SUPERSLAB: Novel Uni-directional Casting Technology for Manufacturing Super Extra-thick Offshore Steel Plate

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The project aims to develop a transformational technology for the production of extra thick and higher strength 'SUPERSLAB' steels required for the growing needs of the off-shore wind, oil, renewable energy and other thick plate using sectors in the UK, China and Europe. These materials are required to meet the requirement for infrastructure development in these growing sectors, to secure the energy needs of the 21st century. There are problems in meeting the need for the thicker, higher strength materials envisaged. The required properties for the thickest plates require rolling from cast slab initially at least four times thicker. Due to the nature of solidification, there is a tendency for the alloys required for increasing strength to segregate towards the centreline. In conventionally cast product this may be trapped at that point. This limits development of higher strength, thicker material and constrains the casting process limiting production rate and requiring significantly bigger, stronger casting machines for which economic justification is difficult. No supplier in the UK or China is currently capable of addressing this need and the thickest slab cast in Europe is limited to 400mm. This project will develop a new casting technology based upon unidirectional solidification which will overcome the issue of centre segregation, opening the way to a step change in both quality and thickness for high strength plate. In doing so it will also open opportunities for producers and machine builders in both countries to develop this growing new market.