Defectos de Inclusiones en Fundicion

Continuous Casting Course Inclusions Prof. Brian G.
Thomas
Inclusions in Steel Castings
Continuous Casting Course Inclusions Prof. Brian G. Thomas
Importance of Inclusions
On Mechanical Properties
Fatigue
Strength
Drawability
On Surface Condition
Visible defects
Individual particles, line defects, patches
Defects in Final Steel Product
Surface delamination
Slivers
Blisters
Cleanliness and Fatigue Life
Bearing steel
Inclusion size and associated defect
A. Cramb, 1999
Inclusion Morphologies
Globular
liquid in solid steel
(Slag)
Dendritic
oxygen rich environment
(eg. short time after Al
addition or reox.)
Cluster
long time
(less oxygen,
many collisions)
(a)
1000
(b)
1000
400m
2D
3D
10m
Al
2
O
3
Inclusion Morphology - SEM
Dendritic
short time after Al addition
(oxygen rich environment)
Coral Shape
long time
1. (less oxygen, many collisions)
2. (Ostwald ripening of dendritic)
Argon bubbles catch inclusions
Fluid Flow Validation behind a
Rigid Sphere in Water
1.5mm diameter rigid particle in water
Water photo,
Clift et al, 1975
Attachment Probability: Steps in
Inclusion attachment to Bubble
Attachment probability, P
C
column in particles
attached particles
P
C
#
#
=
Particle trajectory through molten steel
2. Sliding(time for film drainage)
1. Collision / oscillation
3. Stable attachment
Rising
Bubble
Inclusions
Burty et al, 1993
Effect of Turbulence on Inclusion
Trajectories around a 5 mm Bubble
Non-Stochastic Stochastic
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
0.0 0.5 1.0 1.5 2.0
Attachment probability (%)
D
i
s
t
a
n
c
e

f
r
o
m

t
h
e

a
i
x
s

/

d
B
Effect of Turbulence on the
Attachment of Inclusion to Bubble
Stochastic model: collision diameter 4mm, 16.5% attachment in total
Non-Stochastic model: collision diameter 0.34mm,11.6% attachment in
total
50m inclusions to 1 mm bubble, k<10
-2
m
2
/s
2
bubble
d
B
d
B
0 20 40 60 80 100 120 140
10
-6
10
-4
10
-2
10
0
10
2
10
4 Bubble size
1mm
2mm
5mm
10mm
N
u
m
b
e
r

o
f

i
n
c
l
u
s
i
o
n
s

a
t
t
a
c
h
e
d

o
n

a

b
u
b
b
l
e

Inclusion diameter (m)
How Many Inclusions Attached to
a Bubble?
Measurements, Kiriha et al, ISIJ, 2004
Increases with larger
bubbles and smaller
particles
Photos, Zhang et al, 2004
Defects in Steel
Inclusion Sliver
Pencil blister Sliver
R. Gass, et al., ISSTech2003 Conference Proceedings, ISS, Warrandale, PA, 2003, 3-18.
H. Yin and H.T. Tsai, ISSTech2003 Conference Proceedings, ISS, Warrandale, PA, 2003, 217-226.
Defects in Steel
P. Rocabois, et al, ISSTech2003 Conference Proceedings, ISS, Warrandale, PA, 2003, 995-1006.
Pencil pipe
inclusions from
refractory
Sliver from mold
slag inclusions
Exogenous Inclusions Defects on
the Surface of Foundry Product
http://neon.mems.cmu.edu/afs/afs2/window2.html
Indigenous Inclusions
- Deoxidation products,
normally < 50m, but
possibly > 50m if
clustered;
- Precipitated inclusions
during
cooling/solidification
process of steel, normally
with small sizes.
10m
Dendritic alumina
Refs: L. Zhang, B. Thomas. ISIJ, No.3, 2003
Ref.: Ravi Rastogi and Alan Cramb,
Personal communication, 2002,
Alumina cluster
Exogenous Inclusions
- Reoxidation products, by
- FeO, MnO, SiO
2
and other
oxides in the slag and
refractory linings
- Exposure to the
atmosphere;
- Slag entrapment (of interest)
- Other sources (of interest):
- well block sand
- loose dirt
- broken refractory brickwork
- ceramic lining particles.
- Chemical reactions (Ca
treatment)
Emulsification of slag
Erosion/Reoxidation
http://neon.mems.cmu.edu/afs/afs2/window2.html
Exogenous Inclusions from Refractory
R. Dekkers, et al., ISSTech2003 Conference Proceedings, ISS, Warrandale, PA, 2003, 197-209.
Sand Buildup on Ladle Well Nozzle
SEN Nozzle Clogging
F. Fuhr, et al., "ISSTech2003 Conference
Proceedings, ISS, Warrandale, PA, 2003,
165-175.
Entrapped Nozzle Sand
light gray phase: chromite;
dark gray phase: silica.
Refractory Type Inclusions
Spinel : Al
2
O
3
75%
- MgO 25%
Al
2
O
3
50% - CaO 40%
- SiO
2
10%
Inclusions A. Cramb studies
Inclusions in Aluminum Killed Steel
3 Microns
10 Microns
Sample Crossection - aluminum killed 1006
MnS nucleated from alumina
Alumina before etching
Alumina from Deoxidation after etching sample
Alumina by Deoxidation after etching sample
Alumina Deoxidation Inclusions
alumina
Levitated / Deoxidized Steel Droplet
100 microns
Levitated / Deoxidized Steel - Extracted Inclusions
100 microns
Levitated / Deoxidized Steel - Extracted Inclusions
10 microns
TiN precipitated from alumina in a clog
TiN in Tisulc grade
Twin Growth
Mg-Al Oxide Precipitation
409
Reaction
Zone
Nitride
Oxide
Ti N
Al Mg O
TiN
MgAl
2
O
4
CaO-SiO
2
-Al
2
O
3
MnO-SiO
2
-Al
2
O
3
Inclusion Chemistry
Manganese Silicate
Mn-Si killed steel - deox or re-ox
Manganese Alumino Silicate
Mn-Si killed steel containing less than 0.005 Al
Deox or reox
Alumina
Deox or reox of steel containg more than 0.005
Al
Sources of Inclusions
Deoxidation products
Reoxidation (especially from air exposure)
Slag carryover
Slag entrainment
Refractory erosion
Nozzle clogs (which break off)
Deoxidation products
Form as solubility limits are exceeded
Alumina
Manganese silicate
Iron oxide
Manganese oxide
Iron sulphide
Manganese sulphide
Small initial size (0.5 - 20 microns)
Multi-layer composition as conditions evolve
Reoxidation
Every exposure of steel to air generates
large dendritic inclusions
Avoid air exposure by:
Free-open ladles
Avoid excessive stirring in ladle
Maintain optimized slag coverage
Shroud
Stream control (open pour)
No leaks (good seals; preheat refractories to avoid
cracking
Importance of
Stream Condition
Rough Jet causes:
air entrainment
reoxidation
surface turbulence
level fluctuations
surface defects
Sommerville and McKeogh, 2nd PTD Conf Proc., ISS, 1981, pp256-268
Slag carryover
Stop steel flow before slag enters next
vessel (use slag detection)
Avoid vortexing
keep level above critical minimum
use vortex inhibitors
Slag Entrainment
Large globules: 20-1000 microns (1 mm)
Identified by composition:
(furnace,ladle, tundish, or mold slag)
Causes
Shear from fast surface flows
Vortexing (near end of vessel drainage)
Stream impact (open pouring)
Surface turbulence
poor level control)
During drainage,
At corners in a complex flow pattern
Surface Entrainment of Slag
Worse with
Higher speed surface flow
Thicker flux layers
Lower flux viscosity
Lower interfacial tension
Slag Entrainment mechanism
A. Cramb
Refractory Erosion
Solid particles:
loose sand
Vessel liners
Thermodynamic attack
if slag composition not compatible with
refractory
Inclusion detection
Total oxygen content (alumina)
Microscope examination
Slime extraction
Ultrasonic evaluation of solid cone-shaped
speciman (Timken)
Online inclusion sensors in liquid steel
Surface defects in final product
Large inclusions
worst - total O
2
is
misleading
Clean Steel Practices
Control slag chemistry
Prevent reoxidation (avoid air exposure: slag
cover / submerged nozzles / argon)
Stable refractories
Inclusion modification (eg. Ca treatment)
Optimize flow
argon stirring in ladle,
tundish impact pads, dams, and weirs
Mold tundish streams (billet) and SEN (slabs)
How does calcium treatment
work?
Phase equilibria in steelmaking oxides
Control composition to liquify
inclusions
Sources of different inclusion
sizes
A. Cramb, 1999
Inclusion Defects in
Continuous Casting of Steel
Inclusion defects from:
- nozzle clogging
- air entrainment
- entering nozzle from upstream
- mold slag entrainment
- Level fluctuations
- Surface hook formation
Water
Spray
Molten Steel Pool
Solidifying Steel Shell
Flux
Rim
Submerged Entry Nozzle
Support
Roll
Roll Contact
Ferrostatic
Pressure
Bulging
Roll
Nozzle
Nozzle
copper
mold
Liquid Flux
Air Gap
Flux Powder
jet
nozzle
port
argon
bubbles
Inclusion
particles and
bubbles
Resolidified
Flux
Contact
Resistances
Oscillation
Mark
entrainment
C
L
Inclusion Defects in Foundry
Castings
Inclusion defects in foundry
castings: bubble plumes

Defectos de Inclusiones en Fundicion

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Continuous Casting Course Inclusions Prof. Brian G.

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