The cleanliness of steel impacts the success of steel production and the physical and chemical properties of the final product. Improving the cleanliness of steel, therefore, becomes a necessity in the present time, with an ever-increasing demand for high-quality steel products. The cleanliness can be improved by removing the harmful inclusions through flotation or by modifying their composition and morphology to less detrimental forms. The present study focuses on better understanding the second approach, a specific modification method commonly known as the calcium (Ca) treatment in advanced high strength steel (AHSS) production.
The chemical and morphological evolutions of Al2O3 inclusions under experimental and industrial conditions, as well as the formation of CaS and MnS inclusions, were studied in this work. Six laboratory experiments with different combinations of calcium and sulfur contents of liquid steel were conducted. Samples were taken at different time durations after calcium addition. The inclusions on the sample cross-sections were analyzed using an automated SEM-EDS system to obtain their chemical, size distribution, population, and morphological information. Similar steps were taken in the analysis of industrial samples. The findings obtained based on the automated SEM-EDS analyses were further supported and validated against other analysis results such as manual SEM analysis, thermodynamics, and kinetics calculations.
The modification mechanism for Al2O3 inclusions was established in the first part of the study. After adding 10 ppm, 20 ppm, and 35 ppm Ca, small-sized calcium aluminates CAx (C and A denote CaO and Al2O3, respectively) inclusions become the primary oxygen bearer instead of Al2O3 inclusions. The modification extent of the CAx inclusions depends on the Ca content. CaS inclusions also form at the early stage of calcium treatment. In the later stage, CaS inclusions act as the Ca source to modify the remaining Al2O3 inclusions to CAx inclusions and simultaneously modify the existing CAx inclusions until equilibrium is reached. CaO inclusions only form in steel containing 20 ppm S and 35 ppm Ca; the primary oxygen bearer will change from Al2O3 to CaO, followed by a transformation from CaO to CaS. In other S and Ca contents, CaO inclusions do not form. This finding clarified that modification of Al2O3 inclusions is mainly driven by dissolved Ca and CaS inclusions, with CaO showing a minor direct impact. Moreover, the experimental studies showed that total area fractions of liquid and semi-liquid inclusions, which are inclusions that are partially liquid and partially solid, are correlated with the thermodynamic stability of CaS inclusions. The fraction of liquid inclusions decreases after the area fraction of CaS inclusions drastically increases when steel chemistries allow stable CaS inclusions to precipitate.
The correlation between the steel chemistries and inclusions was improved by
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incorporating more data from industrial heats. Three modification indexes were proposed to estimate the control of CAx, CaS, and MnS inclusions. The fraction of CAx inclusions with more than 50 pct liquid, and the area fraction of CaS and MnS inclusions in tundish samples were correlated with the Ca, Al, Mn, and S contents of liquid steel. Later, these modification indexes were incorporated to evaluate the effectiveness of calcium treatment quantitatively. This makes the present study the first to discuss the correlations between Ca, Al, Mn, and S contents and the number of inclusions in the open literature. The correlations were validated against industrial data, they may be used in industry to determine the optimum Ca content for inclusion control and modification.
Based on the experimental and industrial data, the coarsening of CaS inclusions was initially governed by mass transport, then shifted to collision-related mechanisms. When agitation is absent, Brownian motion shows the most significant impact on the growth of CaS inclusions, while turbulent flow is the critical cause of collision and coagulation when the melt is stirred, such as in industrial conditions. It has been found that CAx inclusion growth mainly occurs in the early stage after Ca addition. The potential reason is that the lack of attraction prevents coagulation after CAx inclusions are modified to liquid and semi-liquid. / Thesis / Doctor of Philosophy (PhD)
| Identifer | oai:union.ndltd.org:mcmaster.ca/oai:macsphere.mcmaster.ca:11375/28000 |
| Date | January 2022 |
| Creators | Miao, Keyan |
| Contributors | Dogan, Neslihan, Sun, Stanley, Materials Science and Engineering |
| Source Sets | McMaster University |
| Language | English |
| Detected Language | English |
| Type | Thesis |
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