Slag inclusion formation during solidification of steel alloys and in cast iron

Abstract: This thesis explores the formation of segregation and inclusions during solidification of steel and cast iron. A better understanding of the formation mechanism should result in decreasing fraction of defects during solidification of ingot and strand material.Density driven macrosegregation was studied both experimentally and theoretically to see the effect of channel segregation on the total segregation. Formation of these pencil-like segregations is due to natural convection in the solidifying metal caused by liquid enrichment of elements with lower density compared to the bulk. It is suggested to change the composition to compensate for this density difference.Inclusion precipitation can be finite by limitations in segregation. Saturated liquid is found in the last solidified areas, often between dendrites. Here the enrichment of the liquid is possible due to microsegregation. Meanwhile crystals form and solidify the elements with low solubility in the solid is pushed out in the remaining liquid. Soon the liquid is saturated to the level where spontaneous formation of inclusions occurs. Microstructure studies by aid of SEM and micro-probe measurements are analysed to find at what point during solidification process the inclusions start to form. In steel making this formation has a detrimental effect on the mechanical properties in contrary to the production of nodular cast iron where the inclusions have a beneficial effect on the graphite formation.Inoculation of cast iron aims at reaching higher number density of graphite nodules, nodule morphology modification and control of nodule distribution during solidification. Late precipitation of nucleation sites has shown to have a positive impact on preventing chill. To find the most potent inoculation agent different additives were tested. Special effort has been made to analyse the effect of oxides and sulphides as nucleation sites.