No description available.

In this thesis, both the wettability and the agglomeration characteristics of non-metallic inclusions in liquid iron/steel were studied by using both experimental results and thermodynamic considerations. The mechanisms of the wettability of different types of inclusions were discussed. Also, the agglomeration behaviors of the inclusions were analyzed. Firstly, the wettability of different types of inclusions (including Al2O3, MgO, Ti2O3, TiO2 and TiN) in contact with the liquid iron/steel was studied. For the TiNcase, there is no reaction formation at the interface between TiN and pureiron/steel. In the caseo f pure Fe, the oxygen increase is the main factor for a contact angle decrease. As for the steel case, a sharp decrease of the contact angle is due to the effects of both an increased oxygen content in the liquid steel and a formation of a Ti(N,C,O) phase at the interface. For the Al2O3 and MgO cases, the formation of a FeAl2O4 and a MgO-FeO reaction layer at the interface, respectively, lead to a contact angle decrease. In the case of the Ti2O3/pure Fe case, the reaction at the interface cannot be identified. For the Ti2O3/steel case, the formation of an Al2TiO5 reaction layer is the main reason for a steep decrease of the contact angle. In the TiO2 case, the melting region appears at the temperature below the melting point of pure iron. This is due to the strong formation of a solid solution TiOx-FeO. The main source of the oxygen for the solid solution formationis due to a TiO2 substrate decomposition and a low partial pressure of oxygen in the chamber. Regarding to the non-metallic particle additions (TiO2 and TiN) into the molten steel, the steel composition should be controlled to have a small Al content (&lt;0.005mass%) and a high Ti content (&gt;0.035mass%), so as togeta high number of Ti-rich oxide inclusions with a small size. This conclusionis supported from the view point of the van der Waals force, liquid-capillary force and wettability. Regarding the Ti/Al complex deoxidation in the melt, the “mainly occupied clustered inclusions” with spherical shape is due to a TiOx-FeO liquid inclusion precipitation after an addition of Ti as a pre-deoxidizer. The much lower cluster number in the Ti/Al case than that in the Al case is mainly due to a coagulation of single TiOx-FeO liquid inclusions. Also, the cluster formation in a complex Ti/Al deoxidation is started after an Al addition rather than after a Ti addition. Regarding the Al2O3 cluster formation in deoxidation, the cavity bridge forceis larger than the van der Waals force. However, the difference between them is smaller than 7 times. In the reoxidation process, the influence of the cavity bridge force due to the wettability decreased, and became similar to that of the liquid-capillary force. / <p>QC 20160301</p>

Non-metallic inclusions in molten steel have received worldwide attention due to their serious influence on both the steel product quality and the steel production process. These inclusions may come from the de-oxidation process, the re-oxidation by air and/or slag due to an entrainment during steel transfer, and so on. The presence of some inclusion types can cause a termination of a casting process by clogging a nozzle. Thus, a good knowledge of the inclusion behavior and deposition rate in steel flows is really important to understand phenomena such as nozzle clogging. In this thesis, inclusion behaviors and deposition rates in steel flows were investigated by using mathematical simulations and validation by experiments. A ladle teeming process was simulated and Ce2O3 inclusion behavior during a teeming stage was studied. A Lagrangian method was used to track the inclusions in a steel flow and to compare the behaviors of inclusions of different sizes. In addition, a statistical analysis was conducted by the use of a stochastic turbulence model to investigate the behaviors of different-sized inclusions in different nozzle regions. The results show that inclusions with a diameter smaller than 20 μm were found to have similar trajectories and velocity distributions in the nozzle. The inertia force and buoyancy force were found to play an important role for the behavior of large-size inclusions or clusters. The statistical analysis results indicate that the region close to the connection region of the straight pipe and the expanding part of the nozzle seems to be very sensitive for an inclusion deposition. In order to know the deposition rate of non-metallic inclusions, an improved Eulerian particle deposition model was developed and subsequently used to predict the deposition rate of inclusions. It accounts for the differences in properties between air and liquid metals and considers Brownian and turbulent diffusion, turbophoresis and thermophoresis as transport mechanisms. A CFD model was firstly built up to obtain the friction velocity caused by a fluid flow. Then, the friction velocity was put into the deposition model to calculate the deposition rate. For  the  case  of  inclusion/particle  deposition  in  vertical  steel  flows,  effects  on  the deposition rate of parameters such as steel flow rate, particle diameter, particle density, wall roughness and temperature gradient near a wall were investigated. The results show that the steel flow rate/friction velocity has a very important influence on the rate of the deposition of large particles, for which turbophoresis is the main deposition mechanism. For small particles, both the wall roughness and thermophoresis have a significant influence on the particle deposition rate. The extended Eulerian model was thereafter used to predict the inclusion deposition rate in a submerged entry nozzle (SEN). Deposition rates of different-size inclusions in the SEN were obtained. The result shows that the steel flow is non-uniform in the SEN of the tundish. This leads to an uneven distribution of the inclusion deposition rates at different locations of the inner wall of the SEN. A large deposition rate was found to occur at the regions near the SEN inlet, the SEN bottom and the upper region of two SEN ports. For the case of an inclusion/particle deposition in horizontal straight channel flows, the deposition rates of particles at different locations of a horizontal straight pipe cross- section were found to be different due to the influence of gravity and buoyancy. For small particles with a small particle relaxation time, the gravity separation is important for their deposition  behaviors  at  high  and  low  parts  of  the  horizontal  pipe  compared  to  the turbophoresis. For large particles with a large particle relaxation time, turbophoresis is the dominating deposition mechanism. / <p>QC 20150326</p>

To stay competitive in the steel industry, steelmakers are utilizing different production methods to reduce production cost without compromising on the quality of their products. In steelmaking, the production process plays a significant role on the steel cleanliness. Recent increasing demands on the cleanliness level therefore require optimization of production process to meet the requirement. Often, the types and distribution of non-metallic inclusions in steel determines the steel cleanliness. In order to optimize the production process, complete assessment of the non-metallic inclusions in the steel is necessary, leading to implementation of measures to control and/or remove non-metallic inclusions in the steel. The present study was performed to investigate the cleanliness level of steel bars produced from a high frequency induction furnace (HF) route at Uddeholms AB. Experimental studies were carried out and characteristics such as number, composition, size distribution and morphology of non-metallic inclusions were investigated. Total oxygen and total nitrogen content were also measured for indirect assessment. Further, the production operations at the HF were observed and evaluated to determine their influence on the inclusion characteristics. The characteristics obtained were compared with characteristics of inclusions in steel bars produced from an electric arc furnace production (EAF) route at Uddeholms AB and a competitor producer sample. The results showed that the level of cleanliness varies from different production routes and is hence dependent on the process at each production route. The number, maximum and mean size of inclusions were found to be higher in the HF route compared to the other routes. More so, there were differences in the types of oxide inclusions observed from each process route. However, sulphide inclusions exhibit similar characteristics from the different process routes. Further, the compositions of oxide inclusions observed from the HF route were found to be closely related to the steel chemistry. More importantly, the types of inclusions formed in the HF route were found to be sensitively affected by the extent of aluminium and calcium contents in the steel. Thus, the oxide inclusion types in the HF samples could be traced to the extent of different additions and operations such as deoxidation and calcium treatment that were carried out during the steelmaking process.

This study aims on characterization of non-metallic inclusions (oxides and sulfides) in steel with and without Calcium treatment. In this paper, the three-dimensional (3-D) investigation method of inclusions on film filter after Electrolytic Extraction (EE) of steel samples is applied on two different steel grades (280, 316L). Image analysis of non-metallic inclusions is carried out on Scanning Electron Microscope (SEM) images following with inclusion characteristic analysis. Steel samples with calcium treatment in the production process and reference samples was investigated and compared in density, size and composition. It shows that higher magnification and larger inclusion size correspond to more accurate result. With restriction of equipment and measurement, 2μm is the smallest size could be measured in ×500 magnification within 5% error. The comparison of distribution of inclusions varies with different zones: center has the largest size with least number of NMI; surface has the smallest size with largest number of NM; middle part has the median properties. In 316L steel, Ca treatment increases the number of oxides inclusions significantly; the content of Ca and Si in oxides inclusions is also increased. Two shapes of oxides inclusions, oval and elongated ones, are found with Ca treatment. In 280 steel, the total amount of NMI decreases slightly with Ca treatment; CaS is found in spherical inclusions; Because of earlier formation of larger size spherical inclusions, higher Ca content is found than that in smaller size spherical inclusions.

The focus of this thesis work is to optimize rare earth metal (REM) addition in Therma 253MA, an austenitic stainless-steel grade in order to get a good trade-off between oxidation resistance property and the amount of big REM inclusions formed. Big REM inclusions are detrimental to material properties and REM is required to be dissolved in the matrix for improving the oxidation resistance. REM optimization can also lead to economical savings for Outokumpu. The distribution of REM between matrix and inclusion is affected by factors such as REM addition, initial oxygen and sulphur contents and time to casting of the melt. The re-oxidation of melt in the tundish also affects the REM distribution. Hence, the effect of these factors on the inclusion characteristics is investigated by analysing samples with different REM additions, using light optical microscope (LOM) and scanning electron microscope (SEM). LOM analysis focussed on stringer inclusion characteristics. SEM+EDS analysis is done using automated "INCA Feature" software with focus on overall inclusion characteristics. Oxidation and creep tests are also performed to study the effect of different REM additions on oxidation and creep behaviour. The results from inclusion analysis show that increasing REM addition and time to casting has a bad effect on stringer and overall inclusion characteristics. The re-oxidation in the tundish influences the inclusion formation, but does not affect the stringer characteristics. The resistance to oxidation of the samples is also compared and is observed to increase within increasing REM addition. Finally, this works suggests an optimal REM addition for Therma 253MA to get a good balance between oxidation resistance and amount of big inclusions. / Fokus för detta avhandlingsarbete är att optimera tillsats av sällsynt jordartsmetall (REM) i Therma 253MA, en austenitisk rostfritt stålkvalitet för att få en bra avvägning mellan oxidationsbeständighetsegenskap och mängden stora REM-inneslutningar som bildas. Stora REM-inneslutningar är skadliga för materialegenskaperna och REM måste lösas i matrisen för att förbättra oxidationsbeständigheten. REM-optimering kan också leda till ekonomiska besparingar för Outokumpu. Fördelningen av REM mellan matris och inkludering påverkas av faktorer såsom REM-tillsats, initialt syre- och svavelinnehåll och tid till gjutning av smältan. Re-oxidation av smälta i tunden påverkar också REM-fördelningen. Följaktligen undersöks effekten av dessa faktorer på inkluderingsegenskaperna genom att analysera prover med olika REM-tillsatser, med användning av ljusoptiskt mikroskop (LOM) och avsökning av elektronmikroskop (SEM). LOM-analys fokuserade på stringer-inkluderingsegenskaper. SEM + EDS-analys görs med hjälp av automatiserad "INCA Feature" -programvara med fokus på övergripande inkluderingsegenskaper. Oxidations- och krypningstest utförs också för att studera effekten av olika REM-tillsatser på oxidation och krypbeteende. Resultaten från inkluderingsanalys visar att ökande REM-tillsats och tid till gjutning har en dålig effekt på stringer och totala inkluderingsegenskaper. Återoxidationen i tunden påverkar inkluderingsbildningen, men påverkar inte stringeregenskaperna. Motståndet mot oxidation av proverna jämförs också och observeras öka inom ökande REM-tillsats. Slutligen föreslår detta ett optimalt REM-tillägg för Therma 253MA för att få en bra balans mellan oxidationsmotstånd och mängd stora inneslutningar.

Investigation of non metallic inclusions in two different steels from Sandvik was made before and after turning. After dissolving the non-metallic inclusions by electrolytic extraction the particles were analysed manually or by INCA feature. This was referred to as 3D analysis. INCA feature analysis without extraction of particles was also performed, this was referred to as 2D analysis. The aim of the report was to a make a characterization of non-metallic inclusions with respect to chemical composition, aspect ratio, size and shape. The aim was also to compare different investigation methods. Samples were prepared and investigated. It was obtained that inclusions with sulphur content was elongated and crushed during the turning process. Broken sulphides were detected in one of the steels, and broken oxysulphides in the other steel in the electrolytically extracted chips created by turning. The first steel, steel 1, mainly contained sulphide and oxysulphide inclusions, and steel 2 mainly contained oxysulphides. The aspect ratio obtained by 2D analysis of the sulphide inclusions in steel 1 before turning showed similar results to the electrolytic extracted inclusions measured by hand. The aspect ratio increased with the length of the inclusion. However the deviation of data obtained by the 2D analysis was larger than deviation from the extracted particles measured by hand. The reason for this was assumed to be that the 2D method was not able to analyse the true shape of the inclusions e.g. if inclusions were partly concealed by metal matrix. In analysis of steel 2 the average aspect ratio decreased for oxides and increased for oxysulphides after turning. The chemical composition of inclusions did not change after the turning process for neither of the steels. Copper was detected in the electrolytic extracted inclusions, however not in the 2D investigation by SEM. This is an interesting topic for future research.

Improving the quality of metal castings for serial production of automotive industry, leading to improvements in the properties of casts and their lower costs. This publication analyzes the non-metallic inclusions contained in casts of heads of internal combustion engines, molded of Nemak Czech Republic, Ltd. Tackling includes analysis of size, shape, chemical composition and hardness of the specific non-metallic inclusions. The thesis describes the purity metal holding furnaces and proposals to eliminate inclusions from metal.

The thesis addressed the effect of a varying MgO grade in MgO-C refractories on both their behavior in contact with a steel melt and the resulting effect on the non-metallic inclusion (NMI) population in the solidified steel. For this purpose, immersion tests were conducted in a semi-industrial steel casting simulator. In addition, the effect of the steel melting process parameters on the NMI population was thoroughly investigated, providing a guideline for the result interpretation for future experiments in the steel casting simulator. Here, a fundamental concept of data evaluation for the NMI characterization in a steel matrix using automated feature analysis was developed. The main NMI types detected in the solidified steel samples were alumina and MnSi-based inclusions. Their number density depended on the steel melt's temperature and amount of dissolved oxygen. A lower MgO grade refractory specimen in contact with the steel melt resulted in a higher proportion of low melting phases on its surface compared to a higher MgO grade specimen. These low-melting phases promoted the formation of MnSi-based inclusions and triggered NMI agglomeration leading to the formation of large alumina inclusions.