In order to clarify the influence mechanism of high pressure on inclusion number distribution, the changes in phase transition sequences, key properties, and heat transfer boundary conditions with pressure have been investigated. Furthermore, the inclusion number distribution of H13 die steel ingot under different pressures (0.1, 1, and 2 MPa) has been numerically simulated by the mathematical model

Chemical variation occurring during the solidification process can cause undesirable effects on the material property, especially for alloys with high solute content. The current study investigated the distributions of solute elements in directional solidified Fe–Mn–C–Al TWIP steels and compared the micro-segregation with various pulling rates and C contents using the phase field model and the grid

In view of the non-renewable reductant resources and carbon neutralization in the process of copper slag cleaning in an electric furnace, this study proposed to use waste cooking oil as reductant to replace fossil energy. Combined with the phase equilibrium theory and experimental results, the harm of excessive magnetite in the copper smelting slag to the cleaning process was clarified. The reduction

Effect of oxygen enrichment on flow field, temperature, concentration distribution, emission, and fuel economy has been studied inside a pilot-scale Rotary Hearth Furnace (RHF) for two separate conditions with or without varying the fuel amount. In varying fuel condition (when amount of fuel is reduced with oxygen enrichment to maintain the flame temperature constant), the fuel consumption was reduced

The kinetic modeling for the nucleation, size growth, and compositional evolution of nonmetallic inclusions in steel was extensively reviewed in the present article. The nucleation and initial growth of inclusion in molten steel during deoxidation as well as the collision growth, motion, removal, and entrapment of inclusions in the molten steel in continuous casting (CC) tundish and strand were discussed

The earlier published values mentioned in the Table V under the column header “Rockliden S7574 Spot1” need to be updated as below. The errors in the published values came up due to a mistake during normalization of the measured EDS composition values. The requested changes will not affect the conclusions drawn from the data in this table.

A series of steel-flux reaction experiments was conducted to elucidate the reaction mechanism between high Mn-high Al steel and CaO-\({\text{SiO}}_2\)-type molten mold flux of low MgO content \((({\text{pct MgO}})_0 = 0\) to 1.8) at 1723 K (\(1450\,^\circ \text {C}\)). Composition evolutions in the liquid steel and the molten flux during the reaction and microstructure change in the flux near the steel-flux

In this study, a set of thermodynamic, kinetic, and microstructure data is presented to simulate the non-equilibrium solidification of Fe-Al-Mn-Si-C alloys. The data were further validated with the experimental measurements and then used in a thermodynamic–kinetic software, IDS, to establish the effect of the alloying and cooling rate on the solidification behavior of high-AlMnSi (Al ≥ 0.5 wt pct,

Permeability is crucial for stable operation and strengthening of smelting in blast furnace ironmaking, especially for the current utilization of low-grade iron ore. The viscosity of the primary slag is an important factor affecting permeability. In this study, the roles of MgO and Al2O3 in the viscous and structural behavior of CaO-MgO-Al2O3-SiO2-10 mass pct FeO (CaO/SiO2 weight ratio of 1.4) primary

Chemical vapor synthesis was used to prepare Nb nanopowders with NbCl5 vapor as a raw material and Na vapor as a reductant. Thermodynamic analysis indicated that Na had a strong ability to reduce NbCl5. X-ray diffraction (XRD), field emission scanning electron microscopy (FESEM) with energy dispersive spectrometry (EDS), and transmission electron microscopy (TEM) were used to analyze and characterize

Increased in-plant recycling and lower quality raw material in terms of alkali content drive the alkali load in the blast furnace (BF) to higher levels. Excessive load of alkalis, primarily potassium, has several negative effects on the BF operation, which necessitates means to control the removal of potassium from the BF. One method to improve the removal is by increasing the potassium retention in

High-concentration Al deoxidation resulting in diversified aggregated patterns of alumina inclusions in high-Al iron melt were observed, especially, a new alumina agglomerate with a ring shape was reported and discussed in the current work. A large number of small alumina particle originated from the explosive nucleation of alumina in Fe-Al-O reaction zone with high-concentration Al in a short time

Synthesis of crystalline slags of 12CaO·7Al2O3 phase from the corresponding melt compositions in different atmospheric conditions and different purities is investigated. Observations using a thermogravimetry coupled with differential thermal analysis showed that the dehydration of a zeolitic 12CaO·7Al2O3 phase occur at 770 °C to 1390 °C before it congruently melts at 1450 °C. The X-ray diffraction

SiC is one of the main intermediate compounds formed during the industrial production of silicon (Si). In the Si process, SiC is produced when carbon added to the raw materials reacts with the silicon monoxide gas (SiO(g)) formed in the furnace. Carbon materials used are either biomass-based (charcoal and wood chips) or based on fossil sources (coal, coke, petroleum coke). The most common forms of

Tellurium is a rare metalloid that is vastly produced from copper anode slime, which is a by-product of the copper electrorefining process. Choosing the proper recovery method strongly depends on the slimes composition, mineralogy, and tellurium concentration. In addition, correctly selecting the right method of leaching, purification, and precipitation in economic and environmental processing of the

This article was updated to correct errors in figure order and citations introduced during production.

Effects of grain refinement on the tensile properties and precipitation kinetics of Al-Si-Mg alloys cast in sand molds by co-alloying of La–B elements were investigated in this work. The kinetics of precipitation after refinement were investigated, including the changes of the precipitation mechanism and decrease of the precipitation activation energy. The reduction of the Avrami exponent indicates

Herein, the effects of BaO (i.e. 5, 10, 15 and 20 pct) on the viscosity and structures of a new fluorine-free CaO-Al2O3-TiO2-based mold flux with w(CaO pct)/w(Al2O3 pct) ratio of 1.0 are investigated using a rotary viscometer, molecular dynamics (MD) simulations, and Raman spectroscopy. The viscosity of the samples (the testing temperature is 1300 °C) decrease from 0.46 to 0.21 Pa·s as the BaO content

In the past several decades, many technologies to recover platinum group metals (PGMs) and rhenium (Re) from electronic waste and spent catalysts have been developed and published. The reasons for the rising interest in this area are: (1) The abundance of these elements in the earth’s crust is < 10−3 ppm (~ 6.6 × 104 tons worldwide); (2) global demand for PGMs is > 590 tons; (3) electronics and catalyst

Mold powders play an integral role in maintaining the stability and efficiency of the continuous casting process as they (1) provide lubrication, (2) control heat transfer, (3) absorb nonmetallic inclusions, and (4) prevent reoxidation of liquid steel during continuous casting of liquid steels. Much of the previous investigations are focused on the characterization of mold powders to understand the

The quest of automobile industries for weight reduction and enhancement of the mechanical strength of components has been a major incentive for new manufacturing technologies such as thixocasting. It is therefore important that the welded joints of such components exhibit adequate strength and formability. The present investigation is on optimization of process parameters to achieve better weld quality

The dripping zone of the blast furnace is important in determining the productivity and quality of hot metal. The permeability of the bed affects both of these factors. Static holdup of hot metal and slag resulting from interfacial phenomena adversely affect the permeability of the bed. To characterize the holdup in the packed bed, we assumed the packed bed as an ensemble of two-sphere contacts at

The effects of basicity and Al2O3 content on the chemistry of phases in iron ore sinter containing ZnO were investigated by Rietveld analysis of the X-ray diffraction (XRD) patterns. Bulk composition analysis was carried out using inductively coupled plasma-atomic emission spectroscopy (ICP-AES) and wet-chemical analysis. The composition of each phase was investigated using a scanning electron microscope-energy

The electromagnetic brake (EMBr) is a well-known and widely applied technology for controlling the melt flow in the continuous casting (CC) of the steel. The effect of a steady (DC) magnetic field (0.31 T) in a CC mold is numerically studied based on the GaInSn experiment. The electrical boundary conditions are varied by considering a perfectly insulating/conductive mold or the presence of a conductive

The general flow characteristics of the molten steel and the behavior of molten steel and liquid slag interface (level fluctuation) in the mold with a new type of electromagnetic brake, freestanding adjustable combination electromagnetic brake (FAC-EMBr), was investigated by numerical simulation. The influences of the magnetic induction intensity, the submerged entry nozzle (SEN) immersion depth, the

Control of non-metallic inclusions is essential for the production of high-quality steel. This review summarizes processes that change inclusion compositions and concentrations during secondary steelmaking—slower changes are limited by reaction between bulk steel and slag or refractory, and faster changes involve direct additions to the steel bath. An example of the former is conversion of alumina

The motion of free grains has a significant influence on the solidification structure, solute distribution, and defects of large casts. However, few studies have modeled the solidification structure of large casts considering grain motion. In this paper, taking into account the motion of free grains, a multiscale cellular automaton model is proposed to predict the solidification structure of continuously

Surface quality and castability of steels are controlled greatly by initial solidification. Peritectic steels suffer more from surface quality problems, including deep oscillation marks and depressions, crack formation, and breakouts than other steels. This paper reviews current understanding of the fundamental mechanisms of initial solidification of peritectic steels that lead to these problems. First

A 1/17th water physical model of a 200-ton steel ladle furnace with a single gas injection was used to simulate bath heating using a single burner to mimic the heat flux due to electric arcs in the industrial steel ladle. Two phases were considered, using water to simulate the molten steel and air to simulate the argon injection at a flow rate of 1.54 NL min−1. The planar Laser-Induced Fluorescence

The smelting technology and flue dust treatment have an influence on the physical and chemical characteristics of flue dusts collected in copper smelting. We characterized flue dusts from a Bottom-Blowing Bath Smelting (BBS) process and from a Flash Smelting (FS) process by determining their comprehensive physical, chemical, and mineralogical characteristics. Annual flue dust generation data showed

In situ observation of the precipitation behavior of MnS in a high-sulfur microalloyed steel has been conducted by means of a confocal laser scanning microscopy (CLSM) with cooling rates increased from 50 to 400 °C/min. Differential scanning calorimetry analysis and thermodynamic calculation were carried out prior to and following the CLSM experiments using scanning electron microscopy (SEM) and X-ray

The crystallography of the Ca2SiO4-Ca3P2O8 solid solutions in the dephosphorization slag in current steelmaking process was determined in this study. Understanding the physical and chemical properties of these Ca2SiO4-Ca3P2O8 solid solutions is a preliminary step towards understanding the role of the Ca2SiO4-Ca3P2O8 solid solutions in the dephosphorization process. The range of Ca3P2O8 in the Ca2SiO4-Ca3P2O8

A series of fused CaF2-SiO2-CaO-based fluxes geared towards submerged arc welding has been prepared with incremental TiO2 additions. Through systematic investigation on physical properties, quantitative relationship between TiO2 content and corresponding structural information has been established, and the roles played by TiO2 have been profiled. It is found that TiO2 has been introduced into the silicate

The IronArc process is a novel approach to ironmaking which aims to reduce the associated \({\hbox {CO}}_{2}\) emissions. By superheating gas using electricity in a plasma generator (PG) the heat required for the process can be supplied without burning of coke. Reduction of hematite and magnetite ores is facilitated by additions of hydrocarbons from liquid natural gas (LNG). The melting and reduction

Applying SAE 9254 steel to springs manufacture requires precise control of non-metallic inclusions. The effects of operational parameters on steel cleanliness such as the amount of BOF slag carry over as well as addition of graphite and ladle Furnace slag basicity have been evaluated using Chemical EQuilibrium Calculations for the Steel Industry (CEQCSI®) software. Slag basicity is expected to strongly

Thermodynamic optimization of the Fe-P system was performed using the CALculation of PHAse Diagrams (CALPHAD) method based on critical evaluation of all available phase equilibria and thermodynamic data. The Gibbs energies of liquid phase and solid solutions were described using the Modified Quasichemical Model and Compound Energy Formalism, respectively. The Fe-P phase diagram, thermodynamic properties

Experimental study on the phase equilibria between copper matte with silica-saturated iron silicate slags was conducted at 1300 °C and \( P_{{{\text{SO}}_{ 2} }} \) = 0.5 atm. The high-temperature isothermal equilibration in silica crucibles under controlled flowing CO-CO2-SO2-Ar was followed by quenching in an ice–water mixture and direct phase composition analyses by an electron probe X-ray microanalyzer

V2O5/CaO diffusion couples were prepared to investigate the reaction characteristics between V2O5 and CaO at 1073 K to 1273 K in air. The distribution, species, and number of phases generated in the proximity of the V2O5/CaO interface were characterized by electron probe microanalysis (EPMA), Fourier transform–infrared (FT–IR) spectroscopy, and X-ray diffraction (XRD) that was capable of selecting

The formation of oxide-related defects, including entrained oxide inclusions and oxide-induced gas/shrinkage porosity, during cavity fill and solidification has been inextricably linked to reduced mechanical properties in aluminum castings. Although the oxide formation and entrainment process can be easily understood, it remains difficult to accurately predict the location and severity of oxide-related

The nozzle-clogging problem is closely related to the agglomeration behavior of inclusions in steel-containing rare earth (RE). The present study first optimized the thermodynamic model by supplementing thermodynamic data of the RE compound to study the formation of various inclusions in the Ce-Al-O-S system. Based on that, laboratory-scale experiments with different Ce and Al contents were designed

The effect of pulse frequency on the transport phenomena and crystal growth behavior in the quasi-continuous-wave laser powder deposition process of single-crystal superalloy were studied through an improved three-dimensional mathematical model and experiments. Laser powder deposition experiments with single-crystal superalloy were conducted to verify the computational results and analyze the crystal

Electrode Induction Melting Inert Gas Atomization (EIGA) is the state-of-the-art process for the high-quality spherical powder production for additive manufacturing needs. The growing demand for EIGA powders drives the interest for the scale-up of well-established atomization of small Ø50 mm Ti-6Al-4V electrodes, as well as atomization of new refractory materials like Tantalum. However, during first

In the present study, a two-dimensional phase field model coupled with Lattice Boltzmann method (PF-LBM) is proposed to predict the dendritic growth and motion in the melt of Fe-C binary alloy, where the phase field method (PF) is used to calculate the dendritic growth, including the phase field and the concentration field, and the lattice Boltzmann method (LBM) is used to calculate the flow field

The study focuses on the effect of mono and combined addition of metallic and ceramic reinforcement particles on the microstructural and corrosion behavior of surface composites fabricated by friction stir processing. Molybdenum, possessing higher corrosion resistance compared to aluminum, is used as the metallic reinforcement, and boron carbide is used as ceramic reinforcement. Combined addition of

A transient three-dimensional (3D) sequentially coupled mathematical model has been developed to explore multiphysical fields in the twin-electrode electroslag remelting (TE-ESR) furnace. The mechanical APDL module based on the finite element method and the Fluid Dynamics module based on the finite volume method were used to resolve the electromagnetic field and simulate the fluid flow, heat transfer

The released NOx during fuel combustion is one of the major air pollutants, directly related to acid rain and photochemical smog. At present, there is not an economical and effective method of inhibiting NOx emission from sintering flue gas. Therefore, controlling the conditions of fuel combustion is extremely required for the reduction in NOx. The current research investigated the effects of different

To increase the utilization fraction of V-Ti-Magnetite ore in the burden of the blast furnace over 80 pct, the technology of “replacing CaO with MgO” was discussed. The high content of TiO2-bearing raw materials leads to a super high TiO2 content in the blast furnace slag, which affects the normal operation of the blast furnace ironmaking process. The physicochemical properties of TiO2-bearing blast

Fused CaF2-TiO2 fluxes are developed and applied on EH36 shipbuilding plates under high heat input submerged arc welding. Transfer behaviors of O and major alloying elements are systematically investigated. TiO2 contributes to O gain in the weld pool, but leads to concurrent losses of Si, Mn, and C via deoxidation and decarburization reactions. Transfer of Ti to the weld metal is suppressed due to

Burden batch weight is a critical operating parameter in the blast furnace (BF) system. It directly affects solid distribution such as coke-layer and ore-layer thickness and thus gas permeability and thermal–chemical conditions inside a BF. However, in the open literature, few quantitative studies have been reported on the influence of burden batch weight on BF performance, such as cohesive zone (CZ)

The method of carbon powder mixed injection with a shrouding supersonic oxygen jet was proposed to increase the utilization efficiency of carbon powder and improve the foaming slag operation during the electric arc furnace (EAF) steelmaking process by delivering the carbon powder more deeply into the molten bath. In this study, the fluid flow characteristics of the carbon powder mixed injection with

Clogging behavior has been investigated by applying a direct current on a submerged entry nozzle (SEN). The relevant experimental results verify that the high-speed friction acting on the SEN not only leads to charging of the inclusions, but also inhibits the clogging behavior and improves the quality of the steel. After DC treatment, the formation of clogging in the SEN decelerates and the stability

Determining the free lime (f-CaO) content in steelmaking slag is critical for road construction because f-CaO is likely to cause road expansion. Herein, we present a method to determine an area fraction of f-CaO from fractions of illuminated areas related to f-CaO in cathodoluminescence (CL) or X-ray excited optical luminescence (XEOL) image of industrial steelmaking slag, which is simpler and quicker

Based on the similarity principle, the slag foaming behavior was simulated with the physical modeling method in this investigation. Under the oxygen lance jet, the chemical reaction of NaCO3 powder dispersed in silicon oil with H2SO4 solution to release CO2 gas simulated the carbon-oxygen reaction between the slag and metal in BOF, during which the height was recorded. The slag viscosity and gas amount

The CALPHAD-type computational thermodynamic databases have been developed since 1970. Several commercial computational thermodynamic software equipped with comprehensive and accurate thermodynamic databases and fast Gibbs energy minimization routine are widely used in the design of new materials and the optimization of materials processing. In this study, the FactSage software, which is the most frequently

Stainless steel pickling sludge is the precipitate from the neutralization process of stainless steel pickling liquor. Until now, many methods about the harmless treatments of pickling sludge have been developed, and among them the most effective one is to produce Fe-Cr-Ni alloy by carbothermic reduction process. However, the carbon and sulfur (harmful elements for steel) contents of the produced Fe-Cr-Ni

With the rapid development of rail vehicles, 301L strip has become the main material of the rail vehicles, and its flatness quality has got much attention. Meanwhile, 20-roll mill becomes the most important cold rolling equipment for 301L strip forming, because of its high precision and wide application. To study the flatness control theory of cold rolling 301L strip in 20-roll mill, a finite element

In order to improve our understanding of the PAMCHR process applied to the processing of Ti alloys, a 3D numerical simulation of the thermal and hydrodynamic behavior of the metal flowing in the refining hearth has been set up, based on Ansys-Fluent CFD software. The solid and liquid phases are governed by a set of transport equations expressing the conservation of mass, momentum, heat, and solutes