Evolution of nonmetallic inclusions in 80-t 9CrMoCoB large-scale ingots during electroslag remelting process

In combination with theoretical calculations,experiments were conducted to investigate the evolution behavior of nonmetallic inclusions(NMIs)during the manufacture of large-scale heat-resistant steel ingots using 9CrMoCoB heat-resistant steel and CaF_(2)–CaO–Al_(2)O_(3)–SiO_(2)–B_(2)O_(3)electroslag remelting(ESR)-type slag in an 80-t industrial ESR furnace.The main types of NMI in the consumable electrode comprised pure alumina,a multiphase oxide consisting of an Al_(2)O_(3)core and liquid CaO–Al_(2)O_(3)–SiO_(2)–MnO shell,and M_(23)C_(6)carbides with an MnS core.The Al_(2)O_(3)and MnS inclusions had higher precipitation temperatures than the M_(23)C_(6)-type carbide under equilibrium and nonequilibrium solidification processes.Therefore,inclusions can act as nucleation sites for carbide layer precipitation.The ESR process completely removed the liquid CaO–Al_(2)O_(3)–SiO_(2)–MnO oxide and MnS inclusion with a carbide shell,and only the Al_(2)O_(3)inclusions and Al_(2)O_(3)core with a carbide shell occupied the remelted ingot.The M_(23)C_(6)-type carbides in steel were determined as Cr_(23)C_(6)based on the analysis of transmission electron microscopy results.The substitution of Cr with W,Fe,or/and Mo in the Cr_(23)C_(6)lattice caused slight changes in the lattice parameter of the Cr_(23)C_(6)carbide.Therefore,Cr_(21.34)Fe_(1.66)C_(6),(Cr_(19)W_(4)C_(6),Cr_(18.4)Mo_(4.6)C_(6),and Cr_(16)Fe_(5)Mo_(2)C_(6)can match the fraction pattern of Cr_(23)C_(6)carbide.The Al_(2)O_(3)inclusions in the remelted ingot formed due to the reduction of CaO,SiO_(2),and MnO components in the liquid inclusion.The increased Al content in liquid steel or the higher supersaturation degree of Al_(2)O_(3)precipitation in the remelted ingot than that in the electrode can be attributed to the evaporation of CaF_(2)and the increase in CaO content in the ESR-type slag.

Controlling oxygen content in electro-slag remelting steel by optimizing slag-steel reaction process

The thermodynamic equilibrium of deoxidation reactions between molten slag and steel was calculated using a slag-steel coupling thermodynamic model and the mass conservation model based on the ion-molecular coexistence theory.The study focused on the effects of slag composition and deoxidizer type on the oxygen content of low alloy steel during the electroslag remelting(ESR)process.The measured and predicted values of the oxygen content in remelted ingots,and the contents of FeO and MnO in slags were compared and analyzed.Results show that the measured content of total oxygen has a certain correlation with the trend of dissolved oxygen predicted by the model when using Ca-Si alloys as deoxidizer,but it is not correlated with the trend of dissolved oxygen predicted by the model when using Al as deoxidizer.The deoxidation mechanisms of Ca-Si and Al are different.Ca-Si alloy directly reacts with FeO and MnO in slag to reduce the oxygen potential of slag,hence it can inhibit the transfer of oxygen from the slag to molten steel.While,when Al deoxidizer is used,the oxygen content in steel is mainly reduced through floating up the alumina inclusions.Compared to Al,utilizing Ca-Si alloy as a deoxidizer is more effective in reducing the oxygen content and the amount of inclusions in ESR ingot.

Mathematical Model for Electroslag Remelting Process

A mathematical model, including electromagnetic field equation, fluid flow equation, and temperature field equation, was established for the simulation of the electroslag remelting process. The distribution of temperature field was obtained by solving this model. The relationship between the local solidification time and the interdendritic spacing during the ingot solidification process was established, which has been regarded as a criterion for the evaluation of the quality of crystallization. For a crucible of 950 mm in diameter, the local solidification time is more than 1 h at the center of the ingot with the longest interdendritic spacing, whereas it is the shortest at the edge of the ingot according to the calculated results. The model can be used to understand the ESR process and to predict the ingot quality.

Characteristics of Al_2O_3, MnS, and TiN inclusions in the remelting process of bearing steel

The Al_2O_3, MnS, and TiN inclusions in bearing steel will deteriorate the steel's mechanical properties. Therefore, elucidating detailed characteristics of these inclusions in consumable electrode during the electroslag remelting process is important for achieving a subsequently clean ingot. In this study, a confocal scanning violet laser microscope was used to simulate the remelting process and observe, in real time, the behaviors of inclusions. The obtained images show that, after the temperature exceeded the steel solidus temperature, MnS and TiN inclusions in the specimen began to dissolve. Higher temperatures led to faster dissolution, and the inclusions disappeared before the steel was fully liquid. In the case of an observed Al_2O_3 inclusion, its shape changed from angular to a smooth ellipsoid in the region where the solid and liquid coexisted and it began to dissolve as the temperature continued to increase. This dissolution was driven by the difference in oxygen potential between the inclusion and the liquid steel.

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.

Microstructure evolution of ZA72 magnesium alloy during partial remelting

The application of some semi-solid forming magnesium alloys is restricted due to their weak mechanical properties. To improve the mechanical properties, it is necessary to research the regularity and theory of semi-solid microstructure evolution of the alloy. In this study, microstructure evolution of ZA72 alloy during the partial remelting, and the effect of holding temperature and holding time on the semi-solid microstructure evolution of ZA72 magnesium alloy were investigated by means of OM, SEM and EDS analysis. The results indicate that the microstructure with small and spheroidal semi-solid particles which are available for thixo-forming can be obtained using proper heating parameters. After being isothermally treated at between 580 and 610 ℃ for 30 min, the equivalent size and shape factor of primary solid phase of ZA72 alloy decrease gradually, while the liquid volume fraction increases. When isothermally treated at 600 ℃ and held for different times from 15 to 60 min, with the increase of holding time, the equivalent size of primary particles decreases at first and then increases gradually; while the shape factor decreases gradually. The best heat treatment parameters in this experiment are to hold at 610 ℃ for 30 min. Compared with as-cast ZA72 alloy, the sizes of the eutectic phase and second α-Mg phase obtained in semi-solid state are smaller due to the higher solidification rate and the higher under-cooling degree than as-cast state. These decrease the fracture probability during tensile stress and improve the properties of the ZA72 alloy by semi-solid forming.

Effect of TiO_2 on the viscosity and structure of low-fluoride slag used for electroslag remelting of Ti-containing steels

The viscosity of CaF_2-CaO-Al_2O_3-MgO-（TiO_2） slag was measured using a rotating crucible viscometer. Raman spectroscopy analysis was performed to correlate the viscosity to slag structure. The viscosity of the slag was found to decrease with increasing TiO_2 content in the slag from 0 to 9.73wt%. The activation energy decreased from 95.16 kJ /mol to 79.40 kJ /mol with increasing TiO_2 content in the slag. The introduction of TiO_2 into the slag played a destructive role in Al-O-Al structural units and Q^4 units by forming simpler structural units of Q^2 and Ti_2O_6^（4-） chain. The amount of Al-O-Al significantly decreased with increasing TiO_2 content. The relative fraction of Q^4 units in the [AlO_4]^（5-）-tetrahedral units shows a decreasing trend, whereas the relative fraction of Q^2 units and Ti_2O_6^（4-） chain increases with increasing TiO_2 content accordingly. Consequently, the polymerization degree of the slag decreases with increasing TiO_2 content. The variation in slag structure is consistent with the change in measured viscosity.

Effect of Laser Remelting on the Microstructure and Corrosion Resistance of Plasma Sprayed Fe-based Coating

Fe-based amorphous and nanocrystalline coatings were fabricated by air plasma spraying. The coatings were further treated by laser remelting process to improve their microstructure and properties. The corrosion resistance of the as-sprayed and laser-remelted coatings in 3.5wt% NaC1 and 1 mol/L HCI solutions was evaluated by electrochemical polarization analysis. It was found that laser-remelted coating appeared much denser than the as-sprayed coating. However, laser-remelted coating contains much more nanocrystalline grains than the as-sprayed coatings, resulting from the lower cooling rate in laser remelting process compared with plasma spraying process. Electrochemical polarization results indicated that the laser-remelted coating has great corrosion resistance than the as-sprayed coating because of its dense structure.

Characteristics of inclusions in high-Al steel during electroslag remelting process

The characteristics of inclusions in high-A1 steel refmed by electroslag remelting （ESR） were investigated by image analysis, scanning electron microscopy （SEM）, and energy-dispersive spectrometry （EDS）. The results show that the size of almost all the inclusions observed in ESR ingots is less than 5 μm. Inclusions smaller than 3 μm take nearly 75% of the total inclusions observed in each ingot. Inclu- sions observed in ESR ingots are pure AIN as dominating precipitates and some fine spherical Al2O3 inclusions with a size of 1 μm or less. It is also found that protective gas operation and slag deoxidation treatment during ESR process have significant effects on the number of inclusions smaller than 2μm but little effects on that of inclusions larger than 2 μm. Thermodynamic calculations show that AIN inclusions are unable to precipitate in the liquid metal pool under the present experimental conditions, while the precipitation of AlN inclusions could take place at the solidifying front due to the microsegregation orAl and N in liquid steel during solidification.

Effect of scanning speed during PTA remelting treatment on the microstructure and wear resistance of nodular cast iron

The surface of nodular cast iron （NCI） with a ferrite substrate was rapidly remelted and solidified by plasma transferred arc （PTA） to induce a chilled structure with high hardness and favorable wear resistance. The effect of scanning speed on the microstructure, micro-hardness distribution, and wear properties of PTA-remelted specimens was systematically investigated. Microstructural characterization in-dicated that the PTA remelting treatment could dissolve most graphite nodules and that the crystallized primary austenite dendrites were transformed into cementite, martensite, an interdendritic network of ledeburite eutectic, and certain residual austenite during rapid solidifica-tion. The dimensions of the remelted zone and its dendrites increase with decreased scanning speed. The microhardness of the remelted zone varied in the range of 650 HV0.2 to 820 HV0.2, which is approximately 2.3-3.1 times higher than the hardness of the substrate. The wear re-sistance of NCI was also significantly improved after the PTA remelting treatment.

A coupled model of TiN inclusion growth in GCr15SiMn during solidification in the electroslag remelting process

TiN inclusions observed in an ingot produced by electroslag remelting （ESR） are extremely harmful to GCrl5SiMn steel. Therefore, accurate predictions of the growth size of these inclusions during steel solidification are significant for clean ESR ingot production. On the basis of our previous work, a coupled model of solute microsegregation and TiN inclusion growth during solidification has been established. The results demonstrate that compared to a non-coupled model, the coupled model predictions of the size of TiN inclusions are in good agreement with experimental results using scanning electron microscopy with energy disperse spectroscopy （SEM-EDS）. Because of high cooling rate, the sizes of TiN inclusions in the edge area of the ingots are relatively small compared to the sizes in the center area. During the ESR process, controlling the content of Ti in the steel is a feasible and effective method of decreasing the sizes of TiN inclusions.

Formation of Liquid Pools Entrapped within Solid Grains of ZA27 Alloys during Partial Remelting

The investigations were performed into the formation processes of liquid pools entrapped within solid grains of three ZA27 alloys, produced respectively by either grain refinement, or traditional permanent casting or mechanical stirring, during partial remelting at semisolid temperature of 460℃. The results show that the rapid coalescence of primary grains due to merging of secondary arms during the initial stage of partial remelting is the main cause for the formation of the entrapped liquid pools. This coalescence resulted in that a high quality of eutectics, especially the 77 phase, was entrapped within the grains, and then remelted to form liquid pools during the subsequent heating. In addition, the growth of the η phase decomposed from the primary α' phase and β phase and the subsequent remelting is another cause for the refined and permanent mould casting alloys. Furthermore, the agglomeration of the solid grains also resulted in the entrapment of liquid in the interior of grains.

Effects of compressing and remelting in SIMA processing on semi-solid structure evolution of an Al-Zn wrought alloy

Structure evolution of an Al-Zn wrought alloy in remelting processing in thestrain induced melt activated (SIMA) serai-solid procedure was observed, and effects of factors, theremelting temperature, the holding time, and the compression strain, on structures and grain sizesof the alloy were investigated. The results show that (1) the proper temperature of remelting is inthe range of 610 to 615℃; (2) the grain size in specimen with greater compression strain is smallerthan that with smaller compression strain in condition of the same remelting temperature andholding time, and the grain size in local area with great local equivalent strain is smaller thanthat with small one; (3) liquid occurs in form of cluster in matrix during remelting and itsquantity increases with remelting time increasing; liquid in specimen with great compression strainoccurs earlier than that with small one, and quantity of liquid in the center of specimen withgreater local equivalent strain is greater than that in the two ends of it; (4) distortion energyafter deforming in matrix of the alloy is the significant factor to activate melting of matrix atlocal area with great local equivalent strain.

Evaluation of the Electroslag Remelting Process in Medical Grade of 316LC Stainless Steel

This study is focused on the effects of electroslag remelting by prefused slag （CaO, Al2O3, and CaF2） on macrostructure and reduction of inclusions in the medical grade of 316LC （316LVM） stainless steel. Analysis of the obtained results indicated that for production of a uniform ingot structure during electroslag remelting, shape and depth of the molten pool should be carefully controlled. High melting rates led to deeper pool depth and interior radial solidification characteristics, while decrease in the melting rates caused more reduction of nonmetallic inclusions. Large shrinkage cavities formed during the conventional casting process in the primary ingots were found to be the cause of the fluctuation in the melting rate, pool depth and extension of equiaxed crystals zone.

Comprehensive model for a slag bath in electroslag remelting process with a current-conductive mould

A mathematical model was developed to describe the interaction of multiple physical fields in a slag bath during electroslag remelting （ESR） process with a current-conductive mould. The distributions of current density, magnetic induction intensity, electromagnetic force, Joule heating, fluid flow and temperature were simulated. The model was verified by temperature measurements during remelting 12CrMoVG steel with a slag of 50wt%-70wt% CaF2, 20wt%-30wt% CaO, 10wt%-20wt% A1203, and 〈10wt% SiO2 in a 600 mm diameter current-conductive mould. There is a good agreement between the calculated temperature results and the measured data in the slag bath. The calculated results show that the maximum values of current density, electromagnetic force and Joule heating are in the region between the comer electrodes and the conductivity element. The characteristics of current density distribution, magnetic induction intensity, electromagnetic force, Joule heating, velocity patterns and temperature profiles in the slag bath during ESR process with current-conductive mould were analyzed.

Review on desulfurization in electroslag remelting

Electroslag remelting(ESR) gives a combination of liquid metal refining and solidification structure control.One of the typical aspects of liquid metal refining during ESR for the advanced steel and alloy production is desulfurization.It involves two patterns, i.e., slag–metal reaction and gas–slag reaction(gasifying desulfurization).In this paper, the advances in desulfurization practices of ESR are reviewed.The effects of processing parameters, including the initial sulfur level of consumable electrode, remelting atmosphere, deoxidation schemes of ESR,slag composition, melting rate, and electrical parameters on the desulfurization in ESR are assessed.The interrelation between desulfurization and sulfide inclusion evolution during ESR is discussed, and advancements in the production of sulfur-bearing steel at a high-sulfur level during ESR are described.The remaining challenges for future work are also proposed.

Effect of laser remelting on microstructure and mechanical properties of CrMnFeCoNi high entropy alloy

Equiatomic CrMnFeCoNi high entropy alloy prepared by powder metallurgy was remelted by laser.The relative density and microstructure of fusion zone are evaluated.The nanoindentation tests are conducted to reveal the hardness difference of dendrite arms and interdendritic areas.Tensile tests are conducted to assess the mechanical properties of remelted HEA.After laser remelting,the number and morphology of voids changed significantly.Dendritic structure with face-centered cubic phase form in the fusion zone.Fe,Cr and Co are enriched in dendrite arm,while Mn and Ni are enriched in interdendritic area.Elements segregation led to a nanohardness difference between dendrite arm and interdendritic area.Local deformation occurs in interdendritic area during tensile tests and results in a fracture with directionality.

Effect of electroslag remelting and homogenization on hydrogen flaking in AMS-4340 ultra-high-strength steels

Hydrogen flakes and elemental segregation are the main causes of steel rejection. To eliminate hydrogen flaking, the present study focuses on the manufacture of AMS-4340 ultra-high-strength steel through an alternate route. AMS-4340 was prepared using three different processing routes. The primary processing route consisted of melting in an electric arc furnace, refining in a ladle refining furnace, and vacuum degassing. After primary processing, the heat processes(D1, D2, and D3) were cast into cylindrical electrodes. For secondary processing, electroslag remelting(ESR) was carried out on the primary heats to obtain four secondary heats: E1, E2, E3, and E4. Homogenization of ingots E1, E2, E3, and E4 was carried out at 1220°C for 14, 12, 12, and 30 h, respectively, followed by an antiflaking treatment at 680°C and air cooling. In addition, the semi-finished ESR ingot E4 was again homogenized at 1220°C for 6–8 h and a second antiflaking treatment was performed at 680°C for 130 h followed by air cooling. The chemical segregation of each heat was monitored through a spectroscopy technique. The least segregation was observed for heat E4. Macrostructure examination revealed the presence of hydrogen flakes in heats E1, E2, and E3, whereas no hydrogen flakes were observed in heat E4. Ultrasonic testing revealed no internal defects in heat E4, whereas internal defects were observed in the other heats. A grain size investigation revealed a finer grain size for E4 compared with those for the other heats. Steel produced in heat E4 also exhibited superior mechanical properties. Therefore, the processing route used for heat E4 can be used to manufacture an AMS-4340 ultra-high-strength steel with superior properties compared with those of AMS-4340 prepared by the other investigated routes.

Effects of electrode configuration on electroslag remelting process of M2 high-speed steel ingot

The electrode configuration determines the thermophysical field during the electroslag remelting(ESR) process and affects the final microstructure of the ingot. In this work, ingot with a diameter of 400 mm was prepared with two electrode configuration modes of single power ESR process, namely one electrode(OE) and two series-connected electrodes(TSCE). Finite element simulation was employed to calculate the electromagnetic field, flow field and temperature field of the ESR system. The results show that the temperature of the slag pool and the metal pool of the TSCE process is lower and more uniform than that of the OE process.The calculated temperature distribution of the ingot could be indirectly verified from the shape of the metal pool by the experiment. The experimental results show that the depth of the metal pool in the OE ingot is about 160 mm, while the depth of the TSCE ingot is nearly 40 mm shallower than that of the OE ingot. Microstructural comparisons indicate that coarse eutectic carbides are formed in the center of the OE ingot, whereas more even eutectic carbides appear in the center of the TSCE ingot. In general, compared with the OE process, the TSCE process is preferred to remelt high speed steel ingots.

Laser Remelting of Plasma Sprayed NiCrAlY and NiCrAlY-Al_2O_3 Coatings

Two types of plasma sprayed coatings (NiCrAlY and NiCrAlY-A12O3) were remelted by a 5 kW cw CO2 laser. With increasing laser power and decreasing traverse speed in the ranges of 200-700 W and 5-30 mm/s respectively, the melted track grew in width and depth. In the optimum range of laser parameters, a homogeneous remelted layer without voids, cavities, unmelted particles and microcracks was formed. On the surface of remelted layers, Al203 and YAIO3 were detected. As a result of isothermal oxidation tests, weight gains of laser remelted coatings were obviously lower than that only plasma sprayed, especially laser remelted NiCrAlY-Al2O3 coatings. The effects of laser remelting and incorporation of A12O3 second phase in N1CrAlY matrix on high temperature oxidation resistance were discussed.