Completed R&D Projects

Nickel Aluminide Transfer Rolls are in full-scale commercial use in a Burns Harbor plate mill to allow non-stop processing and reduce energy use by 33%. (PDF 2.5 MB)

Operating practice permits recycling of waste oxide agglomerates in the steelmaking vessel

Recycling of Waste Oxides (PDF 99 KB)

Mag-Gate™ reduces pouring turbulence, re-oxidation, and impurity entrapment

Magnetic Gate System for Molten Metal Flow Control (PDF 94 KB)

The following projects were recently completed. In some cases, the R&D produced a new technology that is now emerging in the marketplace. In other cases, the R&D results will help to guide future development of energy-efficient technologies and processes for the steel industry. Project factsheets for each project are available as Adobe Acrobat PDFs. Download Adobe Reader.

Advanced Control in Blast Furnace (PDF 86 KB)
Aluminium Bronze Alloys to Improve the System Life of Basic Oxygen and Electric Arc Furnace Hoods, Roofs, and Side Vents (PDF 1.1 MB) (See OSTI's Final Report (PDF 4.0 MB))
Appropriate Resistance Spot Welding Practice for Advanced High Strength Steels (PDF 99 KB) (Final Reports (PDF 3.8 MB), (PDF 246 KB))
Automated Steel Cleanliness Analysis Tool (ASCAT) (PDF 81 KB) (See OSTI's Final Report (PDF 7.0 MB))
CFD Modeling for High Rate Pulverized Coal Injection in the Blast Furnace (PDF 1.1 MB)
Characterization of Fatigue and Crash Performance of a New Generation of HSS (Final Report (PDF 1.2 MB))
Clean Steels: Advancing the State of the Art (PDF 72 KB) (Final Report (PDF 589 KB))
Cold Work Embrittlement of Interstitial-Free Steels (PDF 2.2 MB)
Constitutive Behavior of High Strength Multiphase Sheet Steels under High Strain Rate Deformation Conditions (PDF 124 KB) (Final Report (PDF 3.3 MB))
Controlled Thermal-Mechanical Processing of Tubes and Pipes (PDF 2.2 MB) (Final Report (PDF 5.9 MB))
Dephosphorization When Using Direct Reduced Iron (DRI) or Hot Briquetted Iron (PDF 2.0 MB)
Development and Application of Steel Foam and Structures (PDF 62 KB) (Final Report (PDF 3.3 MB))
Development of a Process to Continuously Melt, Refine, and Cast High Quality Steel (PDF 2.3 MB) (Final Report (PDF 3.0 MB))
Development of Next Generation Heating System for Scale Free Steel Reheating, Phase I (Final Report (PDF 1.4 MB))
Development of O₂-Enriched Furnace (PDF 76 KB)
Elimination or Minimization of Oscillation Marks - A Path to Improved Cast Surface Quality (PDF 1.2 MB)
Enhanced Inclusion Removal from Steel in the Tundish (PDF 1.1 MB)
Enrichment of By-Product Materials from Steel Pickling Acid Regeneration Plants (PDF 1.2 MB)
Feasibility Study for Recycling Use Automotive Oil Filters in a Blast Furnace (Final Report (PDF 538 KB))
Formability Characterization of a New Generation of High Strength Steels (Final Report (PDF 1.9 MB))
Future Steelmaking Processes - Dec. 2003 (PDF 83 KB)
Geological Sequestration of CO₂ by Hydrous Carbonate Formation with Reclaimed Slag (PDF 1.1 MB)
Hydrogen and Nitrogen Control in Ladle and Casting Operations (PDF 72 KB) (Final Report (PDF 929 KB))
Improved Criteria for Acceptable Yield Point Elongation (YPE) of Surface Critical Steels (PDF 1.2 MB)
Inclusion Optimization for Next Generation Steel Products (See OSTI's Final Report (PDF 4.0 MB))
In-Situ, Real-Time Measurement of Melt Constituents (PDF 117 KB)
Integrating Steel Production with Mineral Sequestration (PDF 1.2 MB)
Intelligent Inductive Processing (PDF 80 KB)
Large-Scale Evaluation of Nickel Aluminide Rolls in a Heat-Treat Furnace (PDF 2.6 MB)
Laser Contouring System (PDF 1.1 MB)
Life Improvement of Pot Hardware (PDF 72 KB) (See OSTI's Final Report (PDF 7.0 MB))
Magnetic Gate System for Molten Metal Flow Control (PDF 69 KB)
The Mesabi Nugget Research Project New Ironmaking Technology of the Future: High Quality Iron Nuggets Using a Rotary Hearth Furnace (PDF 701 KB)
Minimizing NOx Emissions from By-Product Fuels in Steelmaking (PDF 67 KB)
New Process for Hot Metal Production at Low Fuel Rate - Phase 1 Feasibility Study (Final Report (PDF 2.4 MB))
New Ultra-Low Carbon Steels With Improved Bake Hard ORNL (PDF 110 KB)
Novel Low-NOx Burners for Boilers in the Steel Industry (PDF 73 KB) (See OSTI's Final Report (PDF 1.0 MB))
Optical Sensor for Post-Combustion Control in Electric Arc Furnace Steelmaking (PDF 2.0 MB)
Optimization of Post Combustion (PDF 104 KB) (Final Report (PDF 705 KB))
Plant Line Trial Evaluation of Viable Non-Chromium Passivation Systems for ETP (Final Report (PDF 20.1 MB))
Processing Electric Arc Furnace Dust into Saleable Chemical Products (PDF 83 KB)
Properties of Galvanized and Galvannealed Advanced High Strength Hot Rolled Steels (PDF 1.2 MB)
Pulverized Coal Injection (PDF 96 KB) (Final Report (PDF 16.4 MB))
Quantifying the Thermal Behavior of Slags (Final Report (PDF 2.0 MB))
Real-Time Melt Temperature Measurement in a Vacuum Degasser Using Optical Optometry
Recycling of Waste Oxides (PDF 72 KB)
Removal of Residual Elements in the Steel Ladle (PDF 101 KB)
Standard Methodology for the Quantitative Measurement of Steel Phase Transformation Kinetics (Final Report (PDF 697 KB))
Strip Casting: Anticipating New Routes to Steel Sheet (PDF 87 KB)
Study of Deformation Behavior of Lightweight Steel Structures (PDF 101 KB)
Submerged Entry Nozzles that Resist Clogging (PDF 68 KB) (Final Report (PDF 8.9 MB))
Suspension Hydrogen Reduction of Iron Oxide Concentrate (PDF 1.2 MB)
Sustainable Steelmaking Using Biomass and Waste Oxides (Final Report (PDF 747 KB))
Technical Feasibility Study of Steelmaking by Molten Oxide Electrolysis (PDF 1.1 MB)
Temperature Measurement of Galvanneal Steel (PDF 87 KB)
Validation of the Hot-Strip Mill Model (PDF 109 KB)
Verification of Steelmaking Slag Iron Content (PDF 103 KB) (Final Report (PDF 3.7 MB))

Projects Relevant to Steel R&D

Other Industrial Technologies Program areas support projects that are highly relevant to steel.

An Energy Saving Model for the Heat Treatment of Castings (Final Report (PDF 8.5 MB))
Development of a Versatile Laser Ultrasonic System and Application to On-Line Measurement for Process Control (PDF 802 KB)

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