2
dvk@siderca.com
Principal Research Engineers
Dr. Ing. Marcela B. Goldschmit
sidgld@siderca.com
Ing. Andrea P. Assanelli
sidasa@siderca.com
Objectives
•
•
The development of finite element formulations and algorithms for modeling the
different manufacturing processes involved in the production of flat and tubular
steel products and for modeling the service performance of steel products.
The analysis of technological problems using numerical simulation methods with
specific applications for the steel industry.
Research Areas
Metal Forming
! Simulation of Continuous Casting Facilities
2
Fellow of the Argentine Academy of Exact, Physical and Natural Sciences
Fellow of the International Association for Computational Mechanics
Finite element code CCAST developed at CINI to simulate the solidification of slabs at
the continuous casting installation of SIDERAR
! Development of the Finite Element Code METFOR for Modeling Metal Forming
Processes (Flow Formulation and Elasto-Plastic Large Strains Formulation)
Compression at high temperature of a cylindrical sample in a Gleeble machine
! Simulation of Different Metal Forming Processes (hot rolling of flat and tubular
steel products, cold rolling of flat steel products, forging, stamping, etc.)
Finite element simulation of steel seamless tube rolling using METFOR (mandrel rolling
at SIDERCA)
Finite element simulation of flat steel rolling using METFOR (SIDERAR)
Computational Fluid Dynamics
! Development of Finite Element Turbulence Models for the Analysis of Liquid
Steel Flows
Model of the liquid steel flow induced by an electromagnetic stirring device at a round
bars continuous casting installation at SIDERCA
! Analysis, Using Finite Element Turbulence Models, of Ladle Furnaces, Tundishes
and Submerged Entry Nozzles Utilized in the Steel Industry
Model of the liquid steel flow in a submerged entry nozzle used in the continuous casting
of rectangular slabs at SIDERAR
Model of the liquid steel flow in a tundish when different internal devices are used
! Analysis, Using Finite Element Turbulence Models, of Heat Treatment
Installations for Tubular Products
It
[mm/s]
Model of the facilities at SIDERCA and DALMINE for external / internal
quenching of seamless tubes
! Analysis of the Mixing of Different Steels That Are Sequentially Casted in a
Continuous Casting Installation (Intermix)
Model of the chemical composition evolution during the transition between different
steels at SIDERCA continuous casting installation
Structural Analysis
! Analysis of OCTG (Oil Country Tubular Goods) Threaded Connections
Finite element analysis of the API-8R threaded connection displaying the “unzipping” of
the connection
Finite element analysis of a DST premium threaded connection for OCTG
! Analysis of the Collapse Behavior of Steel Pipes Including the Post-Collapse
Regime (e.g. Collapse Propagation in Deep Water Linepipes)
Collapse and post-collapse behavior of a Deep Water Line Pipe
Finite Element Software
CODE
ADINA System
METFOR
FANTOM
VOYAGE
PURPOSE
Solid Mechanics Analyses
Fluid Mechanics Analyses
Thermal Analyses
Metal Forming Analyses
Fluid Mechanics Analyses
Convection-Diffusion
Transport Analyses
DEVELOPER
ADINA R&D, MA, USA
CINI added some element
formulations
CINI
CIMNE, Barcelona, Spain
CINI added the turbulence
models
CINI
The Computational Mechanics department also developed special purpose codes such as:
• TCROWN: analysis of rolls heating and thermal expansion during the hot rolling
of steel plates.
• ROLLDEF: analysis of roll deformation during rolling of steel plates.
•
•
CCAST: thermal analysis of the solidification in a continuous casting facility.
GRADE: analysis of the chemical composition evolution during the transition
between different steels in a continuous casting facility.
Publications in the Open Literature (1994 – 1999)
(a) Refereed Journals
1. E. N. Dvorkin and A. P. Assanelli, “Implementation and Stability Analysis of the
QMITC-TLH Elasto-Plastic Finite Strain (2D) Element Formulation,” Computers
& Structures (in press).
2. M. B. Goldschmit, R. J. Príncipe, and M. Koslowski, “Applications of a (k-ε)
Model for the Analysis of Continuous Casting Processes,” International Journal
for Numerical Methods in Engineering, Int. J. Num. Methods in Engng, Vol. 46,
pp. 1505-1519, 1999.
3. E. N. Dvorkin, M. A. Cavaliere, M. B. Goldschmit, and P. M. Amenta, “On the
Modeling of Steel Product Rolling Processes,” International Journal for Forming
Processes, Vol. 1, No. 2, 211-242, 1998.
4. A. P. Assanelli, K. Xu, F. Benedetto, D. H. Johnson, and E. N. Dvorkin,
“Numerical / Experimental Analysis of an API 8-Round Connection,” ASME, J.
Energy Resources Technology, Vol. 119, pp. 81-88, 1997.
5. E. N. Dvorkin, M. B. Goldschmit, M. A. Cavaliere, P. M. Amenta, O. Marini, and
W. Stroppiana, “2D Finite Element Parametric Studies of the Flat Rolling
Process,” Journal of Materials Processing Technology, Vol. 68, pp. 99-107, 1997.
6. M. B. Goldschmit and M. A. Cavaliere, “An Iterative (k-L)-Predictor / (c)Corrector Algorithm for Solving (k-ε) Turbulent Models,” Engineering
Computations, Vol. 14, No. 4, pp. 441-455, 1997.
7. E. N. Dvorkin, “Finite Strain Elasto-Plastic Formulations Using the Method of
Mixed Interpolation of Tensorial Components,” Computational Mechanics, Vol.
18, pp. 290-301, 1996.
8. E. N. Dvorkin, A. P. Assanelli, and R. G. Toscano, “Performance of the QMITC
Element in 2D Elasto-Plastic Analyses,” Computers & Structures, Vol. 58, pp.
1099-1129, 1996.
9. E. N. Dvorkin, M. A. Cavaliere, and M. B. Goldschmit, “A Three Field Element
via Augmented Lagrangian for Modeling Bulk Metal Forming Processes,”
Computational Mechanics, Vol. 16, pp. 1-8, 1995.
10. M. B. Goldschmit, and M. A. Cavaliere, “Modeling of Turbulent Recirculating
Flows via an Iterative (k-L)-Predictor / (ε)-Corrector Scheme,” Applied
Mechanics Reviews, Vol. 48, No. 11, 1995.
11. E. N. Dvorkin, “Nonlinear Analysis of Shells Using the MITC Formulation,”
Archives Comput. Meth. Engng., Vol. 2, pp. 1-50, 1995.
12. E. N. Dvorkin, D. Pantuso, and E. A. Repetto, “A Formulation of the MITC4
Shell Element for Finite Strain Elasto-Plastic Analysis,” Comput. Meth. Appl.
Mechs. Engng., Vol. 125, pp. 17-40, 1995.
13. M. B. Goldschmit and E. N. Dvorkin, “On the Solution of the Steady ConvectionDiffusion Equation Using Quadratic Elements: a Generalized Galerkin
Technique also Reliable with Distorted Meshes,” Engineering Computation, Vol.
11, pp. 565-573, 1994.
14. E. N. Dvorkin, D. Pantuso, and E. A. Repetto, “A Finite Element Formulation for
Finite Strain Elasto-Plastic Analysis Based on Mixed Interpolation of Tensorial
Components,” Comput. Meth. Appl. Mechs. Engng., Vol. 114, pp. 34-54, 1994.
15. R. A. Radovitzky and E. N. Dvorkin, “A 3D Element for Nonlinear Analysis of
Solids,” Communications in Numerical Methods in Engng., Vol. 10, pp. 183-194,
1994.
16. E. N. Dvorkin, M. B. Goldschmit, D. Pantuso y E. A. Repetto, “Comentarios
sobre algunas herramientas utilizadas in la resolución de problemas no-lineales de
mecánica del continuo,” Revista Internacional de Métodos Numéricos para
Cálculo y Diseño en Ingeniería, Vol. 10, No. 1, pp. 47-66, 1994.
(b) Conference Proceedings
1. M. B. Goldschmit, S. P. Ferro, G. Walter, V. Aranda y J. Tena Morelos, “Modelo
de transición de grado de la CC2 de SIDERCA,” 12vo. Seminario de Colada
Continua y 2do. Encuentro de la Sección Argentina de la Iron and Steel Society,
Buenos Aires, November 1999.
2. F. Robiglio, A. Campos, J. Paiuk, M. Maldovan, J. Principe, A. Pignotti y M.
Goldschmit, “Diseño y nodelado numérico del EMS en SIDERCA,” 12vo.
Seminario de Colada Continua y 2do. Encuentro de la Sección Argentina de la
Iron and Steel Society, Buenos Aires, November 1999.
3. M. Goldschmit, J. Príncipe, S. Ferro, J. Petroni, A. Castellá y G. Di Gresia,
“Modelado numérico de buzas y moldes de planchones,” 12vo. Seminario de
Colada Continua y 2do. Encuentro de la Sección Argentina de la Iron and Steel
Society, Buenos Aires, November 1999.
4. J. Príncipe y M. Goldschmit, “Las condiciones de contorno sobre la pared en el
modelado de flujo turbulento,” VI Congreso Argentino de Mecánica
Computacional, MECOM ’99, Mendoza, 1999.
5. E. N. Dvorkin, M. A. Cavaliere, M. G. Zielonka, and M. B. Goldschmit, “New
Developments for the Modeling of Metal Rolling Processes,” Proceedings
European Conference on Computational Mechanics (Ed. W. Wunderlich et al),
München-Germany, 1999.
6. E. N. Dvorkin, A. P. Assanelli y M. B. Goldschmit, “Aplicaciones del método de
elementos finites en desarrollos tecnológicos para la industria siderúrgica,”
Métodos Numéticos en Ingeniería, (Ed. R. Abascal et al), Junio 1999.
7. M. B. Goldschmit, R. J. Príncipe, and M. Koslowski, “Numerical Modeling of
Submerged Entry Nozzle,” 3rd European Conference on Continuous Casting,
Madrid, October 1998.
8. E. N. Dvorkin and A. P. Assanelli, “Stability Analysis of a Finite Strain Element
Formulation,” Computational Mechanics – New Trends and Applications, (Ed. S.
Idelsohn et al), CIMNE, 1998.
9. A. P. Assanelli and E. N. Dvorkin, “Selection of an Adequate Element
Formulation for Modeling OCTG Connections,” Computational Mechanics –
New Trends and Applications, (Ed. S. Idelsohn et al), CIMNE, 1998.
10. M. A. Cavaliere, M. B. Goldschmit, P. Amenta, and E. N. Dvorkin, “Finite
Element Simulation of Rolling Processes,” Computational Mechanics – New
Trends and Applications, (Ed. S. Idelsohn et al), CIMNE, 1998.
11. M. B. Goldschmit and J. R. Príncipe, “Applications of a (k-ε) Model for the
Analysis of Steelmaking Processes,” Computational Mechanics – New Trends
and Applications, (Ed. S. Idelsohn et al), CIMNE, 1998.
12. A. P. Assanelli, R. G. Toscano, and E. N. Dvorkin, “Analysis of the Collapse of
Steel Tubes Under External Pressure,” Computational Mechanics – New Trends
and Applications, (Ed. S. Idelsohn et al), CIMNE, 1998.
13. A. P. Assanelli, R. G. Toscano, D. H. Johnson, and E. N. Dvorkin, “Collapse
Behavior of Castings: Measurement Techniques, Numerical Analyses and Full
Scale Testing,” Proceedings of the 1998 SPE Applied Technology Workshop on
Risk Based Design of Well Casing and Tubing, (SPE paper 51314), The
Woodlands Texas, 1998.
14. A. Campos, M. Goldschmit, E. Rey, G. Walter, P. Ventura, M. Cermignani, E.
Guastella, A. Garamendy y J. Madias, “Mejoras en el tundish de la colada
continua II de SIDERCA,” 11vo. Seminario de Colada Continua, Octubre 1997.
15. A. Campos y M. B. Goldschmit, “Estudio de la distribución de flujo en el tundish
de Siderca,” 2nd International Congress on Metallurgy and Materials Technology,
São Paulo, Brasil, 1997.
16. E. N. Dvorkin, M. B. Goldschmit, and M. A. Cavaliere, “Computational
Mechanics Applications at Siderar Steel Mill,” 2nd International Congress on
Metallurgy and Materials Technology, São Paulo, Brasil, 1997.
17. M. B. Goldschmit, “Computational Fluid Mechanics Applications in Continuous
Casting,” 80th Steelmaking Conference, Chicago, EEUU, 1997.
18. M. A. Cavaliere, M. B. Goldschmit, and E. N. Dvorkin, “3D Modeling of Bulk
Metal Forming Processes via the Flow Formulation and the PseudoConcentrations Technique,” COMPLAS 5, Fifth International Congress on
Computational Plasticity, Barcelona, España, 1997.
19. M. A. Cavaliere, M. B. Goldschmit, P. M. Amenta y E. N. Dvorkin, “Modelado
de procesos de conformado de metales,” V Congreso Argentino de Mecánica
Computacional, MECOM ’96, Tucuman, 1996.
20. E. N. Dvorkin, M. B. Goldschmit, M. A. Cavaliere and P. M. Amenta, “On the
Modeling of Bulk Metal Forming Processes,” ECCOMAS 96, The Second
ECCOMAS Conference on Numerical Methods in Engineering, Paris, Francia,
1996.
21. E. N. Dvorkin, M. A. Cavaliere, and M. B. Goldschmit, “A Three Field Element
via Augmented Lagrangian for Modeling Incompressible Viscoplastic Flows,”
Proceedings Fourth Int. Conf. on Computational Plasticity, (Ed. D. R. J. Owen et
al), Pineridge Press, 1995.
22. E. N. Dvorkin, “MITC Elements for Finite Strain Elasto-Plastic Analysis,”
Proceedings Fourth Int. Conf. on Computational Plasticity, (Ed. D. R. J. Owen et
al), Pineridge Press, 1995.
23. M. B. Goldschmit and M. A. Cavaliere, “Numerical Solution of Turbulent
Recirculating Flows with an Iterative (k-L)-Predictor / (ε)-Corrector Scheme,”
Proceedings Fourth Pan American Congress of Applied Mechanics (PACAM IV),
(Ed. L. Godoy et al), Buenos Aires, 1995.
24. E. N. Dvorkin, “On Finite Strain Elasto-Plastic Analysis of Shells,” Proceedings
Fourth Pan American Congress of Applied Mechanics (PACAM IV), (Ed. L.
Godoy et al), Buenos Aires, 1995.
25. E. N. Dvorkin, “On Finite Strain Elasto-Plastic Analysis Using Elements Based
on Mixed Interpolation of Tensorial Components,” Mec. Comput., Vol. 14, (Ed.
S. Idelsohn et al.), 1994.
26. A. P. Assanelli, D. H. Johnson y E. N. Dvorkin, “Estudio de uniones tubulares
roscadas para aplicaciones petroleras: modelos computacionales y ensayos
experimentales,” Mec. Comput., Vol. 14, (Ed. S. Idelsohn et al.), 1994.
27. M. B. Goldschmit y M. A. Cavaliere, “Modelos de turbulencia y su
implementación en al código de elementos finites FANTOM,” Mec. Comput.,
Vol. 14, (Ed. S. Idelsohn et al.), 1994.
28. M. B. Goldschmit, M. A. Cavaliere, and R. A. Radovitzky, “A PredictorCorrector Iterative Scheme for Solving the k-e Model Equations,” IACM –
WCCM III, The Third World Congress on Computational Mechanics, Vol. 1, 184185, Japon, 1994.
(c) Other Publications
1. E. N. Dvorkin, “Sobre el desarrollo científico tecnológico de la Argentina,”
Boletín Informativo Techint, No. 297, pp. 65-84, 1999.
2. E. N. Dvorkin, “Mecánica Computacional: desarrollos teóricos y aplicaciones
industriales,” Anal. Acad. Nac. Cs, Ex. Fís. Y Nat., Vol. 49, Buenos Aires,
Argentina, 1997.
3. E. N. Dvorkin, “Ingeniería: del tecnólogo intuitivo a la modelización
computacional” en ¿Qué es investigar hoy ? Reflexiones al borde del Nuevo
milenio, Serie Ciencia y Tecnología en la UBA (Ed. A. Fernández Cirelli), 1997.
(d) Editing of Publications
1. International Journal for Numerical Methods in Engineering, Vol. 46, No. 9,
November 1999 (Guest Editors: E. N. Dvorkin, E. Oñate, and G. Bugeda)
2. Computational Mechanics – New Trends and Applications, Proceedings of the 4th
International Congress on Computational Mechanics (Eds. S. Idelsohn, E. Oñate,
and E. N. Dvorkin), CIMNE, 1998.
Department of Materials and Corrosion
Department Head
Ing. Teresa E. Pérez
sidtep@siderca.com
Principal Research Engineers
Guillermo Echaniz, Ph.D.
sidecz@siderca.com
Dr. Ing. Carlos Cicutti
sidcic@siderca.com
Objectives
•
•
•
To study the microstructural evolution through the different production processes
used in the steel industry to develop the basic knowledge that supports TECHINT
steel plants.
To study the relationship between material microstructure, mechanical properties
and product service performance.
Development of new steel products.
Research Areas
Steelmaking and Continuous Casting
! Metal-Slag Reactions
Metal-slag reactions are studied taking samples at different stages of the process.
Mathematical models are developed to describe the main reactions taking place. In
particular, the evolution of metal and slag composition in an LD-LBE converter was
studied.
Evolution of carbon content during metal refining in the converter
! Clean Steel
The different sources of non-metallic inclusions are analyzed. The evolution of the
microinclusions chemical composition and its relationship with the process are also
investigated.
Influence of calcium treatment on the type of inclusions formed and its relationship with
nozzle clogging
! Solidification in Continuous Casting
Evaluation of metallurgical results using electromagnetic stirring (EMS) in the
continuous casting of round bars
! Determination of Hot Ductility Curves to Optimize the Continuous Casting
Process
Hot ductility curve for a Nb-V steel tested at strain rate of 10-3 s-1
Phase Transformation in Carbon and Microalloyed Steels
The objective is to develop a quantitative description of the microstucture evolution of
these materials in different industrial processes such as seamless pipe rolling and heat
treatment, flat hot rolling and annealing processes.
! Microstructural Evolution During Hot Rolling
Different parameters characterize the microstructural state of a steel during and after hot
rolling, and also determine its thermo-mechanical properties: the number, type and
amount of phases, the distribution of precipitates, the grain size and the density of
dislocations (accumulated strain). The physical simulation of the rolling process using
the Gleble machine and the microstructural analysis are the tools used to follow structural
evolution.
Calculated grain size evolution during strip hot rolling. The theoretical model was
adjusted using simulations performed with the Gleeble machine. The micrographs on the
right correspond to the results of some of these simulations
Evolution of the dislocation density and the niobium precipitated fraction in the finishing
process (It is considered that when 5% of the Nb precipitation is completed the
recrystallization is inhibited)
! Annealing
The mechanical properties and behavior of a steel sheet after batch or continuous
annealing depend on many industrial processing parameters as well as on steel chemistry
and microstructure. The aim of this research is to investigate the factors which influence
the final properties of annealed sheet steels.
Orientation distribution function of batch annealed steel sheet at φ2 = 45º section
calculated from X-ray measurements. Good drawability is obtained when a strong {111}
component is present, and when a {100} component is absent
Simulations in Gleeble machine of continuous annealing cycles. Microstructures after
two annealing cycles
! Heat Treatments
The heat treatment and chemical composition determine the microstructure and the final
properties of steel products. The understanding of this relationship is important to obtain
special products such as low alloy-low carbon line pipes. Laboratory tests, plant tests and
microstructural analyses are used to follow structural and properties evolution.
Quenched and tempered microstructure in a low carbon low alloy steel
High Temperature Oxidation Processes
The type of oxides that are produced during the reheating process before hot rolling
and/or during heat treatments can affect the final product quality. The effect of different
process variables on the oxide formation is studied using a laboratory furnace and plant
trials.
SEM (BSE). Low carbon steel oxidized up to 1250ºC in a simulated combustion
atmosphere. Scale-metal interface
SEM/EDAX Mapping. Element distribution. Internal oxidation in low carbon steel
oxidized up to 1250ºC in a simulated combustion atmosphere
Corrosion and Environmentally Assisted Cracking
! Environmentally Assisted Cracking of Pipes
To get basic understanding on the sulfide stress cracking resistance of low alloy carbon
steels, the relationship between the microstructure and the material performance is
studied.
Cr-Mo precipitates in a quenched and tempered microstructure
! CO2 Corrosion Resistance of Low Alloy Carbon Steels and Stainless Steels
There is a growing interest in the application of low alloy steels for down-hole tubulars
and line pipes. However, little basic knowledge about this subject is available,
particularly about the effect of the microstructure and the alloying elements. Laboratory
and field experiences are carried out to study these effects.
Polarization curves for carbon low alloy steel in synthetic formation water. Performance
of fresh ground and pre-corroded steel
Coatings for Steel Sheets and Strips
The requirements for coated steels are growing. To meet these requirements basic studies
are being carried out in hop dip galvanizing, electrogalvanizing and tin plating.
Laboratory scale simulations are used to study the effect of different parameters;
industrial materials are also analyzed.
Al-Zn coating microstructure coating
Element distribution in Al-Zn coating
Tin plate intermetallic
Laboratory Facilities
The main research tools are:
Scanning Elecron-Microscope Phillips LX 30
X Ray Diffractometer Phillips Xpert MPD
Thermo-Mechanical Simulator Gleeble 3500
It enables the carrying out of laboratory physical simulations that accurately reproduce
the thermal and mechanical manufacturing processes.
Corrosion facilities for H2O and CO2 experiments
Hot dip laboratory scale simulator
Laboratory electrochemical cells.
Publications in the Open Literature (1994 – 1999)
(a) Refereed Journals
1. L. Ferro, J. Petroni, D. Dalmaso, J. Madías, and C. Cicutti, “Steel Cleanliness in
Continuous Casing Slabs,” Iron & Steelmaker, pp. 45-48, Nov. 1996.
2. C. Cicutti, “Transferencia de calor en la colada continua de aceros. Parte 1: El
molde,” Revista de Metalugia Madrid, Vol. 33, (5), pp. 333-343, 1997.
3. C. Cicutti, “Transferencia de calor en la dolada continua de aceros. Parte 2: El
enfriamiento secundario,” Revista de Metalurgia Madrid, Vol. 33, (6), pp. 393402, 1997.
4. C. Cicutti, P. Bilmes, and R. Boeri, “Estimation of Primary Dendrite Arm
Spacings in Continuous Casting Products,” Scripta Materialia, Vol. 37, No. 5, pp.
599-604, 1997.
5. C. Cicutti, J. Madías, and J. C. Gonzáles, “Control of Microinclusions in
Calcium-Treated Aluminum Killed Steels,” Ironmaking and Steelmaking, Vol. 24,
No. 2, pp. 155-159, 1997.
6. Y. Kashiwaya, C. Cicutti, and A. Cramb, “An Investigation of the Crystallization
of a Continuous Casting Mold Slag Using the Single Hot Thermocouple
Technique,” ISIJ International, Vol. 38, No. 4, pp. 357-365, 1998.
7. Y. Kashiwaya, C. Cicutti, A. Cramb, and K. Ishii, “Development of Double and
Single Thermocouple Technique for in Situ Observation of Mold Slag
Crystallization,” ISIJ International, Vol. 38, No. 4, pp.348-356, 1998.
8. M. Zapponi, P. Seré, C. Elsner, and A. Di Sarli, “Comparative Corrosion
Behavior of 55% Aluminum-Zinc Alloy and Zinc Hot-Dip Coatings Deposited on
Low Carbon Steel Substrates,” Corrosion Science, Vol. 40, No. 10, pp. 17111723, 1998.
9. M. Zapponi, J. Zubimendi, T. Pérez, J. Von Bergen, and J. Ferrón, “Hot Dip
Galvanized Steel Darkening & Chemical Composition of the Surface,” Planting
& Surface Finishing, pp. 80-82, October 1999.
10. M. Zapponi, A. Quiroga, and T. Pérez, “Segregation of Alloying Elements During
the Hot-Dip Coating Solidification Process,” Surface & Coatings Technology,
122, pp. 18-20, 1999.
11. G. Echaniz, C. Morales, and T. Pérez, “The Effect of Microstructure on the KISSC
of Low Carbon Low Alloy Steels,” Advances in Corrosion Control and Materials
in Oil and Gas Production, European Federation of Corrosion Publications
Number 26, 1999.
(b) Conference Proceedings
1. C. Cicutti, G. Botteri, G. Carcagno, and R. Herrera, “Efecto de la temperatura en
la respuesta mecánica a tracción de un acero al C-Mn obtenido por colada
contnua,” Jornadas Metalúrgicas de la SAM, Bahía Blanca, Argentina, June
1994.
2. C. Cicutti, G. Botteri, G. Carcagno, and R. Herrera, “Influencia de la composición
química sobre las propiedades mecánicas de aceros microaleados a elevadas
temperatures,” CONAMET VIII – ALAMET III, Antofagasta, Chile, August 1994.
3. C. Cicutti, P. Bilmes, and J. Gonzáles, “Estimación del espaciado dendrítico en
barras de colada continua,” CONAMET VIII – ALAMET III, Antofagasta, Chile,
August 1994.
4. G. Echaniz, T. Pérez, C. Pampillo, R. Newman, R. Procter, and G. Lorimer, “The
Effect of Microstructure on Hydrogen Induced Stress Corrosion Cracking of
Quenched and Tempered Steels,” 5th International Conference Hydrogen Effects
on Materials Behavior, Wyoming, U.S.A., September 1994.
5. C. Cicutti, J. Madías, L. Reda, J. Petroni, D. Dalmaso, and D. Schnidrig,
“Limpieza inclusionaria de planchones de colada continua,” XXVI Seminário
sobre Fusão, Refino e Solidificação dos Aços, ABM, Salvador, Brasil, December
1994.
6. J. Madías, W. Santa María, D. Dalmaso, C. Cicutti, J. Petroni, and R. Forconesi,
“Utilización de modelos de agua en la colada continua de desbastes,” XXVI
Seminário sobre Fusão, Refino e Solidificação dos Aços, ABM, Salvador, Brasil,
December 1994.
7. C. Cicutti, J. Madías, M. Dziuba, and J. Petroni, “Desarrollo de un modelo
cinético de desulfuración,” 1st Argentina-USA Bilateral Symposium on Material
Science and Engineering, Buenos Aires, Argentina, pp. 1-7, November 1999.
8. C. Cicutti, R. Ares, H. Ernst, J. Moriconi, and R. Herrera, “Predicción de
propiedades mecánicas en material laminado en caliente destinado a hojalara,” 1st
Argentina-USA Bilateral Symposium on Material Science and Engineering,
Buenos Aires, Argentina, pp. 13-21, November 1995.
9. C. Cicutti, J. Petroni, J. Madías, G. Di Gresia, and H. Recosta, “Estudio de grietas
transversals en desbastes de colada continua,” Jornadas Metalúrgicas de la SAM,
Córdoba, Argentina, May 1995.
10. M. Zapponi, J. Zubimendi, and J. Von Bergen, “Aging Process of Hot Dip
Galvanized Iron,” 1st Argentina-USA Bilateral Symposium on Material Science
and Engineering, Buenos Aires, Argentina, November 1995.
11. M. Zapponi, J. Zubimendi, J. Von Bergen, I. Vaquilla, M. Passeggi, and J. Ferrón,
“Proceso de envejecimiento de chapa galvanizada: correlación entre
ennegrecimiento y composición química de la superficie,” 1st Argentina-USA
Bilateral Symposium on Material Science and Engineering, Buenos Aires,
Argentina, November 1995.
12. J. Zubimendi, C. Baieli, W. Egli, M. Chara, R. Savarezza, and A. Arvía,
“Caracterización de depósitos de estaño producidos por el proceso Ferrostán
mediante microsocopía electrónica de barrido y microscopía de fuerzas atómicas,”
1st Argentina-USA Bilateral Symposium on Material Science and Engineering,
Buenos Aires, Argentina, November 1995.
13. C. Cicutti, J. Madías, R. Vénica, G. Di Gresia, and J. Petroni, “Estudio del origen
de perforaciones y aplicación de un sistema detector,” XXVII Seminário sobre
Fusão, Refino e Solidificação dos Aços, ABM, Belo Horizonte, Brasil, 1996.
14. R. Bruna, D. Dalmaso, J. Petroni, J. Madías, R. Ares, and C. Cicutti, “Reducción
de grietas en caños soldados por resistencia eléctrica para grados API,” 51º
Congresso Annual da ABM, Porto Alegre, Brasil, 1996.
15. L. Ferro, J. Petroni, J. Madías, C. Cicutti, and D. Dalmaso, “Steel Cleanliness in
Continuous Casting Slabs,” 79th ISS Steelmaking Conference, Pittsburgh, U.S.A.,
1996.
16. R. Ares, C. Cicutti, J. Madías, M. Dziuba, J. Petroni, J. Azcuaga, and R. Panelli,
“Reversión de silicio durante la metalurgia de cuchara de aceros de bajo carbono
calmados al aluminio,” Jornadas Metalúrgicas de la SAM, Jujuy, Argentina,
1996.
17. C. Baieli, W. Egli, E. Bossi, A. Nataloni, M. Chara, and J. Zubimendi,
“Contaminación superficial en chapas de aceros de bajo carbono recocido en
atmósfera reductora,” Jornadas SAM ’96, Jujuy, Argentina, June 1996.
18. M. Zapponi and P. Seré, “Comportamiento frente a la corrosión de acero
recubierto con cinc o aluminio cinc aplicados por inmersión,” VII Jornadas
Argentinas de Corrosión y Protección, Mendoza, Argentina, September 1996.
19. M. Zapponi and D. Posadas, “Medida de la impedancia electroquímica para
determinar el espesor de la capa de cromato sobre el acero galvanizado por
inmersión,” VII Jornadas Argentinas de Corrosión y Protección, Mendoza,
Argentina, September 1996.
20. Y. Kashiwaya, C. Cicutti, and A. Cramb, “Development of Double HotThermocouple Technique for Direct Observation of Mold Slag Crystallization,”
ISS Electric Furnace, Chicago, U.S.A., pp. 617-622, 1997.
21. C. Cicutti, R. Ares, J. Madías, J. Petroni, and J. Azcuaga, “Aplicación de
herramientas termodinámicas y cinéticas en el proceso de elaboración de aceros,”
Second International Congress on Metallurgy and Materials Technology, ABM,
São Paulo, Brasil, 1997.
22. R. Panelli, J. Madías, R. Ares, J. Azcuaga, L. Ferro, J. Petroni, and C. Cicutti,
“Improvements in Ladle Metallurgy at Siderar,” Fifth International Conference
on Clean Steel, Hungary, pp. 175-185, 1997.
23. C. Cicutti, J. Petroni, G. Di Gresia, M. Dziuba, and E. Lagos, “Transverse Corner
Crack Formation in Continuously Cast Slabs,” 80th ISS Steelmaking Conference,
Chicago, U.S.A., pp. 365-371, 1997.
24. C. Cicutti, Y. Kashiwaya, and A. Cramb, “A Study of Crystallization Phenomena
in Casting Powders,” 11º Seminario de Acería IAS, Buenos Aires, Argentina,
1997.
25. L. Ferro, R. Panelli, J. Petroni, J. Azcuaga, D. Dalmaso, C. Cicutti, R. Ares, and J.
Madías, “Mejoras en los procesos de aceración de Siderar y su incidencia en la
limpieza inclusionaria del producto,” 11º Seminario de Acería IAS, Buenos Aires,
Argentina, 1997.
26. C. Morales, T. Pérez, and G. Fitzsimons, “Sulfide Stress Cracking: Some
Observations About the DCB Test,” Paper No. 52, NACE CORROSION ’97,
March 1997.
27. J. Zubimendi, C. Baieli, T. Pérez, and W. Egli, “Electroformación de películas de
sílice sobre acero: su importancia a nivel industrial,” X Congreso Argentino de
Fisicoquímica, Tucumán, Argentina, April 1997.
28. J. Zubimendi, C. Baieli, T. Pérez, and W. Egli, “Influencia de las principales
variables del proceso de fabricación de hojalata sobre la morfología del depósito,”
X Congreso Argentino de Fisicoquímica, Tucumán, Argentina, April 1997.
29. C. Cicutti, R. Ares, J. Madías, J. Uzart, C. Guglielmimpietro, and J. Petroni,
“Análisis de falla de un molde de colada continua,” Jornadas Metalúrgicas de la
SAM, Tandil, Argentina, May 1997.
30. M. Zapponi and T. Pérez, “Caracterización de los productos de corrosion
generados en distintas atmósferas sobre aceros desnudos y recubiertos con zinc,”
Jornadas Metalúrgicas de la SAM, Tandil, Argentina, May 1997.
31. M. Zapponi, T. Pérez, J. Zubimendi, and J. VonBergen, “Hot Dip Galvanized
Steel: Relationship Between Darkening, Structure and Segregation,” Intergalva
’97, Birmingham, June 1997.
32. S. Bruno, H. Lazzarino, and D. Posadas, “Characterization of the Morphology of
Zinc Electrodeposits,” INTERGALVA ’97, Birmingham, Inglaterra, June 1997.
33. C. Morales, G. Echaniz, and T. Pérez, “Resistencia a la fisuración bajo tension en
medio sulfídrico de aceros al carbono de baja aleación con diferentes
microestructuras,” 3º Congreso de Corrosión y Protección en la Industria del Gas
y el Petróleo, Buenos Aires, September 1997.
34. G. Echaniz, C. Morales, and T. Pérez, “The Effect of Microstructure on the KISSC
of Low Carbon Low Alloy Steels,” EUROCORR ’97, Noruega, September 1997.
35. J. Madías, C. Cicutti, A. Castellá, G. Di Gresia, L. Ferro, and J. Petroni, “Study of
Breakouts, Implementation of a Detection System and Plant Results,” 82nd ISS
Steelmaking Conference, Chicago, U.S.A., pp. 51-59, 1998.
36. G. Di Gresia, J. Petroni, E. Lagos, M. Dziuba, and C. Cicutti, “Mejoras en la
calidad superficial de planchones de colada continua,” Seminario sobre
Innovaciones Tecnológicas en Acería y Colada continua, ILAFA, Santiago de
Chile, 1998.
37. Y. Kashiwaya, C. Cicutti, and A. Cramb, “Crystallization Behavior of Mold
Slags,” 81st ISS Steelmaking Conference, Toronto, Canada, pp. 185-191, 1998.
38. R. Panelli, J. Azcuaga, L. Ferro, J. Petroni, J. Madías, and C. Cicutti,
“Improvements in Steelmaking Process at Siderar,” 81st ISS Steelmaking
Conference, Toronto, Canada, pp. 221-227, 1998.
39. C. Cicutti, M. Valdez, T. Pérez, E. Bossi, H. Rissone, and J. Moriconi, “Influencia
de las variables de proceso en la evolución de la microestructura durante el
recocido de material destinado a hojalata,” Jornadas SAM ’98 – Iberomet V,
Rosario, Argentina, 1998.
40. M. Zapponi and T. Pérez, “Characterization of Corrosion Products in Steel Sheets
Inside the Packaging,” SCANNING ’98, Baltimore, U.S.A., February 1998.
41. G. Echaniz, C. Morales, and T. Pérez, “The Effect of Microstructure on the KISSC
of Low Alloy Carbon Steels,” NACE CORROSION ’98, San Diego, U.S.A.,
March 1998.
42. T. Pérez, H. Quintanilla, and E. Rey, “Effect of Ca/S Ratio on HIC Resistance of
Seamless Line Pipes,” NACE CORROSION ’98, San Diego, U.S.A., March 1998.
43. M. Zapponi and T. Pérez, “Segregación de aleantes durante el proceso de
Solidificación de recubrimientos hot dip,” Jornadas SAM ’98 – IBEROMET V,
Santa Fé, Argentina, September 1998.
44. M. Cancio, G. Echaniz, T. Pérez, and R. Versaci, “Evalución de los precipitados
en un acero tipo 4130 bajo distintos tratamientos térmicos,” Jornadas SAM ’98 –
Iberomet V, Rosario, Argentina, September 1998.
45. H. Rissone, W. Egli, J. L. Zubimendi, C. Moina, M. Míguez, A. Iorio, G. Bustos,
and M. J. L. Ginés, “Epoxy-Phenolic Ratio and Other Lacquer Application
Conditions. Effects on the Behavior of Lacquer/Tinplate System for Cans,” First
North American Steel Packaging Conference, Illinois, U.S.A., October 1998.
46. M. Zapponi, T. Pérez, P. Seré, and V. Vetere, “Evolución de los productos de
corrosion sobre acero a lo largo de un año en ambiente industrial,” VIII Jornadas
Argentinas de Corrosión y Protección, Santa Fé, Argentina, October 1998.
47. M. Zapponi, T. Pérez, and D. Migliorino, “Influence of Dirtiness and Roughness
of Steel Base Over the Spangle Homogeneity and Size,” 90th Galvanizers
Association Annual Meeting, Indianapolis, U.S.A., November 1998.
48. T. Pérez, G. Echaniz, and C. Morales, “Desarrollo de aceros resistentes a la
fisuración bajo tension en medio sulfídrico,” NACE Latinoamérica 1998, Cancún,
México, 1998.
49. G. Di Gresia, R. Ares, J. Petroni, M. Valdez, C. Cicutti, and T. Pérez,
“Desarrollos recientes en la metalurgia de tundish de Siderar,” XXX Seminário
sobre Fusáo, Refino e Solidificação dos Aços, ABM, Belo Horizonte, Brasil,
1999.
50. M. Valdez, C. Cicutti, T. Pérez, and J. Petroni, “Influencia de la emulsion
metálica en las reacciones de afino del acero en el convertidor,” XI Congreso
Argentino de Fisicoquímica – I Congreso de Fisicoquímica del Mercosur, Santa
Fe, Argentina, April 1999.
51. M. Ginés, G. Benítez, T. Pérez, W. Egli, J. Giuliani, and J. Zubimend, “Estudio
del mecanismo de formación de FeSn2 en la fabricación de hojalata,” XI Congreso
Argentino de Fisicoquímica – I Congreso de Fisicoquímica del Mercosur, Santa
Fe, Argentina, April 1999.
52. C. Cicutti, M. Valdez, T. Pérez, R. Donayo, and J. Petroni, “Estimación del
espumado de las escorias durante el proceso de aceración en un convertidor LDLBE,” Jornadas SAM ’99, Rafaela, Argentina, June 1999.
53. M. Valdez, C. Cicutti, T. Pérez, A. Gómez, and J. Petroni, “Distribución de
fósforo entre metal y escoria durante el proceso de elaboración de aceros,”
Jornadas SAM ’99, Rafaela, Argentina, June 1999.
54. F. Daguerre, A. Quiroga, M. Zapponi, and T. Pérez, “Influencia de la
composición química sobre las características y propiedades de los recubrimientos
de zinc por inmersión,” Jornadas SAM ’99, Rafaela, Argentina, June 1999.
55. M. Ginés, G. Benítez, T. Pérez, E. Bossi, J. Zubimendi, and W. Egli, “Reacciones
superficiales en el proceso de recocido batch,” Jornadas SAM ’99, Rafaela,
Argentina, June 1999.
56. M. Ginés, G. Benítez, T. Pérez, J. Zubimendi, J. Giuliani, and W. Egli, “Cinética
y mecanismo de formación del intermetálico Fe-Sn en la fabricación de hojalata,”
Jornadas SAM ’99, Rafaela, Argentina, June 1999.
57. C. Cicutti, M. Valdez, T. Pérez, R. Donayo, A. Gómez, and J. Petroni, “Estudio
de la evolución de la escoria y el baño metálico en el convertidor,” 12º Seminario
de Acería IAS, Buenos Aires, Argentina, November 1999.
58. R. Ares, R. Panelli, J. Petroni, C. Cicutti, M. Valdez, and T. Pérez, “Evolución de
la limpieza inclusionaria a lo largo del proceso en el Horno Cuchara de Siderar,”
12º Seminario de Acería IAS, Buenos Aires, Argentina, November 1999.
59. A. Campos, F. Fuhr, C. Cicutti, T. Pérez, and A. Dindart, “Resultados de la
aplicación del alitador electromagnético en la colada continua de Siderca,” 12º
Seminario de Acería IAS, Buenos Aires, Argentina, November 1999.
Department of Mechanical Technology
Department Head
Hugo A. Ernst, Ph.D.3
hae@siderca.com
Senior Testing Engineer
Ing. Daniel Johnson
siddhj@siderca.com
Objectives
The objective of the department is to develop knowledge contributing to practical
applications in the areas of mechanical properties of materials and products, structural
reliability, design, tribological systems of rolling and metal working processes, and pipe
characterization.
Research Areas
Design
Components for the Oil Industry (OCTG).
Devices for materials and components testing.
! Pipe Connection for Progressive Cavity Pump (PCP) Sucker Rod
A Hallow Sucker Rod (HSR) has been designed and manufactured (Patent pending, see
section below for details). The HSR is a premium component for driving rotary PCP
pumps used in the extraction of oil. It represents a modern alternative to standard API
sucker rods.
HSR pipe connection drawing
! Test Equipment Design
3
ASTM George Irwin Fracture Mechanics Medal recipient, 1992.
ASTM Sam Tour Award recipient for best paper in the area of corrosion, 1983.
A special test device was designed and built for connection testing. Tension, torque and
alternating bending can be simultaneously applied.
PCP sucker rod fatigue test machine
Steel Sheet Forming Technology
Experimental and theoretical studies are performed to determine formability, anisotropy,
damage, and mechanical properties of base and coated materials.
! Cold Rolled Steel Sheet Formability Studies
Car side panel analyzed for formability showing points of study
! Zinc Coated Steel Sheet Formability
Coated steel sheet cup sample used in formability studies
Structural Reliability Evaluation
Mechanical properties, fatigue, and fracture mechanics concepts are used to assess the
structural reliability of components.
! Arctic Steel Grades
The study of dynamic axial crack propagation in line pipes at low temperatures (-40ºC to
-60ºC).
Notched sample for burst test with crack speed measurement. Test at -60ºC
! Critical Defects in Line Pipes
The critical size of longitudinal defects in line pipes is determined to set NDT systems
detection levels to safe values.
Experimental and theoretical values for burst pressures as a function of defect size
! Sucker Rods for Alternating Pump Oil Extraction
The structural reliability methodology is applied to sucker rods.
Full-scale tests of sucker rod strings are performed to verify product properties.
Tribology
Friction, wear mechanisms, wear of tools, ceramics, thread compounds lubrication, and
machineability are studied.
! High Temperature Tribology: Upsetting and Rolling Tools and Equipment
A study is made of the behavior of bodies under contact at high temperature and with
special lubricants at the interface, simulating working conditions.
! Machineability
The effect of feed rates, turning speeds, and different lubricants is studied to optimize
material removal rates and surface finish quality.
Turning test with three axis dynamometer
Cutting insert surface appearance after
machining test
! Thread Compound Studies
Ring-on-disc tests are run to study the behavior of different OCTG thread dopes.
Ring-on-disk device for tribological studies of thread dope
! Sealability of Metal to Metal Seals in OCTG Connections
Using an analytical and experimental approach, a sealability criterion that explains the
behavior of metal to metal seals has been established. This tool can be used to minimize
“trial and error” methods in connection development.
Test device
Application of leak theory to connection leak behavior
Full Scale Testing
The Department operates a Full Scale Testing Lab where OCTG products are tested for
R&D and Quality Control purposes.
! Pipe Body
Standard collapse, collapse under tension and burst tests are run at the lab to study pipe
body properties.
Collapse under Tension: Casing Test
! Connections
Tests are designed to simulate in service loading conditions. Customer specified and
international testing procedures are also applied.
Connection strain gauged make and break
test with dope pressure measurement
Connection tension compression with
external pressure test
Laboratory and Field Measurements
! Laboratory
Test systems are developed to measure physical parameters at the lab. The determination
of the real shape of a pipe using FFT techniques is an example of these tests.
Shapemeter
! Field Measurements
Physical parameters are measured in the field to validate mathematical models. An
example of this activity is a fully thermocouple instrumented steel casting mold.
Instrumented Continuous Casing Mold
Services
The Department performs tests for Production and Quality Control purposes, as well as
for the other departments of CINI.
Examples of these tests are:
• Collapse testing of OCTG products.
• Burst testing of OCTG products.
• Tensile Testing at Ambient and High Temperature.
• Fracture Mechanics Testing.
• Etc.
Patents
1. “A Premium Sucker Rod Connection Design for Progressive Cavity Pumps” by
G. Murtagian, J. Villasante, D. Johnson, and H. Ernst;” filed at the Dirección
Nacional de la Propiedad Intelectual, No. P99 06162, December 3rd 1999.
Publications in the Open Literature (1994 – 1999)
(a) Refereed Journals
1. K. Y. Rhee and H. A. Ernst, “A Study on the Application of the Work Factor
Approach to Composite Laminates,” Journal of Composite Materials, Vol. 27,
No. 10, pp. 962-972, 1994.
2. H. Tada, H. A. Ernst, and P. C. Paris, “Westergaard Stress Functions for
Displacement-Prescribed Crack Problems. Part II,” International Journal of
Fracture, 1994.
3. H. A. Ernst, P. J. Rush, and D. E. McCabe, “Resistance Curve Analysis of
Surface Cracks,” Fracture Mechanics Twenty-Fourth Symposium, American
Society for Testing and Materials, Special Technical Publication, ASTM STP
1207, pp. 389-409, 1994.
4. D. M. Lambert and H. A. Ernst, “Constraint Effects Observed in Fracture
Resistance Curves and Crack Face Displacements,” Fracture Mechanics Twenty
5.
6.
7.
8.
Sixth Symposium, American Society for Testing and Materials, Special Technical
Publication, ASTM STP 1320, 1996.
K. Y. Rhee and H. A. Ernst, “Computation of Energy Release Rate Components
by Using Near Tip Stress and Displacement Distributions,” Composites Science
and Technology Journal, 1996.
A. P. Assanelli, K. Xu, F. Benedetto, D. Johnson, and E. N. Dvorkin, “Numerical
Experimental Analysis of an API 8-Round Connection,” ASME, J. Energy
Resources Technology, Vol. 119, pp. 81-88, 1997.
G. R. Murtagian, D. D. H. Johnson, and H. A. Ernst, “Dynamic Axial Crack
Propagation on Linepipes. Part I: Experimental Developments,” To be published
in Engineering Fracture Mechanics, 2000.
G. R. Murtagian and H. A. Ernst, “Dynamic Axial Crack Propagation on
Linepipes. Part II: Crack Propagation Modeling,” To be published in
Engineering Fracture Mechanics, 2000.
(b) Conference Proceedings
1. A. P. Assanelli, R. G. Toscano, D. Johnson, and E. N. Dvorkin, “Collapse
Behavior of Casings: Measurements Techniques, Numerical Analysis and Full
Scale Testing,” Proceedings of the 1998 SPE Applied Technology Workshop on
Risk Based Design of Well Casing and Tubing, (SPE paper 51314), The
Woodlands Texas, 1998.
2. A. P. Assanelli, D. Johnson y E. N. Dvorkin, “Estudios de unions tubulares
roscadas para aplicaciones petroleras: modelos computacionales y ensayos
experimentales,” Mec. Comput., Vol. 14, (Ed. Sergio Idehlson et al.), 1994.
(c) Editing of Publications
1. H. A. Ernst for “Engineering Fracture Mechanics”
FUDETEC
Centro de Investigación Industrial
Av. Córdoba 320 (1054) Buenos Aires, Argentina
Tel.: (54)-3489-435302 / Fax: (54)-11-4310-1000
e-mail: dvk@siderca.com