Effect of continuous casting speed on mold surface flow and the related near-surface distribution of non-metallic inclusions

For the control of surface defects in interstitial-free(IF) steel, quantitative metallographic analyses of near-surface inclusions and surface liquid flow detection via the nail-board tipping method were conducted. The results show that, at casting speeds of 0.8 and 1.0 m/min, a thin liquid mold flux layer forms and non-uniform floating of argon bubbles occurs, inducing the entrainment and subsequent entrapment of the liquid flux; fine inclusion particles of Al_2O_3 can also aggregate at the solidification front. At higher casting speeds of 1.4 and 1.6 m/min, the liquid mold flux can be entrained and carried deeper into the liquid steel pool because of strong level fluctuations of the liquid steel and the flux. The optimal casting speed is approximately 1.2 m/min, with the most favorable surface flow status and, correspondingly, the lowest number of inclusions near the slab surface.

Study on the separation process of non-metallic inclusions at the steel-slag interface using water modeling

The separation process of non-metallic inclusions at the steel–slag interface was simulated by physical modeling. Three different kinds of particles (octahedral, plate-like, and spherical) and three different oils (kerosene, bean oil, and pump oil) were used to model inclusions and slags, respectively. The effects of inclusion geometry (shape and size) and slag properties (viscosity and interfacial tension) on the separation process were investigated. The results revealed that the variation of surface free energy and the viscosity of the slag are two significant factors affecting the separation process of inclusions at the steel–slag interface. The variation of surface free energy helped inclusions enter the slag phase, whereas the decrease of slag viscosity shortened the separation time. The deformation of the steel–slag interface could give rise to the resistance force, which would resist inclusions passing through the interface. A liquid film formed on the inclusion as it passed through the steel–slag interface, which might be related to the inclusion’s shape. © 2017, University of Science and Technology Beijing and Springer-Verlag Berlin Heidelberg.

Study on non-metallic inclusions in Al killed high strength alloy steel refined by high basicity and high Al_2O_3 content slag

Laboratory and industrial studies were carried out to investigate non-metallic inclusions in high strength alloy steel refined by high basicity and high Al_2O_3 slag.It was found that the steel/slag reaction time largely affected non-metallic inclusions.With the reaction time increased from 30 min to 90 min in laboratory study,MgO-Al_2O_3 spinels were gradually changed into CaO-MgO-Al_2O_3 system inclusions surrounded by softer CaO-Al_2O_3 surface layers.By using high basicity slag which contained as much as 41%Al_2O_3 in the laboratory study,ratio of low melting temperature CaO-MgO-Al_2O_3 system inclusions was remarkably increased to above 80%.In the industrial experiment,during the secondary refining,the inclusions changed in order of 'Al_2O_3→MgO-Al_2O_3→CaO-MgO-Al_2O_3'.Through the LF and RH refining,most inclusions could be transferred to lower melting temperature CaO-Al_2O_3 and CaO-MgO-Al_2O_3 system inclusions.

Three-dimensional analysis technology for accurately characterizing non-metallic inclusion particles in steel

In this paper, a kind of three-dimensional analysis technology for characterizing non-metallic inclusions in steel was clearly elaborated. It is an electron microscopy observation, namely the non-aqueous electrolysis extraction method with a settled coulometer. In the research,the extraction effects of non-metallic inclusions in different electrolysis systems were studied, and it was concluded that alkalescent 2% TEA non-aqueous electrolyte was applicable for extracting most of non-metallic inclusion particles in steel. And then, in order to ensure the microscopic characterization and statistical calculation of inclusion particles, some electrolysis parameters should be confirmed, such as the size of the sample, control of the electrolysis mass, electric current, etc. Furthermore, for preventing the disturbance of carbides and presenting clear three-dimensional appearance by microscopic characterization, magnetic separation was utilized to separate the inclusion particles from carbides, which was useful for getting more veracious types, particle sizes and chemical composition of inclusions. Moreover, through calculation of quantity and particle size of inclusions in continuous determinate fields, the total quantity per unit volume or area and the particle size distribution of inclusions could be acquired by conversion with electrolysis loss. Besides, the comparison between this method and traditional quantitative metallography was also discussed, and finally, a conclusion was drawn that both of them have respectively applications in characterizing inclusions.

Effect of retained austenite and nonmetallic inclusions on the thermal/electrical properties and resistance spot welding nuggets of Si-containing TRIP steels

Five advanced high-strength transformation-induced plasticity(TRIP) steels with different chemical compositions were studied to correlate the retained austenite and nonmetallic inclusion content with their physical properties and the characteristics of the resistance spot welding nuggets. Electrical and thermal properties and equilibrium phases of TRIP steels were predicted using the JMatPro? software. Retained austenite and nonmetallic inclusions were quantified by X-ray diffraction and saturation magnetization techniques. The nonmetallic inclusions were characterized by scanning electron microscopy. The results show that the contents of Si, C, Al, and Mn in TRIP steels increase both the retained austenite and the nonmetallic inclusion contents. We found that nonmetallic inclusions affect the thermal and electrical properties of the TRIP steels and that the differences between these properties tend to result in different cooling rates during the welding process. The results are discussed in terms of the electrical and thermal properties determined from the chemical composition and their impact on the resistance spot welding nuggets.

Behavior of Non-metallic Inclusions in Centrifugal Induction Electroslag Castings

In order to know the behavior of non-metallic inclusions in centrifugal induction electroslag castings (CIESC), non-metallic inclusions in 5CrMnMo and 4Cr5MoSiV1 were qualitatively and quantitatively analyzed. The largest size of inclusions in the casting and the thermodynamic possibility of TiN precipitation in steel were also calculated. The results show that sulfide inclusions are evenly distributed and the content is low. The amount of oxide inclusions in CIESC: 4Cr5MoSiV1 steel is close to the ESR steel and lower than that in the EAF steel, and there are some differences along radial direction. Nitride inclusions are fine and the diameter of the largest one is 3-1 mum. With the increase of the centrifugal machine's rotational speed, the ratio of round inclusions increases and the ratio of sharp inclusions decreases. According to the experiment and the calculation results, it is pointed out that the largest diameter of non-metallic inclusions in the CIESC 4Cr5MoSiV1 casting is only 6.6 mum, and [N%][Ti%] in 4Cr5MoSiV1 steel should be controlled less than 4.4x 10(-5) in order to further reduce the amount and size of TiN inclusions.

Characterization and analysis of non-metallic inclusions in Ni42-Fe expansive alloy

Cracks and ruptures always occur during wire drawing process of 42% nickel-iron expansive alloy. In order to study the reasons of these phenomena,a method of metallographic observation in combination with sample electrolysis was used to characterize the non-metallic inclusions in the alloy wire. The results indicate that the inclusions in the alloy are oxidation products during the process of melting. There are single or complex phase inclusions composed of elements such as Al,Si,Ca,Ti,Fe,and O2. Among them,the macro-inclusions are TiO2 compound inclusions formed by the adhesion of Al and Si oxides on them. These inclusions are fragile ones with a low strain rate,as well as a rather high hardness,so that they are the main reason that leads to the surface cracks and ruptures in the alloy wires. The analysis has educed that the key point to enhance the product quality is to promote the cleanliness of the melt,control the types and quantity of non-metal inclusions in the alloy.

Non-metallic Inclusions in Continuously Cast Aluminum Killed Steels

In aluminum killed steels, the size, shape, quantity and formation of non-metallic inclusions in ladle steel (before and after RH vacuum treatment) and in tundish as well as in slabs were studied by EPMA (Electron Probe Microanalysis) and by analyzing the total oxygen. The results showed that in the slabs the total oxygen was quite low and the inclusions discovered were mainly small-sized angular alumina inclusions. This indicates that most inclusions have been removed by floating out during the continuous casting process. In addition, the countermeasures were discussed to decrease the alumina inclusions in the slabs further.

ULTRASONIC SEPARATION OF MICRO-SIZED INCLUSIONS IN MOLTEN METAL

The coagulation time and position of micro-sized non-metallic inclusions in molten metal during ultrasonic separation process were investigated, and the motion course of micro-sized non-metallic inclusions in an ultrasonic standing wave field was numerically simulated. The results of theoretical analysis and numerical simulation show that the movement of inclusions depends on the balance between the acoustic radiation force, effective buoyancy force and viscous drag force. It is presented that micro-sized inclusions, agglomerated at antinode-planes may be removed further with horizon tal ultrasound.``

Thermodynamic aspects of inclusion engineering in steels

Tailoring non-metallic inclusions in accordance to the desired effect on steel properties has gained widespread acceptance in the last decades and has become known as “inclusion engineering”. Effective inclusion engineering involves three steps： （a） a good knowledge of how inclusions influence properties, （b） understanding what is the effect of each type of inclusions on these properties and thus which is the most desirable inclusion in a given product and （c） adjusting the processing parameters to obtain these inclusions. A significant portion of the process adjustment is done during steel refining, where the steel can be tailored so that the desired chemical composition of the non-metallic inclusions that will precipi- tate can be altered. Understanding the relations between steel chemistry, processing variables and inclusion chemical composition requires significant understanding of the thermodynamics of the systems involved. These complex equilibrium calculations are best done using computational thermodynamics. In this work some of the basic techniques used to control inclusion composition are reviewed and the thermodynamic information required to perform this task is presented. Several examples of the application of computational thermodynamics to inclusion engineering of different steels grades are presented and compared with experimental results, whenever possible. The potential and limitations of the method are highlighted, in special those related to thermodynamic data and databases.

Non-Metallic Inclusion Distribution in Surface Layer of IF Steel Slabs

Non-metallic inclusion distribution in the surface layer of IF steel slabs during unsteady casting was investigated using the original position statistic distribution analysis（OPA）method.It was found that most non-metallic inclusions larger than 10 μm existed in the subsurface layers of 0.5-3.5 mm from the slab surfaces and very few large non-metallic inclusions were found in the inner regions（≥4.5 mm from slab surfaces）.In addition,it was found that at high casting speed level（1.4 m/min）,even a slight change of casting speed could result in a remarkable increase of the non-metallic inclusions.Thus,at high casting speed,changing the casting speed should be avoided or considerably lower speed changing rate must be used.

Investigation on Non-Metallic Inclusions in LCAK Steel Produced by BOF-LF-FTSC Production Route

The behavior of non-metallic inclusions in LCAK （low carbon aluminum killed） steel produced by BOF （basic oxygen furnace）-LF （ladle furnace） refining-FTSC （flexible thin slab continuous caster） production route was investigated. The results showed that, LF refining for LCAK steel could decrease the wT[o] significantly, and the inclusions were modified by Ca treatment, which prevented nozzle clogging efficiently. However, owing to the unstable casting condition in the earlier stage of casting, a severe reoxidation occurred, accompanied with mold slag entrapment. The transformation of non-metallic inclusions during the steelmaking process was Al2O3→MgO→Al2O3 type inclusion→MgO-Al2O3 O3-CaO type inclusion with a CaS ring, and the mechanism of the transformation was pro posed and discussed via thermodynamic and kinetic analysis. Besides, to avoid CaS precipitation, the product of W[Al] ×w3[S] in steel should be less than 2.0 × 10 10 at 1873 K, which remands higher desulfurization ratio during LF refining.

Influence of Prior Austenite Deformation and Non-Metallic Inclusions on Ferrite Formation in Low-Carbon Steels

Effects of prior austenite deformation and non-metallic inclusions on the ferrite nucleation and grain refine- ment of two kinds of low-carbon steels have been studied. The ferrite nucleation on MnS and V（C, N） is observed. The combination of thermomeehanical processes with adequate amounts of non-metallic inclusions formed in low-car- bon steels could effectively refine the grain size and the microstructure. Ferrite nucleated on the single MnS or V（C, N） inclusions and complex MnS＋V（C,N） inclusion. The proper addition of elements S and V could effectively promote the formation of ferrite and further refinement of ferrite grains.

Chemical Composition Control of Non-Metallic Inclusions in High Alloy Steel Production Process

There is a close relation between the characteristics of products and the chemical composition control of inclusions in steelmaking process. Therefore, it is very important for a warranty of product’s characteristics to improve inclusion quality resulting in defective products. In the present work, the control technique of inclusions’ chemical composition is discussed thermodynamically based on the Redlich-Kister type polynomial to metallic solution and regular solution model to molten oxide solution. It is very effective for the precise chemical composition control of oxides to determine the concentration of deoxidizers based on the thermodynamic relation among dissolved deoxidizers and oxygen, because it is known that oxide inclusions are equilibrated with them in molten steel in the steel making process. High alloy steel production process was focused in the present work.

S含量对18CrNiMo7-6齿轮钢中夹杂物和疲劳性能的影响

以w[S]为0.002%(低S含量)和0.022%(高S含量)的两种18CrNiMo7-6齿轮钢为研究对象,参照齿轮热处理工艺获得伪渗碳试样,并对其力学性能、显微组织、疲劳性能和夹杂物分布进行了分析表征。结果表明,两种齿轮钢的强度基本相当,而高S含量试验钢具有更好的塑性和低温冲击韧性,并且其疲劳极限、疲劳寿命均优于低S含量试验钢,疲强比由0.445提高到0.479。S含量显著影响钢中的夹杂物分布情况:低S含量试验钢中夹杂物以MnS-Oxide为主,数量较少,同时尺寸更大;而高S含量试验钢夹杂物以CaS-MnS-Oxide复合型夹杂物为主,数量提高1倍以上,但尺寸更为细小。高S含量试验钢采用Ca处理工艺对夹杂物进行改性,夹杂物尺寸明显细化,有利于钢的塑韧性提升,并改善疲劳性能。

LD-LF-CC流程冶炼H08A工艺开发

针对H08A钢冶炼可浇性及铸坯易产生皮下气泡等共性问题,通过对LD-LF-CC流程冶炼H08A化学成分控制、脱氧度、铸坯皮下气泡和钢水可浇性等分析,研究了该流程转炉冶炼、LF炉精炼及连铸工艺的关键技术控制。研究表明LD-LF-CC流程冶炼H08A相较于LD-CC流程具有以下特点:钢水化学成分稳定、易实现窄成分控制;在较高的氧活度控制下,铸坯的氧质量分数相对较低,有利于连铸提高拉速;LD-LF-CC流程下冶炼H08A盘条非金属夹杂物评级及金相组织均优于LD-CC流程。为H08A冶炼的稳定性、质量提升及进一步开发低P、S的纯净钢等高附加值产品奠定了良好基础。

高钛焊丝钢ER70S-G冶炼工艺优化实践

高钛焊丝钢ER70S-G研发时经常出现水口结瘤、结晶器“结鱼”、铸坯夹渣等问题,尤其是铸坯夹渣导致轧制后盘条表面出现连续性锯齿状结疤缺陷,严重影响盘条表面质量。引起水口结瘤、结晶器“结鱼”的主要原因是存在TiO_(x)、TiN等高熔点非金属夹杂物。通过控制钢水中氧氮含量、使用纯净合金、降低渣中SiO_(2)活度、调整钛合金化时机及温度等手段,解决了水口结瘤、结晶器“结鱼”、铸坯夹渣等问题,将高钛焊丝钢ER70S-G连浇炉数提高至10炉,盘条成材率提高至97%,优化效果显著。

转炉-CAS-连铸工艺生产低碳铝镇静钢中非金属夹杂物的研究

采用添加示踪剂方法研究了转炉— CAS精炼—连铸工艺生产的低碳铝镇静钢中的非金属夹杂物 ,发现出钢或 CAS精炼过程钢包炉渣与钢液作用生成的夹杂物 ,其中尺寸在 30 μm以下的夹杂物很难从钢液中完全上浮排除。铸坯中主要的非金属夹杂物为来源于钢包炉渣与钢液作用生成的球形夹杂物、块状 Al2 O3夹杂物和簇群状 Al2 O3夹杂物。连铸坯 T[O]在 ( 1 4～ 1 7)× 1 0 - 6之间 ,非金属夹杂物含量在 2 .3mg/ 1 0 kg左右 ,表明该工艺可以生产较高洁净度的低碳铝镇静钢铸坯。

ER70s-6焊丝钢洁净度和表面质量研究

钢的洁净度和铸坯的表面缺陷直接影响焊丝钢的性能。分析了炼钢各工序钢液中的全氧和夹杂物数量、夹杂物成分和形貌;统计了铸坯的表面缺陷。其结果表明,钢中夹杂物主要有以MnO-Al2O3-SiO2-CaO为主的复合脱氧氧化物夹杂物、MnO-Al2O3脱氧产物夹杂,铸坯表面缺陷主要有表面气孔和表面裂纹。

EAF-LF(VD)-CC工艺生产石油管线钢39Mn2V纯净度的分析

分析和研究了EAF-LF（VD）-CC各工序39Mn2V钢的T[O]和[N]以及钢中非金属夹杂物。结果表明，LF（VD）后T[O]为28×10^-6，铸坯T[O]为（8～10）×10^-6；钢中夹杂物主要为Al2O3、MnS、球形铝酸钙，尺寸≤20μm。铸坯存在一些80～300μm夹杂物，主要来源于二次氧化。