nea Maies uepanmeni or uommerce

tional Institute of Standards and Technology

NTSIT Knorinl Puhlirntinn 772

Sponsored by:

National Institute of Standards and Technology

U.S. Department of Energy

American .Iron and Steel Institute

A 11 10 3 !M3Mb7

NATL INST OF STANDARDS & TECH R.I.C.

A1 11 031 43467

/Intelligent processing for primary meta J3C100 .U57 N0.772 T989 V1989 C.2 NIST-PU

NIST

PUBLICATIONS

Intelligent Process

for Primary Meta>

Edited by:

A. Cramb

W. E. Eckhart, Jr.

D. Watanapongse

J. Early

J. Kor

R. Sussman

A. V. Clark, Jr.

I

100

U57

772

1989
rhe National Institute of Standards and Technology1 was established by an act of Congress on March 3, 1901. The Institute's overall goal is to strengthen and advance the Nation's science and technology and

facilitate their effective application for public benefit To this end, the Institute conducts research to assure international competitiveness and leadership of U.S. industry, science and technology. NIST work involves development

and transfer of measurements, standards and related science and technology, in support of continually improving

U.S. productivity, product quality and reliability, innovation and underlying science and engineering. The Institute's technical work is performed by the National Measurement Laboratory, the National Engineering Laboratory, the National Computer Systems Laboratory, and the Institute for Materials Science and Engineering.

The National Measurement Laboratory

Provides the national system of physical and chemical measurement;

coordinates the system with measurement systems of other nations and furnishes essential services leading to accurate and uniform

physical and chemical measurement throughout the Nation's scientific community, industry, and commerce; provides advisory and research

services to other Government agencies; conducts physical and chemical

research; develops, produces, and distributes Standard Reference

Materials; provides calibration services; and manages the National

Standard Reference Data System. The Laboratory consists of the following centers: The National Engineering Laboratory

Basic Standards2 Radiation Research

Chemical Physics

Analytical Chemistry

Provides technology and technical services to the public and private

sectors to address national needs and to solve national problems;

conducts research in engineering and applied science in support of these

efforts; builds and maintains competence in the necessary disciplines

required to carry out this research and technical service; develops engineering data and measurement capabilities; provides engineering measure- ment traceability services; develops test methods and proposes engineering standards and code changes; develops and proposes new

engineering practices; and develops and improves mechanisms to

transfer results of its research to the ultimate user. The Laboratory

consists of the following centers: The National Computer Systems Laboratory

Computing and Applied

Mathematics

Electronics and Electrical Engineering2 Manufacturing Engineering

Building Technology

Fire Research

Chemical Engineering3

Conducts research and provides scientific and technical services to aid Federal agencies in the selection, acquisition, application, and use of

computer technology to improve effectiveness and economy in Govern- ment operations in accordance with Public Law 89-306 (40 U.S.C. 759), relevant Executive Orders, and other directives; carries out this mission

by managing the Federal Information Processing Standards Program,

developing Federal ADP standards guidelines, and managing Federal

participation in ADP voluntary standardization activities; provides scientific and technological advisory services and assistance to Federal

agencies; and provides the technical foundation for computer-related

policies of the Federal Government The Laboratory consists of the following divisions: The Institute for Materials Science and Engineering

Information Systems

Engineering

Systems and Software

Technology

Computer Security

Systems and Network

Architecture

Advanced Systems

Conducts research and provides measurements, data, standards, refer- ence materials, quantitative understanding and other technical information fundamental to the processing, structure, properties and perfor- mance of materials; addresses the scientific basis for new advanced

materials technologies; plans research around cross-cutting scientific themes such as nondestructive evaluation and phase diagram development; oversees Institute-wide technical programs in nuclear reactor

radiation research and nondestructive evaluation; and broadly disseminates generic technical information resulting from its programs. The

Institute consists of the following divisions:

Ceramics

Fracture and Deformation3 Polymers

Metallurgy Reactor Radiation

'Headquarters and Laboratories at Gaithersburg, MD, unless otherwise noted; mailing address

Gaithersburg, MD 20899.

2Some divisions within the center are located at Boulder, CO 80303.

3 Located at Boulder, CO, with some elements at Gaithersburg, MD.
NIST Special Publication 772

Intelligent Processing

for Primary Metals

Report of Workshop: August 29-30, 1989

Gaithersburg, MD 20899

Edited by:

A. Cramb, Carnegie-Mellon University

W. E. Eckhart, Jr., U.S. Department of Energy

D. Watanapongse, Inland Steel

J. Early, NIST

J. Kor, Timken Company

R. Sussman, ARMCO, Inc. A. V. Clark, Jr., NIST

Issued November 1989

NATIONAL INSTITUTE OF STANDARDS &

TECHNOLOGY

Research Information Center

Gaithersburg, MD 20899 U.S. Department of Commerce

Robert A. Mosbacher, Secretary

National Institute of Standards and Technology

Raymond G. Kammer, Acting Director
Library of Congress U.S. Government Printing Office

Catalog Card Number: 89-600773 Washington: 1989

National Institute of Standards

and Technology

Special Publication 772

Natl. Inst. Stand. Technol.

Spec. Publ. 772

40 pages (Nov. 1989)

CODEN: NSPUE2

For sale by the Superintendent

of Documents

U.S. Government Printing Office

Washington, DC 20402
Contents

Intelligent Processing for Primary Metals

Workshop Organization iv

Introduction , . . . 1

Direct Liquid Metal Production 5

Near-Net Shape Casting 13

Finishing and Coating Processes 19

Appendices

Workshop Program 26

Workshop Attendance List 35

iii
INTELLIGENT PROCESSING FOR PRIMARY METALS

WORKSHOP ORGANIZATION

WORKSHOP CHAIRMAN

Lyle H. Schwartz

National Institute of Standards and Technology

STEERING COMMITTEE

Ian F. Hughes

Inland Steel

Lyle H. Schwartz

National Institute of

Standards and. Technology

W. Eugene Eckhart

Department of Energy William Dennis

American Iron and

Donald Pitts Steel Institute

Aluminum Association

Robert Bonewitz

Alcoa

William Dresher

International Copper

Research Association

ORGANIZING COMMITTEE

James Early

National Institute of

Standards and Technology

W. Eugene Eckhart

Department of Energy

Dhani Watanapongse

Inland Steel

Robert Green

Johns Hopkins University

iv
INTRODUCTION

A Workshop on Intelligent Processing for Primary Metals was convened on August

29-30, 1989 at the National Institute of Standards and Technology, Gaithersburg,

Maryland. It was sponsored by the American Iron and Steel Institute (AISI), the

Department of Energy (DOE), and the National Institute of Standards and

Technology (NIST). Attendance was by invitation and the more than 80 participants

were primarily senior technical staff and managers from steel, aluminum, and copper

companies.

The past 5 years have witnessed extensive advances in the enabling technologies

needed for intelligent processing of materials. These include: advanced sensors for

on-line monitoring of material and process parameters, the knowledge base and

materials characterization techniques to develop process models relating process

parameters to material properties, and hierarchical computer control strategies for

implementing artificial intelligence/expert systems concepts. Several recent national

programs have been initiated to integrate elements of these advances to control the

processing of advanced materials such as gallium arsenide crystals, powder metals,

and composites. Similar opportunities appear to exist in the primary metals

industries.

The goal of this industry-led workshop was to highlight the recent advances in

sensing, modeling, and process control, to identify areas of need in the primary

metals industries, and to develop a strategy for implementation of research results.

Industry, university, and government participants assessed information provided by

researchers and operating staff from industry to develop a research agenda for

coupling the advancing state of materials processing in the primary metals industries.

This report is the proceedings of the deliberations from this Workshop. The

summaries of the three working sessions were produced by the session chairmen

from their notes.

The genesis of this workshop may be traced to two events. First, the signing into

law in late 1988 of the Steel and Aluminum Energy Conservation and Technology

Competitiveness Act that authorizes DOE and NIST to carry out coordinated

programs in support of the primary metals industries, primarily steel, aluminum, and

copper. As authorized in this Act, DOE would focus on cost-sharing projects in

priority R&D areas, including, but not limited to: direct production of liquid steel,

production of near-net shape products, the development of advanced coatings for

steel, and the application of automated processing technology. NIST would

concentrate on providing instrumentation and measurement R&D.

1
The second event was the January 1989 forum at Northwestern University to identify

long-range research opportunities for the North American steel industry. The

industry participants concluded that research opportunities could best be addressed

in the context of three specific long-range development projects: direct production

of liquid steel, near-net shape casting, and finishing and coating operations. Further,

it was recognized that the successful integration of these three contiguous unit

operations would yield important benefits by responding to the increasing constraints

on traditional batch processing, by developing new product properties to match

customer needs, and by taking advantage of this era of computational plenty to

control processes for increased efficiency and product quality.

To capitalize on these events, planning was initiated through a steering committee

with representatives from steel, aluminum, and copper trade associations, individual

companies, the academic community, and Federal agencies. The consensus was to

address the process control needs of the broad spectrum of primary metal industries

and the role of intelligent processing concepts in solving these needs by focusing on

three generic areas: primary metal production/refining, production of near-net shape

products, and finishing/coating to final properties. Emphasis would be on future,

advanced processes and technologies.

The workshop was organized into three working sessions:

I. Direct Liquid Metal Production

II. Near-Net Shape Casting

III. Finishing and Coating

Within these areas, the key elements of intelligent processing were stressed. The

relationships between fundamentals and processing were explored through the

integration of process modeling, sensor technology, and control strategies.

Although the strategy was to achieve a workshop relevant to steel, aluminum and

copper, the program contained a strong orientation toward steel-related issues. Since

early in this decade, the steel industry has worked to develop a consensus on

technical advances needed to improve traditional production practices and on

identifying the future steel-making technologies. The steering committee recognized

that the steel industry would be particularly well-positioned to play an important role

and make major contributions to the workshop.

2
The Organizing Committee was pleased to have participation by representatives of

the aluminum and copper industries because the workshop structure is applicable to

the processing of these metals. An overlap or commonality of process control needs

is likely in some areas of processing. The success of this workshop could lead to

other industries using this approach to develop process control priorities.

Leading off the first day of the Workshop was an introduction to intelligent

processing of materials concepts through applications to aerospace and other

advanced materials followed by an overview of the process control research needs

for the production of steel and aluminum. The workshop format, organized into

three working sessions responsible for Direct Liquid Metal Production, Near-Net

Shape Casting, and Finishing/Coating, took place in the afternoon of the first day

and the morning of the second day to permit a wide range of inputs from the

participants. Coordinated presentations were given in these working sessions on the

status of sensors, process models, and control approaches, the available technology,

and the benefits to relevant research. After the morning sessions on the second day, a brief, verbal synopsis of the deliberations in each of the three working sessions was

presented to the assembled workshop participants.

The following three sections, prepared by the co-chairmen of the working sessions,

contain the more detailed summaries of the discussions, including the consensus reached on specific topics and recommended actions. The complete list of

participants in each session is found in the Appendix.

3

DIRECT LIQUID METAL PRODUCTION

Session Co-Chairmen

Alan W. Cramb, Carnegie-Mellon University

Jan Kor, Timken Company

Speakers

J. Kor, Timken Company

P. Koros, LTV Steel Company

J. Fay, ASARCO, Inc. A. McLean, University of Toronto

D. Hardesty, Sandia National Laboratory

C. Alcock, Notre Dame University

Y. Kim, Lehigh University

R. Guthrie, McGill University

M. Shah, IBM

S. Ray, NIST

BACKGROUND/OBJECTIVE

A new generation of processes for direct liquid metal production is evolving. These

processes will be continuous rather than batch and involve fewer processing steps,

resulting in substantially lower capital and operating costs.

The objective for this session is to define the role that modern techniques for

intelligent processing, i.e., sensors, modeling, and computer process control, should

play in these major process developments. Based on this assessment, specific

recommendations should be made for further cause of action.

The session was organized into two parts: the first part was an information exchange

between experts on sensor technology, process control, modeling, and the application

of advanced computer decision making techniques1

, while the second part was to

define and prioritize specific needs in the area of intelligent processing of liquid

metals.

lrThis phrase used instead of terms "artificial intelligence" and "expert systems" which were

overused in this context.

5
Three major thrust areas were determined: Sensors, Process Modeling and Intelligent

Processing. Within each area specific needs were identified. The sensor area was

considered to be the area of highest importance and it was the consensus of the

group that sensor development and implementation should be the major focus of any

endeavor.

SENSORS

Three separate groups of sensors were distinguished: continuous temperature sensors; continuous chemical sensors for liquid metal and hot, dirty gases; and, physical sensors to measure reaction intensity.

Continuous Temperature Measurement

This is an area of immediate need. Discussions indicated that this is not necessarily a problem of temperature measurement itself but more a problem of sensor life in

the steel-making environment. It was noted that reactions at the metal/slag interface can be particularly severe when continuous liquid steel measurements are made, and

that abrasion in hot, dirty gases can also be a problem. The capability of continuous

liquid metal temperature measurement at temperatures between 1450 °C and

1700 °C to an accuracy of plus or minus 1 °C is necessary, while hot gas temperature

measurement must be available up to temperatures of 1800 °C.

Continuous Chemical Sensors for Gases and Liquids

This is another area of immediate need and a list of identified sensor needs is given

in table 1. Highest priority was given to continuous carbon determination; however,

carbon monoxide, carbon dioxide, hydrogen and water contents of the off-gas were

also given a high priority. Both of these sensor needs are immediate. A carbon

sensor capable of measuring carbon from 0.005 to 4.0 weight percent would be

optimum and cover all needs; however, a sensor capable of 0.1 to 4.0 percent would

be a good starting point for process control. In gas chemical analysis the major

anticipated problems were related to continuous sampling of the hot, dirty gas.

6
Physical Sensors of Conditions in the System

This area of need is again immediate from the point of view of reaction control;

however, since an appropriate sensor could not be identified2

, it was felt that this

may be a longer term development. The goal of this sensor development is to

develop a real time, on-line measurement of reaction intensity within the bath. A

vessel sensor, using some physical measurement which can be made either on or

within the vessel (such as a sonic or vibrational measurement) would then be

interpreted to give an index of reaction intensity. It was agreed that any such sensor development would need tandem development of appropriate computerized pattern

recognition techniques to be successful in a reasonable time frame. "Neural

Networks" were mentioned in this context.

MODELING

The area of process modeling was identified as the second most important area for

research at this time. Two separate groups of needs were outlined:

(1) Process Control Models

(2) In-Detail Process Models.

Process Control Models

Due to the nature of a continuous reaction vessel, the need was identified for simple

on-line process control models, based on sensor and operator input, which will

control the operation and act as an operator guide. This is an area of immediate

need and the system would be upgraded and developed during pilot plant operation.

In-Detail Process Models

A long range need was determined in the area of process modeling. Although a complete, fundamental heat, mass and fluid flow model of the process was not

thought to be realistic, certain portions of the problem were worthy of independent

development. Such portions were: heat, fluid flow, droplet size distribution in the

foaming emulsion, bubble surface area, jet penetration and solids behavior.

2A number of ideas, documented in table 2, were discussed.

7
INTELLIGENT PROCESSING

In the area of Intelligent Processing there was a concern that current "Artificial

Intelligence" techniques might not be applicable to on-line control in a broad sense; however, in certain well-defined circumstances it may be useful. In addition, it was

felt that the computer science involved in process control and decision making was

sufficiently rapid that a mechanism should be set up so that appropriate advances can be implemented within the industry in a reasonable time frame. Three separate

groups of needs were identified.

Operator Feedback and Instruction

This group is tied to the first group under MODELING. It was felt that "Artificial

Intelligence" techniques might be appropriate in operator guidance systems.

System Integration

A problem identified generally with the implementation of computer techniques was

standardization and portability. It should not be necessary for each company or

plant to custom design their own systems. A group needs to be set up to develop

and recommend standards in system integration. Appropriate areas of endeavor are communications, estimation techniques and numerical data bases.

Technology Transfer

To combat the problem of imminent development of appropriate computer

technologies, it was felt that a "watch-dog" group should be set up to monitor

emerging technologies and to act as a center of technology transfer when

appropriate. It was felt that this group should be dynamic, i.e., a group that would

be aggressive in attempts to find collaborators interested in industrial development

of advances and also be involved in such implementation. The group would also

become a center of knowledge in this area and a resource to the industry.

8
FINAL COMMENTS

The following recommendations emerged from a more general discussion at the end

of the workshop:

o Groups should be set up which are multidisciplinary and focussed on a defined

task, e.g., a team of sensor, refractory and control specialists should be given the

task of developing a continuous carbon sensor which would be fully operational

within 2 years.

o A team approach to "intelligent processing" should be initiated early in the project

and knowledge integration should be emphasized.

o Research teams should be encouraged, where feasible, to develop generalized

approaches and solutions, including computer software, to enhance applicability

in the broad area of metal smelting and refining.

o All potential spin-offs should be well publicized and aggressively pursued.

In addition, a participant from a copper company (J. Fay) closed the session by

stating that many of the sensors highlighted during this meeting would also be of use

to the copper industry3 and that although the sessions had focused on in-bath

smelting the outcome could have more widespread applicability.

Prepared by: Alan W. Cramb

Jan Kor

See table 3.

9
Table 1. Necessary Chemical Sensors

Carbon Content of Liquid Metal

Oxygen Activity of Liquid Metal

Sulfur Content of Liquid Metal

Carbon Monoxide Content of Gas

Carbon Dioxide Content of Gas

Water Content of Gas

Hydrogen Content of Gas

Nitrogen Content of Gas

Slag FeO Content

Fe3+\Fe2+ ratio of slag

10
Table 2. Potential Physical Sensor Techniques

Vibration

Ultrasonics

Static Pressure

Acceleration

Refractory Life

11
Table 3. Sensor Needs for Copper Industry

Bath Level Measurement

Continuous Temperature Measurement*

Continuous Chemical Analysis of Matte and Slag*

Flame Length Measurement

Refractory Life*

Matte-Slag Interface

Off-Gas Composition*

Solid Feed Rate Measurement

Vessel Content (weight, etc.)

'denotes sensor need area to be similar to in-bath smelting needs.

12
NEAR-NET SHAPE CASTING

Session Co-Chairmen

W. Eugene Eckhart, Jr., U. S. Department of Energy

Richard Sussman, ARMCO, Inc.

Speakers

M. R. Moore, USS Division of USX

R. A. Gleixner, Battelle Memorial Laboratories

L. T. Shiang, Inland Steel Company

Y. Sahai, Ohio State University

H. N. G. Wadley, University of Virginia

J. A. Walton, ARMCO, Inc.

BACKGROUND/OBJECTIVE

The Near-Net Shape Casting session was organized with the realization that several

research efforts are underway within North America, indeed worldwide, investigating

different casting concepts. No single method has emerged as significantly more

advantageous than the others. Accordingly, the principal objective of this session was

to determine whether there are common needs that could lead to research projects

that would serve a broad constituency in this subject area. The areas of opportunity

could include sensors, controls, mathematical and physical modeling, and issues

relating to final product properties.

This session was conducted in two parts, according to the agenda shown in the

Appendix of this report. The first day was characterized by astute presentations

made by experts in their respective fields. Each presentation generated a modest

number of questions within the subject area. It is noteworthy that no process-specific

problems were detailed during the first-day presentations, to the disappointment of

some of the participants. It was emphasized that the intent of the first-day session

was to present a broad overview of the subject area, with concentrations on specific

problems slated for discussion the following day.

The second day of this session was started by brief presentations made by individuals

having hands-on experience with near-net shape casting of metal. Despite the

obvious differences between the various casting methods, needs were categorized into

three distinct areas: liquid metal handling, casting, and strip collection. With these

categories, numerous needs were cited for each of the different processes, many of

which were similar from one process to another.

13
The discussions showed a clear understanding of the need for the development of

specific on-line sensors which could provide necessary real-time information on

process variables. Some needs in the areas of modeling were identified; these were

more general in nature. There was little expression of need for (or understanding

of) intelligent control systems. The lack of comprehensive understanding of near- net shape casting processes is clearly reflected in these latter areas.

SENSORS

Eight sensors were identified as critical to the successful development of a commercial strip casting process. It was recognized that each of these must be

employed in a manner in which it could be actively used to control the outcome of

the process, and not merely in a passive role to provide information. Attempts were

made to determine the range and precision needed for each of the sensors. In

many cases, the identified range was quite accurate, but the estimated precision

reflected that required of the product; the sensor may require greater sensitivity. For

example, if the thickness of a strip is required to be controlled to within 2 percent

of its nominal thickness, the measuring sensor must be able to detect a variation of

possibly one tenth of that amount in order to effect proper control. The sensor needs were prioritized as follows:

1. Rapid On-line Strip Thickness and Profile Sensing

- Short time constant, 20X today's technology

- +/- 2% of nominal thickness, edge-to-edge

2. Liquid Metal Level Sensor

- +/- 2 mm

3. Continuous Temperature Mapping of the Substrate Surface

- +/- 5 °C

4. On-line Hot Strip Inspection System

5. Liquid Metal Inclusion Sensor

6. Continuous Temperature Measurement of the Melt

- +/- 1 °C

7. Continuous Topography Sensing of the Substrate

- 20 to 200 microinches

8. Liquid Metal Nitrogen Sensor

14
It bears repeating that the specifications listed with each of these sensors reflects the

limits of control that must be met to produce satisfactory strip. The participants

agreed that additional investigation of each of these sensors is necessary to determine

operational specifications required of each. The discussions were specifically steered

away from including potential solutions to each of the needs; this was not the intent

of the session.

MODELING

In the area of mathematical modeling, it was agreed that most models are processspecific. Nonetheless, there exist many commercially available models of the two

principal phenomena involved in near-net shape casting, heat transfer and fluid flow.

It was determined after considerable discussion that the industry would benefit from

a comprehensive review of such models currently available, along with their

respective strengths and weaknesses, and a strategy for implementation of selected

models. Such a review would assist research groups undertaking projects in this area.

INTELLIGENT PROCESS CONTROL

In the area of process control, it was recognized that the overall state of knowledge

of near-net shape casting makes it difficult to design a comprehensive control system

at this stage of development. It was determined that it would be meritorious to

undertake an intelligent process simulation project to serve as a model for the metals

industry. Such a project would introduce many of the features of intelligent

processing to the primary metals industry, while simultaneously assist in defining the

specifications required for specific sensors.

An extension of this project might involve commissioning the development of an

expert system shell, specifically designed for strip casting. It was overwhelmingly

agreed that it would not be desirable to attempt to modify an existing shell designed

for another process.

15
FINAL COMMENTS

The interactive discussions that accompanied the session led to the clear observation

of the necessity for industry to take the lead role in defining the specifications

required of each sensor, particularly in regard to the constraints imposed by the

operating environment.

Shortly, after the close of the Workshop, correspondence was received from a

participant from the copper industry (B. G. Lewis) expressing observations of

similarities and differences between the perceived need of the copper and steel

industries. These observations are summarized in table 1.

Prepared by: W. Eugene Eckhart, Jr. Richard Sussman

16
TABLE 1. Copper-base Alloys: Near-Net Shape Casting

Process Control Needs:

PRIORITIES*

Copper Steel Process Details Sensors/Model I ing/Control Industry Industry

Melt Furnace Accurate continuous temperature sensor. H M Fast/continuous chemical analysis. H M Inclusion monitor. M H

Transfer Launder Accurate continuous temperature sensor. H M Dissolved oxygen analysis. H L Melt level sensor. M M

Mold Melt level sensor. H H 2D mold temperature sensor. H H 2D melt temperature sensor. H H In mold friction force sensor. H M Air gap sensor. H M Liquid/Solid interface sensor. M M Mold distortion sensor. M M Model of the melt delivery system. H H Fast 3D Model combining fluid flow, heat transfer, solidification. H M*

Submold 2D Cast strip temperature. H H 2D strip thickness measurements. H H 2D on line strip inspection of surface and bulk quality/uniformity. H H

The high thermal conductivity of copper

alloys requires 3D thermal analysis.

17

FINISHING AND COATING PROCESSES

Session Co-Chairmen

Dhani Watanapongse, Inland Steel

A. Van Clark, Jr., NIST

Speakers

D. Reinbold, Bethlehem Steel

P. Southwick, Inland Steel

S. Denner, National Steel

K. Brimacombe, University of British Columbia

J. Monchalin, IMRI Canada

A. V. Clark, Jr., NIST

L. Lowry, Jet Propulsion Laboratory

A. Meystel, Drexel University

BACKGROUND/OBJECTIVE

The finishing and coating processes of the future will become continuous and will be

flexible to meet the changing market needs. The objectives of this session of the

Workshop were to:

1. Define which intelligent processing technologies can be utilized

to enhance product/process development, and to achieve high

levels of control and optimization.

2. Recommend specific directions necessary for the formulation of

future research programs to develop and apply these technologies

in the finishing and coating processes.

The session consisted of two meetings designed to facilitate interaction between

national experts and industry experts. The goal of the first meeting was to

understand and assess the states of knowledge in intelligent processing; namely,

product/process knowledge, process modeling, sensors, integrated process control, and

artificial intelligence. The product/process relationships for steel substrates and

coated steel were presented along with the needs for future improvements.

Subsequent presentations were in sensor development, process modeling, and

advanced control. The goal of the second meeting was to address the issues and

resolutions that can enhance the success of future research programs to develop and

19
apply intelligent processing technologies. Finally, summary and recommendations of

the overall session were formulated and general consensus obtained at the conclusion

of the session.

The major thrust that emerged was the need for integration of metallurgical

knowledge with intelligent processing technologies; namely, sensor, process model,

and advanced control. The development of identified sensors was perceived to be

of the highest priority, since some sensors can have significant and immediate

paybacks on the existing processes. Project team formulation, technology transfer,

customer requirements were cited as the issues that must be addressed to enhance

the success of future Research programs. Specifically, the group recommended that

future efforts be focused on intelligent processing of hot-dip galvanizing process.

The details of the summary and recommendations are as follows.

SENSORS

Although there is a wide range of sensor needs in the finishing and coating

processes, five sensors listed below were identified as having highest priority.

Further attempts to prioritize among the five or to define specific ranges and

accuracy of the sensors were considered inappropriate by the group because sensor requirements must be specified as an integral part of process modeling and control

system development. Attempts were made, however, to estimate the developmental

time for the sensors based on current understanding of available principles and

technologies. The five sensors are:

1. Continuous Measurement of Temperature of Strip [S]

4

- Highest priority should be directed to the exit point

from the post-galvannealing furnace where the strip exhibits low and

widely varying emissivity.

2. On-line Measurement of Chemical Composition and Phase

Identification in Coating [S]

- iron, zinc, and intermetallic phases

3. Measurement of Surface Topography and Surface Chemistry of

Strip [S, M]

4

[S] Short Range 1-2 Years

[M] Medium Range 3-4 Years

[L] Long Range 5+ Years

20
4. Measurement of Lubricant Film Thickness [S]

5. Measurement of Mechanical Properties/Microstructure [S to L]

- direct or predicted measurement of strength and formability in

final product

Based on the discussion, it was believed that EMAT5 technology has been sufficiently

demonstrated for R-value measurement to the point that on-line measurement of Rvalue can be realized within a relatively short time frame. For coating composition

measurement, Energy Dispersive X-Ray Fluorescence has shown promise over

conventional X-Ray Diffraction and Fluorescence techniques. Even though further

investigation is needed in this area, the group believed that on-line measurement of

coating composition can also be achieved within a short time frame. Laser-ultrasonic

is another technology that has shown promise for phase-transformation and grain

size measurements and odd-shape gauging. This technique provides excellent

potentials for on-line remote sensing as well.

PROCESS MODELING

In general, product/process relationships for steel substrates are known. However,

these relationships need to be further quantified and integrated with sensor information and expert knowledge to form working control systems, i.e., intelligent

processing technologies. Engineered surfaces and microstructural engineering were

cited as the important areas needing further modeling studies.

In the coating processes, much work is needed to understand and model coating

adherence mechanisms for a range of coating materials, steel substrates, surface

morphology, and processing parameters. In addition, press performance of coated

materials in terms of stampability and powdering characteristics must be studied and

modeled.

The significance of knowing the product end-use was emphasized by the industry

experts. A concept of "component engineering" was introduced and discussed. This

concept requires that customer manufacturing processes and required product

properties be understood and the information utilized as the driver to product and

process development. For example, formability, weldability, and paint appearance

are as essential as corrosion resistance in a coated product for automotive

applications.

EMAT = ElectroMagnetic Acoustic Transducer, an ultrasonic device requiring no medium

to couple sound from transducer to moving sheet.

21
Specific modeling needs are:

1. Obtain the state-of-the-art of zinc coating and annealing

processes.

2. Development coating adherence and coating mechanism models.

3. Develop engineered product property models for coated and

uncoated steel.

4. Develop engineered surface model.

Finally, it was noted that product and process knowledge is the limiting factor to

process modeling, not the modeling techniques. As such, no new modeling tools

were recommended by the group. However, a need was identified for fundamental

studies to measure parameters (such as heat transfer coefficients) which are inputs

to the various models.

INTELLIGENT PROCESSING

Intelligent Processing was perhaps the most misunderstood subject of the discussion.

For the purpose of this report, Intelligent Processing is defined as the integration of

product/process expert knowledge, process models, and real-time sensors into an

intelligent control system. As such, Intelligent Processing is not a replacement of

expert knowledge, but rather a systematic approach to integrate a range of existing

technologies into a working control system to achieve product consistency, design

flexibility, and process optimization.

The group believed that Intelligent Processing has definitive roles in the finishing and

coating processes, in terms of new product and process design and on-line process

control. Specific recommendations are:

1. Develop real-time expert models for control to supplement

process models.

2. Develop implementable intelligent processing systems from hot

rolling to coating, with emphasis on continuous processing.

22
Since Intelligent Processing involves implementation and also a wide range of

multidisciplinary backgrounds, the significance of project team formation, technology

transfer, designed-in safety and maintenance were discussed at length. It was

believed and recommended that a project team be formed to include from the start the industry, government, university, and equipment supplier, as shown in figure 1. There was some discussion on whether the customer should have input and should

be a part of the project team. However, no resolution was reached. Finally, the

incorporation of technology transfer from the beginning of the project was stressed

as the key element to achieving a successful development and implementation of the

technology.

SUMMARY OF RECOMMENDATIONS

A formation of a broad-based and multidisciplinary project team to develop an

implementable Intelligent Processing Technologies for the hot-dip coated product was

recommended. The needs identified include the development of key on-line sensors,

process models, and integrated process control systems. Both short- and long-term

results can be expected, all of which can provide positive impacts to the existing

products and processes. The developed technology will enable the processes to be

responsive to changes in the marketplace. The technology will have applicability to

the production of uncoated products as well. Finally, customer inputs will be

essential to the success of the project. However, the proper role of the customers

on the project must be further defined.

While the primary focus of the session was the needs of the steel industry, there was

also a component directed to nonferrous metals. The relevancy of the

recommendation to the copper and brass fabricating industry is shown in table 5

(submitted by B. G. Lewis of Olin Corporation) which suggests areas of need with

a high degree of overlap between the two industries.

Prepared by: Dhani Watanapongse

A. Van Clark, Jr.

23
Figure 1

Project Team Concept

24
TABLE 1. Copper-base Alloys: Finishing and Coating Issues

Process Control Needs;

Process Details Sensors/Mode 1 1 i ng/Cont ro

PRIORITIES

Copper Steel

Industry Industn

Hot rolling

6" -> 0.5M

, batch

rolling, 25' bars

single strand mill

Monitor temperature through rolling/quenching (emissivity

independent).

Final structure assessment (uniformity).

% IACS for certain alloys. No microstructure based feed back envisioned.

M

Coil milling

0.5M -> 0.4",

removal of surface

oxides and residual

casting defects;

20-60 ft/min.

Surface inspection required. Two sided examination for

surface defects against a background milling pattern.

% IACS for certain alloys.

Not Applicable

Cold breakdown

0.4" -> 0.1",

tandem mill,

50-500 ft/min.

Surface quality/mechanical defects

Strip anneal

gas heater

15-100 ft/min.

Temperature/temperature distribution

Properties* (texture, grain size, strength/YS, hardness

as determined by recrystallization, stabilization and aging).

Cleaning

Acid cleaning,

20-60 ft/min.

Surface quality (inorganic tarnish).

Solderabi lity/toolwear are important properties.

Not Applicable

Cold rolling

0.1" -> 0.005",

200-1500 ft/min.

Gauge and width are standard but critical issues.

Surface quality (mechanical defects/cosmetics).

Properties* (as strip anneal, plus formabi lity/internal inclusions).

Coating Coating thickness (not chemistry). H H Pb-Sn, Sn coatings Surface topography. (galvanizing)

1-10 urn, 100-300 ft/min. In process temperatures.

* High (H), medium (M), low (L)

+ Absolute property measurements are not seen as essential. A measure of product uniformity

that is tightly correlated with a property or category of properties would permit the

manufacture of product that could be certified according to customer needs off line (static).
APPENDIX

PROGRAM

Monday Evening, August 28, 1989

6:00-8:00 pm Wine & Cheese Reception and Registration

Gaithersburg Marriott

Tuesday Morning, August 29. 1989

8:00 am Bus from Hotel to NIST

8:15 am Registration

Green Auditorium, NIST

COFFEE - Employees Lounge

PLENARY SESSION

Green Auditorium

Chairman: Dr. Lyle H. Schwartz Co-Chairman

National Institute of

Standards and Technology

Welcome and Introduction to Workshop

- L. H. Schwartz (NIST)

Overview of Intelligent Processing of Materials

- W. Barker (DARPA)

Intelligent Processing of Aerospace Materials

- D. Backman (GE)

COFFEE - Employees Lounge

Long Range Research - North American Steel's Competitive

Edge - /. Hughes (Inland Steel)

Sensor, Process Models, and Control Needs in the Aluminum

Industry - R. Bonewitz (Alcoa)

Introduction ofSession Chairmen/Workshop Instructions- L. H. Schwartz (NIST)

LUNCH

West Square Cafeteria

Dr. Ian F. Hughes

Inland Steel Company

9:00 am

9:15 am

10:00 am

10:45 am

11:15 am

12:00 pm

12:45 pm

1:00 pm

26
Tuesday Afternoon, August 29, 1989

2:00 pm

2:10 pm

2:30 pm

3:00 pm

3:20 pm

3:40 pm

4:30 pm

4:50 pm

5:10 pm

5:30 pm

5:45 pm

DIRECT LIQUID METAL PRODUCTION SESSION

Session Objectives and Overview

- E. Aukrust (AISI)*

The AISI/DOE Direct Steelmaking Process

- G.J. W. Kor (Timken)

Sensor Requirements for the AISI Direct Steelmaking

Process - P. Koros (LTV Steel)

Sensor Needs in Copper Smelting

- /. Fay (ASARCO, Inc.)

COFFEE - Employees Lounge

Sensors - A. McLean (University of Toronto), Chairman

Signals from Molten Metal

- A. McLean (University of Toronto)

Optical Diagnostics for In-Situ Measurements in Combustion Environments - D. Hardesty (Sandia)

Electrochemical Sensors for Intelligent Processing

- C. B. Alcock (Notre Dame University)

Continuous Measurements of Molten Metal Composition

- Y. Kim (Lehigh University)

Process Modeling - Mathematical Models for Metallurgical

Operations - R. Guthrie (McGill University)

Application of Control Theory and Artificial Intelligence

in Process Development - M. Shah (IBM)

Architecture and Integration Techniques Used in AMRF

- C. McLean (NIST)

End of First Day's Session

Bus to Hotel

Lecture Room D

Chairman: Dr. Egil Aukrust*

AISI Direct Steelmaking

and LTV Steel

Co-Chairman Dr. Alan Cramb

Carnegie-Mellon

University

'G.J.W. Kor substituted for E. Aukrust during Workshop.

27
Tuesday Afternoon, August 29, 1989

NEAR-NET SHAPE CASTING SESSION

Lecture Room B

Chairman: W. Eugene Eckhart Co-Chairman: Dr. Richard Sussman

Department of Energy Armco, Inc.

2:00 pm Session Objective and Overview

- W. E. Eckhart (DoE)

2:05 pm Review of Near-Net Shape Casting of Steel Strip

- M. Moore (USS)

2:35 pm Process Control Considerations for Direct Strip Casting

of Steel Sheet - R. Gleixner (Battelle)

3:05 pm Product Issues

- K Blazek (Inland Steel)

3:30 pm COFFEE - Employees Lounge

3:50 pm Process Modeling

- Y. Sahai (Ohio State University)

4:20 pm Sensor Principles

- H. Wadley (University of Virginia)

4:50 pm Artificial Intelligence in Process Control

- /. Walton (Armco)

5:20 pm Summary and Preview of Issues

- R. Sussman (Armco)

5:30 pm End of First Day's Session

5:45 pm Bus to Hotel

28
Tuesday Afternoon. August 29. 1989

FINISHING AND COATING SESSION

Lecture Room A

Chairman: Dr. Dhani Watanapongse Co-Chairman: Dr. A. Van Clark, Jr. Inland Steel Company National Institute of

Standards and Technology

2:00 pm Session Objective and Overview

- D. Watanapongse (Inland Steel)

2:10 pm Process Description, Measurement Status, and Needs

- D. Reinbold (Bethlehem Steel)

2:30 pm Steel Products by Design: The Challenge of the Future

- P. Southwick (Inland Steel)

2:50 pm Coating Processes

- S. Denner (National Steel)

3:10 pm Microstructural Engineering: Models Linking Products and

Processes - K Brimacombe (University of British Columbia)

3:30 pm COFFEE - Employees Lounge

3:50 pm Laser Ultrasonics: A Novel Sensor Technology

- /. Monchalin (IMPI)

4:10 pm Measurement of Steel Sheet Formability (R-Value)

- V. Clark (NIST)

4:30 pm X-Ray Methods for Coating Composition Measurement

- L. Lowry (Jet Propulsion Laboratory)

4:50 pm Integrated Control with Incomplete Information

- A. Meystel (Drexel University)

5:10 pm Summary and Preview of Issues

- D. Watanapongse (Inland Steel)

5:30 pm End of First Day's Session

5:45 pm Bus to Hotel

29
Tuesday Evening. AugHSt 29. 1989

6:00 pm Social Hour - Cash Bar

Gaithersburg Marriott

7:00 pm Workshop Dinner

Gaithersburg Marriott

Thomas J. Murrin

Deputy Secretary of Commerce

New Metals Technologies:

Making the Government-Industry

Connection Work

30
Wednesday Mornine. August 30. 1989

7:45 am Bus from Hotel to NIST

COFFEE - Employees Lounge

DIRECT UQUID METAL PRODUCTION SESSION (com.)

Lecture Room D

Chairman: Dr. Egil Aukrust* Co-Chairman: Dr. Alan Cramb

AISI Direct Steelmaking Carnegie-Mellon

and LTV Steel University

8:30 am Session Objectives and Introduction

- A. Cramb (Carnegie-Mellon University)

8:40 am Panel Discussions

Sensors - J. Hoffman (Bethlehem Steel), Group Leader

Sensor Developments in Steelmaking

- /. Hoffman (Bethlehem Steel)

Problems in Continuous Measurement Applications

- Y. Kim (Lehigh University)

Discussion

Integration and Measurements

- E. Swanson (Inland Steel), Group Leader

Discussion

10:40 am COFFEE - Employees Lounge

11:00 am Intelligent Processing - M. Shah (IBM), Group Leader

Discussion

12:00 pm Review, Summary, and Recommendations

- A. Cramb (Carnegie-Mellon University)

1:00 pm LUNCH

West Square Cafeteria

*G.J. W. Kor substituted for E. Aukrust during Workshop.

31
Wednesday Morning, August 30. 1989

7:45 am Bus from Hotel to NIST

COFFEE - Employees Lounge

NEAR-NET SHAPE CASTING SESSION (com.)

Lecture Room B

Chairman: Dr. Richard Sussman Co-Chairman: W. Eugene Eckhart

Armco, Inc. Department of Energy

8:30 am Review Issues and Expected Outcome

- R. Sussman (Armco)

8:45 am Review of Process-Specific Needs

R. Sussman (Armco)

E. Mizikar (LTV Steel)

T. Conarty (Bethlehem Steel)

J. Naumann (Allegheny Ludlum)

J. McKay (Projet Bessemer)

K Blazek (Inland Steel)

T. Gaspar (Ribtec)

10:30 am COFFEE - Employees Lounge

10:45 am Round Table Panel Discussion

Degree of Process Understanding

Similarity/Differences Between Processes Mechanism Needed to Integrate Modeling, Sensing, and

Controlling

Model Plan to Implement Emerging Technology

Survivability Requirements of Sensors

12:45 pm Summary and Recommendations

- R. Sussman (Armco)

1:00 pm LUNCH

West Square Cafeteria

32
Wednesday Morning, August 30, 1989

7:45 am Bus from Hotel to NIST

COFFEE - Employees Lounge

FINISHING AND COATING SESSION (com.)

Lecture Room A

Chairman: Dr. Dhani Watanapongse Co-Chairman: Dr. A. Van Clark, Jr. Inland Steel Company National Institute of

Standards and Technology

8:30 am Session Objectives and Overview

- V. Clark (NIST)

8:40 am Round Table Discussion: Sensors Development

- D. Tyler (Olin Brass), Group Leader

Priorities for Sensor Needs

- C. Romberger (Bethlehem Steel)

Probabilities of Success

- T. Judd (LTV Steel)

- M. Adams (JPL)

Sources for Expertise

- B. Thompson (Ames Laboratory)

Difficulties of Implementation

- B. Muly (University of Tennessee)

- T Munson (Reynolds Metals)

10:20 am COFFEE - Employees Lounge

10:45 am Integration of Process Understanding and Modeling

- W. R D. Wilson (Northwestern University)

11:15 am Impact of Rapid Product/Process Changes

- A. Gibson (Armco)

11:45 am Management of Multidisciplines

- B. Kushner (BDM Corp.)

12:15 pm Technology Transfer to Plant Floor

- W A. Wilson (Weirton Steel)

12:45 pm Summary and Recommendations - V. Clark (NIST)

1:00 pm LUNCH

West Square Cafeteria

33
Wednesday Afternoon, August 30, 1989

1:45 pm Laboratory Tour

Bus to Industrial Building

- Intelligent Processing of Metal Powders

- Texture Sensor

- Aluminum Extrusion Temperature Sensor

SUMMARY SESSION

Green Auditorium

Chairman: Dr. Ian F. Hughes Co-Chairman: Dr. Lyle H. Schwartz

Inland Steel Company National Institute of

Standards and Technology

3:00 pm Summary of Direct Liquid Metal Production Session

- A. Cramb

3:20 pm Summary of Near-Net Shape Casting Session

- W. E. Eckhart

3:40 pm Summary of Finishing and Coating Session

- D. Watanapongse

4:00 pm Workshop Relevance to NIST Program Planning

- L. H. Schwartz

4:20 pm Workshop Relevance to DOE Program Planning

- T. Gross

4:40 pm Workshop Wrap-Up

- L. H. Schwartz (NIST)

5:00 pm End of Workshop and Departure

34
APPENDIX

ATTENDANCE LIST

NIST/DOE/AISI

Workshop on INTELLIGENT PROCESSING FOR PRIMARY METALS

August 29-30, 1989

National Institute of Standards and Technology

Gaithersburg, Maryland

Session #1: Direct Liquid Metal Production

Session #2: Near-Net Shape Casting

Session #3: Finishing and Coating

If session number not indicated, attended multiple sessions

Dr. Dibyajyoti Aichbhaumik Dr. Dan Backman

Weirton Steel Corporation General Electric Company

400 Three Springs Drive Aircraft Engine Business Group

Weirton, WV 26062 1000 Western Avenue

(304) 797-4409 Lynn, MA 01910

Session #2 (617) 594-4554

Dr. Charles Alcock Mr. William Barker

Materials Science and Engineering Materials Science Division

Department DARPA

Notre Dame University 1400 Wilson Blvd.

Notre Dame, IN 46556 Arlington, VA 22209

(219) 239-5330 (202) 695-9374

Session #1

Mr. Kenneth Blazek

Mr. Brian Aranha Inland Steel Company

AISI Fellow Research Laboratory

American Iron & Steel Institute 3001 E. Columbus Drive

1133 15th Street, N.W. East Chicago, IN 46312

Washington, DC 20005 (219) 399-6216

(202) 452-7267 Session #2

Session #1

Dr. Robert Bonewitz

Dr. Brian Attwood Director, Product Design &

LTV Steel Company Manufacturing

6801 Breckville Road Alcoa

Independence, OH 44131 Alcoa Center, PA 15069

(216) 642-7222 (412) 337-2107

Session #3 Session #2

35
Mr. Robert Bouman

Manager, Process Research Division

Bethlehem Steel Corporation

Technology Center

Bethlehem, PA 18016

(215) 694-6792

Session #1

Dr. J. Keith Brimacombe

Department of Metallurgical Engineering

University of British Columbia

Vancover B.C. V6T 1W5

Canada

(604) 228-3667

Session #3

Dr. A. Van Clark, Jr. Fracture and Deformation Division

NIST

Building 2, Room 2601C

325 Broadway

Boulder, CO 80303-3328

(303) 497-3159

Session #3

Mr. Eugene Colombo

LTV Steel

Cleveland, OH 44115

(216) 622-5877

Session #1

Mr. Tom Conarty

Bethlehem Steel Corporation

Homer Research Laboratories

Bethlehem, PA 18016

(215) 694-6562

Session #2

Prof. Alan W. Cramb

Department of Metallurgy and Materials

Science

Carnegie-Mellon University

2315 Wean Hall

Pittsburgh, PA 15213-3890

(412) 268-3517

Session #1

Dr. Stephen G. Denner

Director, Technical Research Center

National Steel

12261 Market Street Livonia, MI 48150

(313) 591-5653

Session #3

Dr. William E. Dennis

Vice President

Manufacturing and Technology

AISI

1133 15th Street, N.W.

Washington, DC 20005

(202) 425-7265

Session #1

Dr. James G. Early

NIST/IMSE

Building 223, Room B309

Gaithersburg, MD 20899

(301) 975-6113

Mr. W. Eugene Eckhart

Office of Industrial Programs

Department of Energy

1000 Independence Avenue, S.W.

CE-142

Washington, DC 20585

(202) 586-8668

Session #2

Dr. John F. Elliott Department of Materials

Science and Engineering

Massachusetts Institute of

Technology

Room 4-138

Cambridge, MA 02139

(617) 253-3305

Session #1

Dr. Kory Eman

Northwestern University

Evanston, IL 60208

(312) 491-3263

Session #3

Dr. John E. Fay

ASARCO, Inc. Technical Services Center

3422 South 700 West

Salt Lake City, UT 84117

(801) 262-2459

Session #1

36
Dr. Chris Fortunko

Fracture and Deformation Division

NIST/IMSE

325 Broadway

Boulder, CO 80303-3328

(303) 497-3062

Session #3

Mr. Thomas A Gaspar

Ribbon Technology Corporation

P. O. Box 30758

Gahanna, OH 43230

(614) 864-5444

Session #2

Dr. Gordon H. Geiger

Executive Vice President

North Star Steel Company

P. O. Box 9300

Department 47

Minneapolis, MN 55440

(612) 475-5466

Session #2

Mr. Alan F. Gibson

General Manager of Products R&D

Armco, Inc. 703 Curtis

Middletown, OH 45043

(513) 425-2257

Session #3

Dr. Richard A. Gleixner

Principle Research Scientist Battelle 505 King Avenue

Columbus, OH 43201-2693

(614) 424-5872

Session #2

Mr. Samuel S. Gould

Oak Ridge National Laboratory

Oak Ridge, TN 37831-8066

(615) 574-0350

Mr. Thomas J. Gross

Director, Division of Improved

Energy Productivity

Department of Energy

1000 Independence Avenue, S.W.

CE-142

Washington, DC 20585

(202) 586-9487

Prof. R. I. L. Guthrie

McGill University

F.D.A Building 3450, Room 106

University Street Montreal, Quebec H3A 2A7

Canada

(514) 398-4364

Session #1

Dr. Donald R. Hardesty

Supervisor, Combustion Research Division

Sandia National Laboratories

Livermore, CA 94551-0969

(415) 294-2321

Session #1

Mr. John Hoffman

Senior Engineer

Bethlehem Steel Corporation

HRL, Room C355, Building C

Bethlehem, PA 18016-7699

(215) 694-6607

Session #1

Dr. Ian F. Hughes

Vice President, Technology

Inland Steel Company

3001 East Columbus Drive

East Chicago, IN 46312

(219) 399-3262

Mr. Charles J. Jarrow

Metal Industries Specialist

IBM Corporation

Four Allegheny Center

Pittsburgh, PA 15212

(412) 237-7730

Session #1

Mr. Tyler W. Judd

Manager, NDT

LTV Research

6801 Brecksville Road

Independence, OH 44131

(216) 642-7253

Session #3

Dr. Yong Kim

Physics Department

Lehigh University

Building 16

Bethlehem, PA 18015

(215) 758-3922

Session #1

37
Dr. G. Jan W. Kor

Timken Company - Research

1835 Dueber Avenue, S.W.

Canton, OH 44706-2798

(216) 497-2349

Session #1

Dr. Peter J. Koros

Senior Research Consultant

LTV Steel Company

6801 Brecksville Road

Independence, OH 44131

(216) 642-7211

Session #1

Dr. Ken Kreider

NIST/CCT

Building 221, Room B312

Gaithersburg, MD 20899

(301) 975-2619

Session #1

Dr. Brian Kushner

Vice President

Information Science Technology

BDM Corporation

1300 N. 17th Street Suite 950

Arlington, VA 22209

(703) 247-0350

Session #3

Dr. Brian Lewis

Olin Corporation

Metals Research Laboratory

91 Shelton Avenue

New Haven, CT 06511

(203) 781-5501

Session #2

Ms. Lynn Lowry

Jet Propulsion Laboratory

4800 Oak Grove Drive

Mailstop 158-103

Pasadena, CA 91011

(818) 354-3759

Session #3

Mr. Thomas Mansfield

Reynolds Metals Company

P. O. Box 27003

Richmond, VA 23219

(804) 788-7407

Session #3

Dr. William McCulla

Deputy Leader

Process Development Group

J 565, CLS-3

Los Alamos National Laboratory

Los Alamos, NM 87545

(505) 667-6686

Session #1

Mr. John McKay

Projet Bessemer

492 Wicklow Road

Burlington, Ontario L7L 2H8

Canada

(416) 632-2015

Session #2

Prof. Alexander McLean

Department of Metallurgy and

Materials Science

University of Toronto

184 College Street Toronto, Ontario M5S 1A4

Canada

(416) 978-3552

Session #1

Dr. Alex Meystel

Professor of Electrical and

Computer Engineering

Drexel University

Philadelphia, PA 19104

(215) 895-2220

Session #3

Mr. Eugene Mizikar

LTV Steel Company

Technology Center

6801 Grecksville Road

Independence, OH 44131

(216) 642-7206

Session #2

38
Mr. Jean-Pierre Monchalin

National Research Council of Canada

IMRI Division

75 Mortagne Blvd. Boucherville, Quebec J4B 6Y4

Canada

(514) 641-2280

Session #3

Dr. Michael R. Moore

Senior Research Consultant

USS Technical Center

4000 Tech Center Drive

Monroeville, PA 15146

(412) 825-2328

Session #2

Dr. Emil C. Muly

Director, Measurement and Control

Center

University of Tennessee

101 Perkins Hall

Knoxville, TN 37996-2000

(615) 974-2375

Session #3

Dr. John Nauman

Allegheny-Ludlum Steel Corporation

Research Center

River Road

Brackenridge, PA 15014

(412) 226-6213

Session #2

Mr. Stephen Osella

NIST/CME

Metrology Building, Room A127

Gaithersburg, MD 20899

(301) 975-3551

Session #2

Dr. Phillip Parrish

BDM International

Arlington, VA 22209

(703) 247-0390

Mr. Allan Rathbone

Director, Research Steel and

Related Resources

USS Division, USX

4000 Tech Center Drive

Monroeville, PA 15146

(412) 825-2130

Session #2

Dr. Steven R. Ray

NIST/CME

Metrology Building, Room A127

Gaithersburg, MD 20899

(301) 975-3524

Session #1

Mr. David W. Reinbold

Manager, Finishing Process Division

Bethlehem Steel Corporation

Research Department

Bethlehem, PA 18018

(215) 694-6837

Session #3

Dr. Malcolm J. Roberts

Director of Research

Bethlehem Steel Corporation

Homer Research Laboratory

Bethlehem, PA 18016

(215) 694-6598

Session #3

Mr. Charles Romberger

Supervisor, Finishing Processes Division

Homer Research Laboratories

Bethlehem Steel Corporation

Bethlehem, PA 18016

(215) 694-7152

Session #3

Dr. Yogesh Sahai

Ohio State University

Department of Materials Science

and Engineering

116 West 19th Avenue

Columbus, OH 43210-1179

(614) 292-1968

Session #2

Mr. Steven Sanders

Reynolds Metals Co.

P. O. Box 27003

Richmond, VA 23261

(804) 788-7515

Session #2

Dr. Lyle H. Schwartz

NIST/IMSE

Materials Building, Room B309

Gaithersburg, MD 20899

(301) 975-5658

Session #3

39
Dr. Manesh Shah

Advanced Manufacturing Process Control Department

IBM Corporation

Department 605/503

5600 Cottle Road

San Jose, CA 95193

(408) 256-8774

Session #1

Dr. Liantay Shiang

Inland Steel Company

3001 E. Columbus Drive

E. Chicago, IN 46319

(219) 399-6334

Session #2

Dr. Peter D. Southwick

General Manager, Quality Dept.

Inland Steel Company

3210 Watling Street

E. Chicago, IN 46312

(219) 399-6008

Session #3

Dr. Richard Sussman

Manager, Casting Department

ARMCO

Middletown, OH 45043

(513) 425-5445

Session #2

Dr. Edward Swanson

Section Manager, Process Automation

Inland Steel Company

3210 Watling Street MC-2-465

East Chicago, IN 46312

(219) 399-5104

Session #1

Mr. Robert Sylvester

Senior Research Engineer

Weirton Steel Corporation

3006 Birch Drive

Weirton, WV 26062

(304) 797-4456

Session #1

Dr. R. Bruce Thompson

Ames Laboratory

Iowa State University

216 Applied Science Center

Ames, IA 50011

(515) 294-4628

Session #3

Dr. Richard Vierod

Olin Brass New Haven, CT 06511

(203) 781-5733

Session #3

Dr. Haydn N. G. Wadley

University of Virginia

Department of Materials Science

Charlottesville, VA 22901

(804) 924-7543

Session #2

Mr. John Walton

Principle Research Engineer

Armco Research and Technology

Middletown, OH 45043

(513) 425-5729

Session #2

Dr. Dhani Watanapongse

Staff Scientist Inland Steel Research Laboratories

3001 E. Columbus Drive

E. Chicago, IN 46312

(219) 399-6322

Session #3

Dr. Walter A. Wilson

Corporate Liaison

Weirton Steel Corporation

3006 Birch Drive

Weirton, WV 26062

(304) 797-4415

Session #3

Dr. William R. D. Wilson

Associate Director

Steel Resource Center

Northwestern University

Evanston, IL 60028

(312) 491-7099

Session #3

40
Mr. Gerald Worth

National Steel Company

20 Stanwix Street Pittsburgh, PA 15241

(412) 394-4381

Session #2

Dr. H. Thomas Yolken

NIST/IMSE

Materials Building, Room B344

Gaithersburg, MD 20899

(301) 975-5727

Session #1

NIST-114A

(REV. 3-89) U.S. DEPARTMENT OF COMMERCE

NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY

BIBLIOGRAPHIC DATA SHEET

1 . PUBLICATION OR REPORT NUMBER

NIST/SP-772

2. PERFORMING ORGANIZATION REPORT NUMBER

3. PUBUCATION DATE November 1989

4. TITLE AND SUBTITLE Intelligent Processing for Primary Metals

Report of Workshop

5. AUTHOR(S)

Editors: Alan Cramb, W. Eugene Eckhart, Jr., Dhani Watanapongse , James Early, Jan Kor

Richard Sussman, A. Van Clark, Jr.

6. PERFORMING ORGANIZATION (IF JOINT OR OTHER THAN NIST, SEE INSTRUCTIONS)

U.S. DEPARTMENT OF COMMERCE

NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY

GAITHERSBURG, MD 20899

7. CONTRACT/GRANT NUMBER

8. TYPE OF REPORT AND PERIOD COVERED

Final

9. SPONSORING ORGANIZATION NAME AND COMPLETE ADDRESS (STREET, CITY, STATE, ZIP) National Institute of Standards and Technology

Department of Energy

American Iron and Steel Institute

10. SUPPLEMENTARY NOTES

Library of Congress Catalog Card Number: 89-600773

DOCUMENT DESCRIBES A COMPUTER PROGRAM; SF-185, FIPS SOFTWARE SUMMARY, IS ATTACHED.

11. ABSTRACT (A 200-WORD OR LESS FACTUAL SUMMARY OF MOST SIGNIFICANT INFORMATION. IF DOCUMENT INCLUDES A SIGNIFICANT BIBUOGRAPHY OR

LITERATURE SURVEY, MENTION IT HERE.)

This industry-led workshop highlighted the recent important advances in sensing, modeling,

and process control, identified areas of application in primary metals production, and

developed a strategy for implementation of research results. Industry, university, and

government participants assessed information provided by researchers and operating staff

from industry and developed a research agenda for coupling the advancing state of materials

processing in the primary metals industries. This report is the proceedings of the

deliberations from the Workshop.

12. KEY WORDS (6 TO 12 ENTRIES; ALPHABETICAL ORDER; CAPITAUZE ONLY PROPER NAMES; AND SEPARATE KEY WORDS BY SEMICOLONS)

control strategy; intelligent processing; primary metals; process models; sensors, steel

13. AVAILABILITY UNLIMITED FOR OFFICIAL DISTRIBUTION. DO NOT RELEASE TO NATIONAL TECHNICAL INFORMATION SERVICE (NTIS). ORDER FROM SUPERINTENDENT OF DOCUMENTS, U.S. GOVERNMENT PRINTING OFFICE, WASHINGTON, DC 20402. ORDER FROM NATIONAL TECHNICAL INFORMATION SERVICE (NTIS), SPRINGFIELD, VA 22161.

14. NUMBER OF PRINTED PAGES

40

157 PRICE

ELECTRONIC FORM

NISTiTechnical Publications

Periodical

Journal of Research of the National Institute of Standards and Technology—Reports NIST research

and development in those disciplines of the physical and engineering sciences in which the Institute

is active. These include physics, chemistry, engineering, mathematics, and computer sciences.

Papers cover a broad range of subjects, with major emphasis on measurement methodology and

the basic technology underlying standardization. Also included from time to time are survey articles on topics closely related to the Institute's technical and scientific programs. Issued six times a year.

Nonperiodicals

Monographs—Major contributions to the technical literature on various subjects related to the

Institute's scientific and technical activities. Handbooks—Recommended codes of engineering and industrial practice (including safety codes) developed in cooperation with interested industries, professional organizations, and regulatory bodies.

Special Publications—Include proceedings of conferences sponsored by NIST, NIST annual reports,

and other special publications appropriate to this grouping such as wall charts, pocket cards, and

bibliographies.

Applied Mathematics Series—Mathematical tables, manuals, and studies of special interest to physicists, engineers, chemists, biologists, mathematicians, computer programmers, and others engaged in

scientific and technical work.

National Standard Reference Data Series—Provides quantitative data on the physical and chemical

properties of materials, compiled from the world's literature and critically evaluated. Developed un- der a worldwide program coordinated by NIST under the authority of the National Standard Data

Act (Public Law 90-396). NOTE: The Journal of Physical and Chemical Reference Data (JPCRD)

is published quarterly for NIST by the American Chemical Society (ACS) and the American Insti- tute of Physics (AIP). Subscriptions, reprints, and supplements are available from ACS, 1155 Six- teenth St., NW., Washington, DC 20056.

Building Science Series—Disseminates technical information developed at the Institute on building

materials, components, systems, and whole structures. The series presents research results, test methods, and performance criteria related to the structural and environmental functions and the

durability and safety characteristics of building elements and systems.

Technical Notes—Studies or reports which are complete in themselves but restrictive in their treat- ment of a subject. Analogous to monographs but not so comprehensive in scope or definitive in treatment of the subject area. Often serve as a vehicle for final reports of work performed at NIST

under the sponsorship of other government agencies.

Voluntary Product Standards—Developed under procedures published by the Department of Commerce in Part 10, Title 15, of the Code of Federal Regulations. The standards establish nationally

recognized requirements for products, and provide all concerned interests with a basis for common

understanding of the characteristics of the products. NIST administers this program as a supplement

to the activities of the private sector standardizing organizations.

Consumer Information Series—Practical information, based on NIST research and experience, covering areas of interest to the consumer. Easily understandable language and illustrations provide useful background knowledge for shopping in today's technological marketplace.

Order the above NISTpublications from: Superintendent of Documents, Government Printing Office,

Washington, DC 20402.

Order the following NISTpublications—FIPS and NISTIRs—from the National Technical Information

Service, Springfield, VA 22161.

Federal Information Processing Standards Publications (FIPS PUB)—Publications in this series col- lectively constitute the Federal Information Processing Standards Register. The Register serves as the official source of information in the Federal Government regarding standards issued by NIST

pursuant to the Federal Property and Administrative Services Act of 1949 as amended, Public Law

89-306 (79 Stat. 1127), and as implemented by Executive Order 11717 (38 FR 12315, dated May 11, 1973) and Part 6 of Title 15 CFR (Code of Federal Regulations).

NIST Interagency Reports (NISTIR)—A special series of interim or final reports on work performed

by NIST for outside sponsors (both government and non-government). In general, initial distribu- tion is handled by the sponsor; public distribution is by the National Technical Information Service,

Springfield, VA 22161, in paper copy or microfiche form.
U.S. Department of Commerce

National Institute of Standards and Technology

(formerly National Bureau of Standards)

Gaithersburg, MD 20899

Official Business

Penalty for Private Use $300