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

International Journal of Minerals,Metallurgy and Materials 2024年第7期31卷 1525-1539页

作者： Shengchao Duan Min Joo Lee Yao Su Wangzhong Mu Dong Soo Kim Joo Hyun Park School of Mechanical and Materials Engineering North China University of TechnologyBeijing 100144China Department of Materials Science and Chemical Engineering Hanyang UniversityAnsan 15588Rep.of Korea Department of Materials Science and Engineering KTH Royal Institute of TechnologyBrinellvägen 23Stockholm 10044Sweden Department of Engineering Science and Mathematics Division of Materials ScienceLuleåUniversity of Technology97187 LuleåSweden Casting&Forging Business Unit Nuclear Business GroupDoosan EnerbilityChangwon 51711Rep.of Korea

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.

关键词： nonmetallic inclusion heat-resistant steel electroslag remelting M_(23)C_(6) carbide MnS inclusion supersaturation degree

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Effect of electrical parameters and slag system on macrostructure of electroslag ingot

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China Foundry 2024年第1期21卷 44-50页

作者： Bing-jie Wang Yu Wang Meng-jun Wang Lei Zhao Li-zhong Chang Xiao-fang Shi School of Metallurgy engineering Anhui University of TechnologyMa'anshan 243002AnhuiChina

To investigate the influence of electric parameters and slag system on the solidification quality of electroslag ingot during electroslag remelting,different power supply modes,current strengths and remelting slag systems were used to conduct electroslag remelting experiments on 304L austenitic stainless steel,and the macrostructure of electroslag ingots was analyzed.The results indicate that the depth of the metal pool decreases with the reduction of remelting frequency in the low frequency power supply mode.The effects of different power supply modes,such as low-frequency,direct current straight polarity(DCSP),and direct current reverse polarity(DCRP),on reducing the depth of the metal pool increase in that order.By reducing the remelting current strength in the same power supply mode,the depth of metal pool is reduced.When compared to the binary slag system of 70%CaF2+30%Al2O3,the ternary slag system of 60%CaF2+20%Al2O3+20%CaO is more effective in reducing the depth of the metal pool during remelting.Utilizing the 60%CaF2+20%Al2O3+20%CaO ternary slag system results in a shallower and flatter metal pool,with columnar crystal growth occurring closer to the axial crystal.This effect is observed for both low frequency and direct current(DC)power supply modes.

关键词： electroslag remelting frequency slag system solidification quality

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XGBoost-based model for predicting hydrogen content in electroslag remelting

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Journal of Iron and Steel Research(International) 2023年第5期30卷 887-896页

作者： Yu-xiao Liu Yan-wu Dong Zhou-hua Jiang Yu-shuo Li Wei Zha Yao-xin Du Shu-yang Du School of Metallurgy Northeastern UniversityShenyang 110819LiaoningChina Key Laboratory of Ecological Metallurgy of Multimetallic Mineral Northeastern UniversityShenyang 110819LiaoningChina State Key Laboratory of Rolling and Automation Northeastern UniversityShenyang 110819LiaoningChina

An Xtreme Gradient Boosting(XGBoost)-based endpoint hydrogen content prediction model was proposed for the electroslag remelting process,the data collected in the field were pre-processed,and the characteristic variables of the physical parameters related to the variation of hydrogen content in the electroslag remelting process were selected by machine learning analysis and metallurgical mechanism.The kernel ridge regression model,ridge regression model,XGBoost model,support vector regression model and gradient boosting regression model were developed and validated using the electroslag remelting data collected from the steel mills,and the model structure and parameters were adjusted several times.The prediction accuracy of hydrogen content was compared horizontally.The XGBoost model was validated for the test set with the following hit rates:70.59%,82.35% and 100% for the endpoint hits at the allowable hydrogen content error of ±0.05×10^(-6),±0.10×10^(-6) and ±0.50×10^(-6),respectively.

关键词： electroslag remelting Hydrogen content Machine learning XGBoost Prediction model

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Effect of CaO/Al_(2)O_(3)on structure,viscosity,and surface tension of electroslag remelting-type CeO_(2)-bearing slag

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Journal of Iron and Steel Research(International) 2023年第4期30卷 717-725页

作者： Ding-li Zheng Guo-jun Ma Xiang Zhang Meng-ke Liu Ju Xu Hubei Provincial Key Laboratory for New Processes of Ironmaking and Steelmaking Wuhan University of Science and TechnologyWuhan 430081HubeiChina The State Key Laboratory of Refractories and Metallurgy Wuhan University of Science and TechnologyWuhan 430081HubeiChina Key Laboratory for Ferrous Metallurgy and Resources Utilization of Ministry of Education Wuhan University of Science and TechnologyWuhan 430081HubeiChina

The structure of electroslag remelting-type CaF_(2)–CaO–Al_(2)O_(3)–CeO_(2)slag with various CaO/Al_(2)O_(3)mass ratios and its correlation with viscosity and surface tension were investigated.The Raman analysis of the slag shows that with increasing CaO/Al_(2)O_(3)mass ratio from 0.70 to 1.29 in the slag,the polymerization degree of the slag decreased,which was because more complex[AlO_(4)]-tetrahedral units of Q_(Al)^(3) and Q_(Al)^(4)were depolymerized to form relatively simpler structural units Q_(Al)^(0),Q_(Al)^(1),and Q_(Al)^(2),and the excess oxygen ions introduced by CaO promoted the transformation of[AlO_(4)]-tetrahedral units to[AlO_(6)]-octahedral units.Increasing CaO/Al_(2)O_(3)mass ratio has an obvious effect on reducing the viscosity and activation energy for viscous flow of the slag,resulting from the depolymerization of the slag.Owing to the decrease in the polymerization degree and the increase in the total Ca^(2+)content of the slag,the surface tension of the slag increases with the increase in CaO/Al_(2)O_(3)mass ratio.The surface tension of the slag changes slightly with the temperature,irrespective of CaO/Al_(2)O_(3)mass ratio from 0.70 to 1.29 in the slag.

关键词： electroslag remelting CeO_(2)-bearing slag CaO/Al_(2)O_(3) Structure Viscosity Surface tension

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Desulfurization of rejected electrolytic manganese metal by electroslag remelting furnace with a water-cooled electrode

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Journal of Iron and Steel Research(International) 2023年第7期30卷 1411-1425页

作者： Ru Lu Ran-ran Yu Guang-qiang Li Yu Liu Qiang Wang Hai-chuan Wang School of Metallurgical Engineering Anhui University of TechnologyMa’anshan 243002AnhuiChina The State Key Laboratory of Refractories and Metallurgy Wuhan University of Science and TechnologyWuhan 430081HubeiChina Key Laboratory for Ferrous Metallurgy and Resources Utilization of Ministry of Education Wuhan University of Science and TechnologyWuhan 430081HubeiChina

remelting rejected electrolytic manganese metal (EMM) scrap was investigated by electroslag remelting (ESR) process through industrial experiment. The results indicated that the ANF-6 slag (70 wt.% CaF_(2) + 30 wt.% Al_(2)O_(3)) and deoxidizer could promote the desulfurization of ESR manganese in an air atmosphere. Under an air atmosphere, the sulfur in the ingot decreased to 0.0534 wt.% with a desulfurization ratio of ESR manganese of 53.2% by using ANF-6 slag and water-cooled copper electrode electroslag remelting rejected EMM scrap, suggesting its efficient removal. The electroslag ingots exhibited uneven chemical composition in an air atmosphere and cooling condition of the ESR process. The metal manganese could be oxidized by electroslag remelting of rejected EMM scrap in an air atmosphere with MnO content in the final slag of 21.9 wt.%. Besides, the activity of MnO in slag increased with increasing remelting temperature, resulting in a reduction in the slag–manganese sulfur partition ratio and desulfurization ratio. Moreover, with the accumulation of sulfur in slag and the oxidation of metallic manganese liquid, the slag showed a lower cleanliness and more oxidation, leading to an increase in sulfur and oxygen content in the electroslag ingot with the increase in ingot height.

关键词： Rejected electrolytic manganese metal scrap Desulfurization electroslag remelting Thermodynamics

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Effect of nitrogen on microstructure and microsegregation of martensitic stainless steel 4Cr13 produced by electroslag remelting

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Journal of Iron and Steel Research(International) 2023年第9期30卷 1854-1861页

作者： Shou-hui Li Jing Li Jie Zhang Cheng-bin Shi State Key Laboratory of Advanced Metallurgy University of Science and Technology BeijingBeijing 100083China

Two ingots of 4Cr13 martensitic stainless steel with different nitrogen contents,0.023 and 0.121 mass%,were produced by vacuum induction furnace and electroslag remelting.The microstructure and the microsegregation of the electroslag remelting ingot were analyzed by optical microscopy,scanning electron microscopy and electron microprobe analysis.Thermo-Calc software was used to calculate the nitrogen solubility changes during solidification of high nitrogen martensitic stainless steel and the equilibrium and non-equilibrium phase diagrams of 4Cr13 steel with different nitrogen contents.The solubility of nitrogen in 4Cr13 steel reached the lowest value of 0.118%before the start of the peritectic reaction.The microstructure of 4Cr13 steel was martensite,retained austenite and primary carbide M_(7)C_(3).Higher nitrogen content increased the content of retained austenite in martensitic stainless steel,inhibited the precipitation of primary carbides and refined the dendrites.Higher nitrogen content could effectively inhibit the microsegregation of C element in martensitic stainless steel;however,it had little effect on Cr,V,Nb and Ti.The peritectic reaction was first carried out in high nitrogen steel during solidification,which advanced the transformation of austenite and inhibited the microsegregation of C element.

关键词： Nitrogen Martensitic stainless steel electroslag remelting Microsegregation Microstructure

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An innovative method for calibrating local cooling rate in electroslag remelting of M42 high-speed steel

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Journal of Iron and Steel Research(International) 2021年第8期28卷 990-996页

作者： Wan-ming Li Shi-chao Jiao Wen-jie Tong Xi-min Zang De-jun Li Zhou-hua Jiang Hua-bing Li Yu-an Jing School of Material and Metallurgy University of Science and Technology LiaoningAnshan 114051LiaoningChina State Key Laboratory of Marine Engineering Anshan 114051LiaoningChina School of Metallurgy Northeastern UniversityShenyang 110819LiaoningChina

The determination of the local cooling rate has a great significance in optimizing the parameters of electroslag remelting(ESR)and improving the quality of the ingots.An innovative method was proposed for calibrating the local cooling rate of M42 high-speed steel(HSS)in the ESR process.After resolidification at different cooling rates under high-temperature laser confocal microscopy,the carbide network spacing of the specimen was observed using a scanning electron microscope.A functional relationship between the cooling rate and average carbide network spacing was established.The average local cooling rate of the solidification process of the M42 HSS ingot was calibrated.The results show that the higher the cool-ing rate,the smaller the network spacing of the carbides.For the steel ingot with a diameter of 360 mm,the average local cooling rate was 0.562℃/s at the surface,0.057℃/s at the position of 0.25D(where D is the diameter of the ingot),and 0.046℃/s at the center of the ingot.

关键词： Cooling rate electroslag remelting Carbide Network spacing Calibrating High-speed steel

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Mathematical model for design of optimized multi component slag for electroslag remelting

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Journal of Iron and Steel Research(International) 2020年第4期27卷 380-391页

作者： Shi-jian Li Guo-guang Cheng Yu Huang Wei-xing Dai Zhi-qi Miao State Key Laboratory of Advanced Metallurgy University of Science and Technology BeijingBeijing 100083China

Slag is the heart of electroslag remelting(ESR)process.A new mathematical model to design the optimized slag for ESR was developed based on slag–metal equilibrium theory,ion and molecule coexistence theory and modified Butler’s equation.It was assumed that an overall thermodynamic equilibrium did exist at electrode tip–slag interface.With this model,the equilibrium slag and its surface tension could be obtained quantitatively when the initial compositions of consumable electrode were given.An industrial experiment with four types of slags was carried out in a special steel plant in China.The variation of Al,Si and Mn corresponded well with the deviation of corresponding oxide from equilibrium,reflecting the reasonability of the model.Besides that,the effects of Al in electrode as well as CaO,CaF2 and MgO in slag on the equilibrium slag,dissolved oxygen and surface tension were discussed in detail.

关键词： electroslag remelting Model Slag design Ion and molecule coexistence theory Equilibrium slag

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Review on desulfurization in electroslag remelting

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International Journal of Minerals,Metallurgy and Materials 2021年第1期28卷 18-29页

作者： Cheng-bin Shi Yi Huang Jian-xiao Zhang Jing Li Xin Zheng State Key Laboratory of Advanced Metallurgy University of Science and Technology BeijingBeijing 100083China

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.

关键词： electroslag remelting desulfurization sulfide inclusions sulfur-bearing steel gasifying desulfurization desulfurization mechanism

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Effect of electrode change on solidification of slag and metal pool profile in electroslag remelting process

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Journal of Iron and Steel Research(International) 2021年第12期28卷 1582-1590页

作者： Yi-ru Duan Bao-kuan Li Xue-chi Huang Zhong-qiu Liu School of Metallurgy Northeastern UniversityShenyang110819LiaoningChina

A two-dimensional axisymmetric model is established to study the effect of electrode change on the solidification of slag and metal pool profile during electroslag remelting process.The basic considerations of flow and heat transfer are included in the model,and the growth of ingot is described by the dynamic mesh technique.The electrode melting rate is predicted based on the transient thermal conductivity model between slag and electrode.The results indicate that in the electrode change stage,the slag temperature drops from 1847 to 1763 K gradually and the“hot heart”phenomenon is observed.And the metal pool profile is slightly changed with a depth decrease from 0.3984 to 0.3688 m.In the heating and melting stage of new electrode,the maximum slag temperature firstly increases from 1763 to 1892 K,then decreases to 1845 K,and finally at 3558 s,the maximum slag temperature is stable at 1884 K.Solidified slag shell with a maximum volume of 7.31×10^(-3) m^(3) is formed at the electrode tip,and then,the solidified slag melts completely.The depth of metal pool firstly rises to 0.3700 m and then drops to 0.3565 m.As the preheating temperature of the new electrode increases from 473 to 973 K,the maximum volume of solidified slag decreases from 0.00748 to 0.00592 m^(3),and the time from heating to melting of the new electrode decreases from 996 to 887 s.

关键词： electroslag remelting Electrode change Metal pool profile Solidified slag Numerical simulation

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