INCLUSION
ENGINEERING
Submitted by-
Chirag Jain
Sahil Khan
Table of Content
[Link]
[Link] of Inclusions
[Link] of Inclusions on Steel Properties
[Link] Engineering For Clean Steels
5. Behavior of Different types of Inclusions during
Deformation
INTRODUCTION
◦ Inclusion engineering in the field of ferrous process metallurgy deals with the control of the amount, size distribution,
and composition of nonmetallic inclusions formed in the liquid metal during refining and solidification. The concept of
nonmetallic inclusions in steel usually includes oxides, sulfides, oxy-sulfides, nitrides, carbides, and carbonitrides.
◦ However, the last three are rather classified as “precipitates” because they are generally formed in solid steel where
they can have strong influences on steel properties via such mechanisms like grain refinement and precipitation
strengthening.
◦ Inclusions are often called with such terms like “slag inclusions” or “macro slags” and “micro slags” which expressions
point to their origin or character. This is, however, not generally valid as most inclusions are endogenous, i.e., formed
inside the steel, and thus independent on the slag on the steel surface.
◦ Generally, typical slag-based inclusions in steel are macro inclusions, mixed oxides which through their composition
often can be traced to the ambient slag in ladle, tundish, or mold. In steelmaking, the control of the metallurgical
process is aimed at obtaining the desired amount and properties of inclusions.
◦ The process thus plays a vital role and reproducibility in the production is of fundamental importance to prevent
overelaboration to secure the quality. The concept of steel usually concerns alloys with an iron content of more than
50%and with carbon content below 2%. This means that the commercial steels range from almost pure iron to low
alloyed steels with up to 2% alloying totally, to high alloyed steels containing several tenths of percents alloying
elements. This must also have effects on the production line and many alternative routes have been developed.
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◦ Also depending on the steel composition, different inclusions are formed as a combined result of deoxidation
and alloying. Depending on the manufacturing process and the pursued steel properties, quite different
requirements for inclusions can be set. Inclusion engineering is thus more or less “individual tailoring” of
inclusions for a certain steel grade with aim to generate such inclusions in steel which are beneficial or at least
harmless during the process and in the final steel end product. Thus, it means control of the amount, size
distribution, and composition as well as properties of nonmetallic inclusion in steel.
Fig:1
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Types of inclusions
◦ The inclusions are produced in liquid steel during refining at high temperatures and or from precipitation during
solidification. Inclusions which are produced during steel refining at high temperatures are known as primary
inclusions and inclusions which are produced during solidification are known as secondary inclusions. Once
inclusions are formed in steel, the characteristics of the inclusions such as size, quantity, composition, and
morphology remain the same or change / evolve due to physico-chemical reactions in the liquid steel, between
the liquid steel and surrounding slag and ladle refractory, and from deformation. Depending on their final
characteristics, they can be harmful to the casting process, reduce the steel mechanical properties, and
decrease the surface and overall quality of the steel product. Inclusions, the presence of which defines purity of
steel, are classified by chemical and mineralogical content, by stability, and by origin.
◦ According to a traditional classification, the inclusions can be distinguished in two main classes as a function of
their origin. These classes are
(i) Endogenous Inclusions
(ii) Exogenous Inclusions
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Endogenous Inclusions
◦ Endogenous inclusions (also being known as indigenous inclusions) occur within the liquid steel,
precipitating out during cooling and solidification. The inclusions belonging to this class result from additives
to the steel. They are deoxidation products or precipitated inclusions during cooling and solidification of
steel. Alumina (Al2O3) inclusions in LCAK (low carbon aluminum killed) steel, and silica (SiO2) inclusions in
silicon-killed steel are generated by the reaction between the dissolved oxygen and the added aluminum
and silicon deoxidants are typical deoxidation inclusions.
◦ Alumina inclusions are dendritic when formed in a high oxygen environment (Fig 2). Cluster-type alumina
inclusions from deoxidation or reoxidation (Fig 2) are typical of aluminum killed steels. Alumina inclusions
easily form three dimensional clusters through collision and aggregation due to their high interfacial energy.
Individual inclusions in the cluster can be 1 micrometer to 5 micrometers in diameter. Before collision,
break-up or aggregation with other particles, they can be in the shape of flower plate or (aggregated)
polyhedral inclusions. Alternatively coral-like alumina inclusions are believed to result from ‘Ostwald-
ripening’ of originally dendritic or clustered alumina inclusions. Silica inclusions are normally spherical owing
to being in a liquid or glassy state in the liquid steel. Silica can also agglomerate into clusters.
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◦ Precipitated inclusions form during cooling and solidification of the steel. During cooling, the concentration of
dissolved oxygen / nitrogen / Sulphur in the liquid becomes larger while the solubility of those elements decreases.
Thus, inclusions such as alumina, silica, aluminum nitride, and sulphide precipitate. Sulphides form inter-dendritically
during solidification, and frequently nucleate on oxides already present in the liquid steel. These inclusions are
normally small (less than 10 micrometers).
◦ Endogenous inclusions are typically more uniformly distributed than exogenous inclusions, which are entrapments of
materials from refractory interfaces, slag, or other materials in contact with the liquid steel. The endogenous inclusions
are naturally occurring and hence can only be minimized and cannot be completely eliminated. Primary and
endogenous oxides such as alumina and magnesium-spinel clog submerged entry nozzles and their irregular shapes
act as stress risers during the deformation and decrease the steel mechanical strength.
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Fig:2
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Exogenous inclusions
◦ Exogenous inclusions arise from unintentional
chemical
with its and mechanical
surroundings. They interaction
are normallyof liquid
harmfulsteel
to
fracture
of their sensitive
large of mechanical
sizethese
and location properties
near the because
surface.
The majority
reoxidation in which inclusions
liquid steel, are formed
having by
‘free’
deoxidants
calcium) (aluminum,
dissolved in thesilicon,
liquid manganese,
steel, picks or
up
oxygen
and from contact
transportation with the
through the air during
gating pouring
system. In
addition,
the liquid inclusions can
steel with preheated be formed
gases or water by reaction
vaporizing of
from
the
Exogenousimproperlyinclusions transfer
are normally vessels.
entrapped
accidentally
solidification during
resulting tapping,
in a random pouring and
distribution
throughout
inclusions act theas cast steel products.
heterogeneous nucleation These
sites
for precipitation
motion in the liquid [Link] new inclusions during their
◦ Exogenous
incidental inclusions
chemical arise primarily
(reoxidation) and from the
mechanical
interaction
entrainment of and
liquiderosion
steel with of its surroundings
lining refractory).(slagIn
machining,
gouges they produce
on the surface chatter, causing pits and
frequent breakages, as wellofas machined
excessive toolsections,
wear
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Exogenous inclusions
following common have
characteristics. the
• Compound
the phenomena composition
(i) due / multiphase
to the reaction isbetween
caused by the
liquid
lining steel and
refractory silica,
with theFeO, and
generated MnO in
alumina the slag and
inclusions
exogenous can stay on move,
inclusions their surface,
due to (ii) as
their large size,
they can
alumina entrap deoxidation
on their surface, inclusions
(iii) exogenous such as
inclusions
act
of as
new heterogeneous
inclusions during nucleus
their sites
motion for
in precipitation
the liquid
steel,
react and the
with (iv) lining
slag or reoxidationorinclusions
refractories dislodged can
further
material into steel.
• Irregular
entrainment shape,
or if not spherical
deoxidation product fromsilica.
slag The
spherical
(larger exogenous
than 50 inclusions
micrometers) and are normally
mostly large
multiphase,
but
smalltheandspherical deoxidation inclusions are normally
single phase.
• Sporadic
dispersed distribution
as small in the steel
inclusions. and they
Since not well-
are
normally entrapped
solidification, their in steel
incidence during
is teeming
accidental and
and
sporadic.
only On the other
concentrate in hand,ofthey
regions the easilysection
steel float out, so
which
their solidifyby
escape most rapidly
flotation is or
in in zones
some way from which
hampered.
As a result, they are frequently found near the
surface.
• More harmful
inclusions to steel
because of properties
their large than [Link]
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Influence of Inclusions on Steel Properties
It is well known that the amount and type of nonmetallic inclusions in steel have a direct influence on different
properties such as:
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By controlling the composition, size, and distribution of the inclusions, the possibilities of
obtaining the desired properties are improved. The composition of the inclusions has a direct
effect on their mechanical properties. This means that the inclusions, depending on their
composition and structure, will show different behaviors during metal working.
Principally four different types of deformation of inclusions can be seen in steel that has been
hot rolled, Fig:3 Typical behavior and characterization of inclusions are:
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– Deformation in a similar way as the steel matrix. These inclusions are ductile
and are heavily prolonged in the rolling direction. Deformable silicates and
manganese sulphides.
– Hard brittle inclusions that are broken up into stringers or separated fragments during
metal working. Alumina inclusions and clusters.
– Inclusions that consist of a hard core surrounded by deformable phase. These types of
inclusions usually show a ductile behavior at low degrees of deformation, while they
often will have a thick center and prolonged ends at higher deformation. Complex
multiphase inclusions.
– Very limited or no deformation of the inclusions. In the rolling direction, sometimes
cavities in the metal matrix at high reduction rate in rolling can be seen.
Ca-aluminate inclusions.
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(a) (b) (c)
(d)
Different types of oxide inclusions in hot-rolled steel: (a) ductile elongated inclusion,
(b) brittle-broken inclusions, (c) brittle–ductile complex inclusion, and (d) undeformed
inclusion with
deformed sulfide “tails”. The scale in figures vary from few microns to tens of
microns [1].
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Inclusion Engineering For Clean Steels
◦ Solid-phase inclusions can cluster together to clog nozzles and other flow control systems which mediate the
flow of liquid steel, posing a threat to the process operations. Some inclusion chemistries reduce ductility,
resistance to fatigue, or overall toughness in steels. The absence of inclusions poses issues as well because
the ‘clean steels’ can be harder to machine, decreasing the lifespan of cutting tools, and require higher power
consumption for machining. Understanding their nature is of critical importance in steelmaking operations, and
‘inclusion engineering’ is needed to be an operational focus during the process of steelmaking.
◦ The term ‘inclusions engineering’ means the design of the inclusions so as to alleviate their harmful effects on
the product properties. Inclusion engineering does not refer to removal of inclusions but it refers to modify them
either in terms of chemical composition or shape so that harmful effects of the inclusions can be converted to
improve the steel properties. Inclusion engineering also involves distribution of inclusion uniformly in the matrix,
so that composite properties can be generated in the product. In some cases, deliberate attempts are made to
form very fine inclusions (e.g. nitrides, and carbo-nitrides inclusions in hardening steel). Such inclusion can form
by reaction between tungsten, titanium, aluminum with oxygen, nitrogen, Sulphur, or carbon.
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◦ As far as inclusion modification and shape control are concerned, the inclusions of interest are the endogenous
type, particularly the inclusions which result from the process of deoxidation and sulphide-type inclusions. Oxides
and sulphides are the two predominant inclusions in steel. The sources of oxides and sulphides are inherent to the
steelmaking process. Oxygen is employed to react with the impurity elements (e.g. silicon, manganese) and carbon
to generate chemical energy for the melting process. However, a significant amount of the oxygen ends up being
dissolved in the liquid steel.
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Behavior of Different types of Inclusions
during Deformation
‘Stringer’ formation, type (b) and (c),
increases the directionality of
mechanical properties, adversely
affecting the toughness and ductility in
particular. The worst inclusions for
toughness and ductility, particularly in
through thickness direction properties of
flat-rolled product, are those deforming
with the matrix, like (d) in Fig:3
Fig:3 [Link]
ineering-and-clean-steels/
Source
1) [Link]
inclusion-engineering-and-clean-steel
s/
2) Inclusion Engineering
Lauri Holappaa and Olle Wijkb
Department of Materials Science and
Engineering, Aalto University, School of
Chemical Technology, Espoo, Finland
B Sandvik Materials Technology,
Sandviken, Sweden
[Link]
8-6.00008-0
3) Non-metallic inclusions in steels –
origin and control
André Luiz Vasconcellos da Costa e Silva
[Link]
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