Dissolution behavior of Al_(2)O_(3)inclusions into CaO-MgO-SiO_(2)-Al_(2)O_(3)-TiO_(2)system ladle slags

To investigate the dissolution behaviors of Al_(2)O_(3)inclusions in CaO-5wt%MgO-SiO_(2)-30wt%Al_(2)O_(3)-TiO_(2)system ladle slags,confocal scanning laser microscopy was conducted on the slags with different TiO_(2)contents(0-10wt%),and scanning electron microscopy was performed to study the interfacial reaction between Al_(2)O_(3)and this slag system.The results disclose that the dissolution of Al_(2)O_(3)inclusions does not result in the formation of new phases at the boundary between the slag and the inclusions.In TiO_(2)-bearing and TiO_(2)-free ladle slags,there is no difference in the dissolution mechanism of Al_(2)O_(3)inclusions at steelmaking temperatures.Boundary layer diffusion is found as the controlling step of the dissolution of Al_(2)O_(3),and the diffusion coefficient is in the range of 4.18×10^(-10)to 2.18×10^(-9)m^(2)/s at 1450-1500℃.Compared with the solubility of Al_(2)O_(3)in the slags,slag viscosity and temperature play a more profound role in the dissolution of Al_(2)O_(3)inclusions.A lower viscosity and a lower melting point of the slags are beneficial for the dissolution.Suitable addition of TiO_(2)(e.g.,5wt%)in ladle slags can enhance the dissolution of Al_(2)O_(3)inclusions because of the low viscosity and melting point of the slags,while excessive addition of TiO_(2)(e.g.,10wt%)shows the opposite trend.

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.

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.

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.

Effect of hafnium and molybdenum addition on inclusion characteristics in Co-based dual-phase high-entropy alloys

Specific grades of high-entropy alloys(HEAs)can provide opportunities for optimizing properties toward high-temperature applications.In this work,the Co-based HEA with a chemical composition of Co_(47.5)Cr_(30)Fe_(7.5)Mn_(7.5)Ni_(7.5)(at%)was chosen.The refractory metallic elements hafnium(Hf)and molybdenum(Mo)were added in small amounts(1.5at%)because of their well-known positive effects on high-temperature properties.Inclusion characteristics were comprehensively explored by using a two-dimensional cross-sectional method and extracted by using a three-dimensional electrolytic extraction method.The results revealed that the addition of Hf can reduce Al_(2)O_(3)inclusions and lead to the formation of more stable Hf-rich inclusions as the main phase.Mo addition cannot influence the inclusion type but could influence the inclusion characteristics by affecting the physical parameters of the HEA melt.The calculated coagulation coefficient and collision rate of Al_(2)O_(3)inclusions were higher than those of HfO_(2)inclusions,but the inclusion amount played a larger role in the agglomeration behavior of HfO_(2)and Al_(2)O_(3)inclusions.The impurity level and active elements in HEAs were the crucial factors affecting inclusion formation.

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.

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.

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.

Evaluation of Characteristics of Non-Metallic Inclusions in P/M Ni-Base Superalloy by Automatic Image Analysis

Non-metallic inclusions,especially the large ones,within P/M Ni-base superalloy have a major influence on fatigue characteristics,but are not directly measurable by routine inspection.In this paper,a method,automatic image analysis,is proposed for estimation of the content,size and amount of non-metallic inclusions in superalloy.The methodology for the practical application of this method is described and the factors affecting the precision of the estimation are discussed.In the experiment,the characteristics of the non-metallic inclusions in Ni-base P/M superalloy are analyzed.

Top slag refining for inclusion composition transform control in tire cord steel

Controlling conditions for inclusion plasticization were calculated by FactSage, and the steel/slag reaction equilibration time was determined by pre-equilibrium experiments. Laboratory experiments with different top slags were carried out in 90 rain, and industrial tests were performed based on the results of calculation and laboratory experiments. Scanning electron microscopy （SEM） and energy-dispersive spectroscopy （EDS） were used to determine the morphology and composition of inclusions in tire cord steel. It is found that the shape of in- clusions can be controlled well, and the composition of inclusions varies in the industrial test as the following transformation route： MnO-A1EOa-SiO2→CaO-AIEOa-SiO2→MnO-A1203-SiO2. Inclusion plasticization can be achieved by controlling the binary basicity of top slag （CaO/SiO2 by mass） around 1.0 and the （A1203） content in top slag below 10wt%. Under these controlling conditions in the industrial test, almost all of inclusions in the wire rods achieve plastic deformation.

Effect of slag on oxide inclusions in carburized bearing steel during industrial electroslag remelting

Industrial experiments with three types of slags were performed to investigate the effect of slag on oxide inclusions during electroslag remelting(ESR) process. G20CrNi2Mo bearing steel was used as the consumable electrode and remelted using a 2400-kg industrial furnace. The results showed that most inclusions in the electrode were low-melting-point CaO-MgO-Al_2O_3. After ESR, all the inclusions in ingots were located outside the liquid region. When the slag consisted of 65.70 wt% CaF_2, 28.58 wt% Al_2O_3, and 4.42 wt% CaO was used, pure Al_2O_3 were the dominant inclusions in ingot, some of which presented a clear trend of agglomeration. When the ingot was remelted by a multi-component slag with 16.83 wt% CaO, a certain amount of sphere CaAl_4O_7 inclusions larger than 5 μm were generated in ingot. The slag with 8.18 wt% CaO exhibited greater capacity to control the inclusion characteristics. Thermodynamic calculations indicated that the total Ca and Mg in ingots were attributed from the relics in electrode and strongly influenced by the slag composition. The formation of ingot inclusions was calculated by FactSage^(TM) 7.0, and the results were basically in accordance with the observed inclusions, indicating that a quasi-thermodynamic equilibrium could be obtained in the metal pool.

Dynamic mass variation and multiphase interaction among steel, slag, lining refractory and nonmetallic inclusions: Laboratory experiments and mathematical prediction

The mass transfer among the multiphase interactions among the steel, slag, lining refractory, and nonmetallic inclusions during the refining process of a bearing steel was studied using laboratory experiments and numerical kinetic prediction. Experiments on the system with and without the slag phase were carried out to evaluate the influence of the refractory and the slag on the mass transfer. A mathematical model coupled the ion and molecule coexistence theory, coupled-reaction model, and the surface renewal theory was established to predict the dynamic mass transfer and composition transformation of the steel, the slag, and nonmetallic inclusions in the steel. During the refining process,Al_(2)O_(3) inclusions transformed into Mg O inclusions owing to the mass transfer of [Mg] at the steel/refractory interface and(Mg O) at the slag/refractory interface. Most of the aluminum involved in the transport entered the slag and a small part of the aluminum transferred to lining refractory, forming the Al_(2)O_(3) or Mg O·Al_(2)O_(3). The slag had a significant acceleration effect on the mass transfer. The mass transfer rate(or the reaction rate) of the system with the slag was approximately 5 times larger than that of the system without the slag. In the first 20 min of the refining, rates of magnesium mass transfer at the steel/inclusion interface, steel/refractory interface, and steel/slag interface were x, 1.1 x, and 2.2 x,respectively. The composition transformation of inclusions and the mass transfer of magnesium and aluminum in the steel were predicted with an acceptable accuracy using the established kinetic model.

Dissolution of Al_2TiO_5 inclusions in CaO-SiO_2-Al_2O_3 slags at 1823 K

Al-Ti-O inclusions always clog submerged nozzles in Ti-bearing Al-killed steel.A typical synthesized Al2TiO5 inclusion was immersed in a CaO-SiO2-Al2O3 molten slag for different durations at 1823 K.The Al2TiO5 dissolution paths and mechanism were revealed by scanning electron microscopy （SEM） and energy dispersive spectroscopy （EDS）.Decreased amounts of Ti and Al and increased amounts of Si and Ca at the dissolution boundary prove that inclusion dissolution and slag penetration simultaneously occur.SiO2 diffuses or penetrates the inclusion more quickly than CaO,as indicated by the w（CaO）/w（SiO2） value in the reaction region.A liquid product （containing 0.7-1.2 w（CaO）/w（SiO2）,15wt%-20wt% Al2O3,and 5wt%-15wt% TiO2） forms on the inclusion surface when Al2TiO5 is dissolved in the slag.Al2TiO5 initially dissolves faster than the diffusion rate of the liquid product toward the bulk slag.With increasing reaction time,the boundary reaches its largest distance,the Al2TiO5 dissolution rate equals the liquid product diffusion rate,and the dissolution process remains stable until the inclusion is completely dissolved.

Inclusion and Bubble in Steel——A Review

The type, morphology and sources of inclusion in steels, including indigenous and exogenous inclusions, were discussed and reviewed. Indigenous inclusions are deoxidation products or inclusions precipitated during cooling and solidification of steel. Exogenous inclusions arise primarily from the incidental chemical （reoxidation） and mechanical interaction of liquid steel with its surroundings （slag entrainment and erosion of lining refractory）. Types and causes for the nozzle clogging were also summarized. Reasons for bubble formation and bubble size distribution in steels were discussed thereafter. Finally, morphology and causes of inclusion-related defects in continuously cast steel products were reviewed, such as flange cracking in cans, slag spots and line defects on strips.

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.

Modification of Inclusions in ESR Bearing Steel

Electroslag remelting (ESR) process using consumable electrode deoxidized with Ca-Si and Fe-Si instead of Al, and acid slag (CaF_2SiO_2Al_2O_3CaO) instead of universal slag ANF_6(CaF_2. 70 %+A1_2O_3.30 %) could change brittle inclusion (alumina) to ductile inclusion (silicate) in remelted steel. Fatigue life of bearing steel could be increased significantly in this way.

Formation mechanism and control of MgO·Al_2O_3 inclusions in non-oriented silicon steel

On the basis of the practical production of non-oriented silicon steel, the formation of Mg O·Al2O3 inclusions was analyzed in the process of ＂basic oxygen furnace（BOF） → RH → compact strip production（CSP）＂. The thermodynamic and kinetic conditions of the formation of Mg O·Al2O3 inclusions were discussed, and the behavior of slag entrapment in molten steel during RH refining was simulated by computational fluid dynamics（CFD） software. The results showed that the Mg O/Al2O3 mass ratio was in the range from 0.005 to 0.017 and that Mg O·Al2O3 inclusions were not observed before the RH refining process. In contrast, the Mg O/Al2O3 mass ratio was in the range from 0.30 to 0.50, and the percentage of Mg O·Al2O3 spinel inclusions reached 58.4% of the total inclusions after the RH refining process. The compositions of the slag were similar to those of the inclusions; furthermore, the critical velocity of slag entrapment was calculated to be 0.45 m·s^-1 at an argon flow rate of 698 L·min^-1, as simulated using CFD software. When the test steel was in equilibrium with the slag, [Mg] was 0.00024wt%–0.00028wt% and [Al]s was 0.31wt%–0.37wt%; these concentrations were theoretically calculated to fall within the Mg O·Al2O3formation zone, thereby leading to the formation of Mg O·Al2O3 inclusions in the steel. Thus, the formation of Mg O·Al2O3 inclusions would be inhibited by reducing the quantity of slag entrapment, controlling the roughing slag during casting, and controlling the composition of the slag and the Mg O content in the ladle refractory.

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.

In situ observation of the dissolution kinetics of Al_(2)O_(3) particles in CaO–Al_(2)O_(3)–SiO_(2) slags using laser confocal scanning microscopy

The dissolution kinetics of Al_(2)O_(3) in CaO-Al_(2)O_(3) SiOslags was studied using a high-temperature confocal scanning laser microscope at 1773 to 1873 K.The results show that the controlling step during the Al_(2)O_(3) dissolution was the diffusionin molten slag.It was found that the dissolution curves of Al_(2)O_(3) particles were hardly agreed with the traditional boundary layer diffusion model with the increase of the CaO/Al_(2)O_(3) ratio of slag.A modified diffusion equation considering slag viscosity was developed to study the dissolution mechanism of Al_(2)O_(3) in slag.Diffusion coefficients of Al_(2)O_(3) in slag were calculated as 2.8×10to 4.1×10m~2/s at the temperature of 1773-1873 K.The dissolution rate of Al_(2)O_(3) increased with higher temperature,CaO/Al_(2)O_(3),and particle size.A new model was shown to be v_(Al_(2)O_(3))=0.16×r_(0)^(1.58)×x^(3.52)×(T-T_(mp))^(1.11)to predict the dissolution rate and the total dissolution time of Al_(2)O_(3) inclusions with various sizes,where vAl_(2)O_(3) is the dissolution rate of Al_(2)O_(3) in volume,μm^(3)/s;x is the value of CaO/Al_(2)O_(3) mass ratio;R_(0) is the initial radius of Al_(2)O_(3),μm;T is the temperature,K;T_(mp) is the melting point of slag,K.

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.``