Calcium metal cored wire is widely used in the steelmaking production to control slag quality, improve aluminum killed-steel continuous casting and solve nozzle blockage. This wire reduces the loss due to oxidation of metal calcium and increases the rate at which calcium is absorbed in the molten steel. However, there are a number of challenges in the production of pure calcium cored wire.
In order to overcome these challenges, AFFIVAL has developed an advanced cored wire with an integrated thermal insulation layer. This new design increases performance in steelmaking, reduces carbon dioxide emissions, and also conserves energy.
Its high purity and outstanding mechanical properties are the key factors in the success of this new wire. This wire has a thin, cold-rolled strip of low carbon steel wrapped around it. The inside is then filled with pure Calcium or Calcium Iron Alloy powder. Combining these materials allows for a faster melting of steel with lower temperatures and melting points. The cored wire is able to penetrate the slag into the bottom layer of molten metal.
The wire core is protected by an air-tight steel casing to avoid oxidation. The steel strip is sealed with the inner granules of calcium metal, and the gap in between them can be closed using "non fusion welding", a welding technique.
Since adopting this technology, the metallurgical results are promising. Hi-Cal, compared to conventional calcium-cored wires, produced higher yields as well as a more stable state metallurgical in the steel melting. With the introduction of this new cored steel wire, the consumption of power in the arc as well the emissions from nitrogen oxide were both reduced.
Besides being simple to install, it does not need any significant modifications. The uniqueness of the design and its high-quality material are to thank for that. The wire is easier to use and handle, and produces the same results as standard wires.
AFFIVAL cored wires have the additional benefit, in addition to all the advantages listed above, of reducing fumes when welding. The fumes can be reduced by up to half compared to flux-cored wires. This reduces significantly the costs of additional air systems to remove slag and clean. It is the perfect alternative to traditional cored-wires for applications that require a low level of slag. This is especially true in the area of repair welding on components such as 2.25Cr-1M or CrMoV. The AFFIVAL team is committed to improving the cored steel wire as well as its feeding system in order to increase the benefit of this cored core wire to the industry.
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