In the quest for stronger, more reliable steel, researchers have uncovered a breakthrough that could reshape the energy sector. Zong Hao, a researcher affiliated with an undisclosed institution, has published a study in the journal *Teshugang* (translated to “Iron and Steel”) that delves into the effects of spray combined cooling on the microstructure and properties of high-speed wire rods. The findings could have significant implications for the production of steel used in critical energy infrastructure.
The study, which focuses on ϕ12.0 mm hard wire steel, explores how different controlled cooling processes affect the cooling curve, microstructure morphology, mechanical properties, and surface quality of high-speed wire rods. The results are promising, demonstrating that spray cooling can significantly enhance the strength of steel by refining the pearlite lamellar spacing.
“When we adopted spray cooling, we saw a notable improvement in strength,” Hao explains. “By increasing the cooling rate, we were able to refine the pearlite lamellar spacing, which is crucial for the mechanical properties of the steel.”
But the benefits don’t stop there. The study also found that combining spray cooling with air cooling can further enhance the steel’s properties. “By utilizing the conditioning effect of air cooling, we were able to suppress the temperature rise after cooling, resulting in a more complete and uniform sorbite cluster,” Hao adds.
The research also highlights the importance of optimizing the spray pressure. Increasing the spray pressure allows phase transformation to occur at lower temperatures, promoting significant refinement of cementite and simultaneous improvement in strength and ductility. However, the study cautions against using excessively high pressure, as it can lead to the formation of hard and brittle martensite, causing significant performance fluctuations and brittle fracture.
The commercial impacts of this research are substantial. Compared with traditional Stelmor air cooling, the new process reduces the temperature difference between the overlap point and the center point from 60°C to 10°C. It also reduces the variation of tensile strength from 60 MPa to 30 MPa, the reduction of area from 10% to 5%, and increases the sorbite content from an average of 80% to 95%.
“This process has been verified by customers to be effective and provides a reliable path for process improvement in similar products,” Hao states.
The optimal process identified in the study involves spray cooling with a roller table speed of 0.50 m/s, 10 insulation covers, 4 fans turned on, and a nozzle pressure of 3.5 MPa. This breakthrough could pave the way for more efficient and cost-effective production of high-quality steel, benefiting the energy sector and beyond.
As the world continues to demand stronger, more reliable materials for energy infrastructure, this research offers a promising path forward. By refining the cooling process, manufacturers can produce steel that meets the highest standards of strength and durability, ensuring the safety and efficiency of energy systems worldwide.
The study, published in *Teshugang*, offers a glimpse into the future of steel production, where precision cooling techniques can unlock the full potential of this vital material. As the energy sector continues to evolve, such innovations will be crucial in meeting the demands of a rapidly changing world.