Simulation and Process Optimization of Online Cooling for S460 Thick Plates

Marine engineering thick plates are essential structural materials for large vessels and offshore platforms, and optimizing their manufacturing processes is critical for advancing marine equipment. This study examined the microstructural and property variations in 120 mm-thick S460 plates fabricated by thermo-mechanical controlled processing (TMCP). A finite element model was developed to simulate the cooling phase, enabling the prediction of the internal cooling path in the thick plate. An optimized cooling scheme was proposed, which was validated against the model and implemented. The following key results were obtained: (1) Under the initial cooling parameters (initial temperature: 715 °C, duration: 130 s), the 60 mm depth toughness was severely compromised, as evidenced by a low -40 °C impact energy of 59 J, significantly lower than values observed at the10 mm and 30 mm depth positions. Microstructural analysis revealed that the 60 mm depth region was dominated by ferritic bainite and pearlite, with a pearlite content of 8.7%. Numerical simulations further indicated a 60 mm depth cooling rate of 1.10 °C/s under these conditions. (2) Model predictions confirmed the original 60 mm depth cooling rate of 1.10 °C/s. The optimized process increased the initial cooling temperature to 725 °C and extended the cooling time to 160 s, achieving an enhanced 60 mm depth cooling rate of 1.36 °C/s. (3) The optimized process remarkably improved the 60 mm depth impact energy to 144 J, achieving near-complete elimination of pearlite, increased granular bainite content, refined M-A constituent size, and enhanced density of high-angle grain boundaries. This study demonstrates that enhancing internal temperature gradients and prolonging cooling durations can effectively inhibit microstructural degradation in 60 mm depth regions of thick plates, providing both theoretical foundations and practical methodologies for optimizing TMCP processes of extra-thick steel plates.