Formation of Complex Inclusions in Gear Steels for Modification of Manganese Sulphide

Suitable MnS inclusions in gear steel can significantly improve the steel machinability and reduce the manufacturing costs. Two gear steel samples with different sulphur contents were prepared via aluminium deoxidation followed by calcium treatment. The shape, size, composition and percentage distribution of the inclusions present in the steel samples were analyzed using an electron probe micro-analysis (EPMA) technique. The average diameter of MnS precipitated on an oxide inclusion is less than 5 µm. It was found that the steel with high sulphur content contains a greater number of elongated MnS precipitates than low sulphur steel. Moreover, there are more oxide inclusions such as calcium-aluminates and spinels with a small amount of solid solution of (Ca,Mn)S in low content sulphur steel after calcium treatment, which indicates the modification of solid alumina inclusions into liquid aluminates. The typical inclusions generated in high sulphur steel are sulphide encapsulating oxide inclusions and some core oxides were observed as spinel. The formation mechanisms of complex inclusions with different sulphur and calcium contents are discussed. The results are in good agreement with thermodynamic calculations.

Prediction of Inclusion Types From BSE Images: RF vs. CNN

The analysis of non-metallic inclusions is crucial for the assessment of steel properties. Scanning electron microscopy (SEM) coupled with energy dispersive spectroscopy (EDS) is one of the most prominent methods for inclusion analysis. This study utilizes the output generated from SEM/EDS analysis to predict inclusion types from BSE images. Prediction models were generated using two different algorithms, Random Forest (RF) and convolutional neural networks (CNN), for comparison. For each method, three separate models were developed. Starting with a simple binary model to differentiate between inclusions and non-inclusions, then developing to more complex four and five class models. For the 4-class model, inclusions were split into oxides, sulfides, and oxy-sulfides, in addition to the non-inclusion class. The 5-class model included specific types of inclusions only, namely alumina, calcium aluminates, calcium sulfides, complex calcium-manganese sulfides, and oxy-sulfide inclusions. CNN achieved better accuracy for the binary (92%) and 4-class (78%) models, compared to RF (binary 87%, 4-class 75%). For the 5-class model, the results were similar, 60% accuracy for RF and 59% for CNN.

Evolution of oxide and nitride inclusions during processing of stainless steel

Because of its superior properties, stainless steel has been widely used for many applications. Nonmetallic inclusions can influence the quality of stainless steel products. A set of samples was used to track the response of inclusion composition during processing of a heat of titanium-bearing 18% chromium steel, from deoxidation after decarburization, to the solidified slab. The oxide inclusions responded as expected to additions of deoxidizers and calcium treatment, changing from silica to alumina and spinels, and then to calcium aluminates. The samples confirmed that titanium nitride can nucleate on liquid calcium aluminate during steel solidification.

Thermodynamic modeling of the synthesis of the main minerals of cement clinker from technogenic raw materials

In this article, thermodynamic studies of modeling the formation of the main minerals of cement clinker as a function of the Gibbs energy (ΔG) on temperature were investigated. The temperature range of the studies was 873-1873 K. In the course of modeling studies, the reactions of formation of cement clinker minerals (C2S - belite, C3S - alite, C3A – three calcium aluminates, C4AF – four calcium aluminium ferrite) from standard raw materials and non – standard-technogenic raw materials containing non-ferrous metals were calculated. Equations describing the dependence of the Gibbs energy on temperature with approximation coefficients (R2) equal to 0.99 are found. According to the results of the conducted studies, the beginning (Tb) temperatures of the course of the compared clinker formation reactions were determined, which were 1008 K for the standard reaction, and 1023 K for the non-standard reaction. It was found that the reactions begin to occur in the temperature intervals for the standard (1008 K – 1873 K), for the non - standard (1023 K - 1873 K). At the same time, the values at the initial stage of the course of the standard reaction have a more negative value of the Gibbs energy than the non-standard reaction. With a further increase in temperature, it becomes evident that the Gibbs energy of the non-standard reaction of mineral formation in the temperature range 1173-1873K becomes more negative in comparison with the values of the standard reaction and exceeds its values from 9 to 19.01%.

Liquid Inclusion Collision and Agglomeration in Calcium-Treated Aluminum-Killed Steel

This work addresses conflicting results in the literature regarding liquid inclusion agglomeration. To assess whether liquid calcium aluminates do agglomerate in liquid steel, laboratory experiments were performed: melting electrolytic iron, deoxidizing the melt with aluminum and subsequently calcium treating the deoxidation products (alumina and magnesia-alumina spinel inclusions). Under laboratory conditions, solid spinels and alumina inclusions were successfully modified, producing a new population of much smaller calcium aluminate inclusions. The new population of inclusions forms because the presence of calcium in the liquid steel destabilizes alumina and MgO-alumina inclusions, which then dissolve into the melt. The liquid inclusions exhibited a weak but statistically significant tendency to agglomerate. Laboratory results were assessed in the light of different collision mechanisms. Agglomeration mainly occurs by Stokes and laminar fluid flow collision when no external stirring is imposed. Monte Carlo simulations of collisions agree reasonably well with experimental results. For industrial conditions, where the liquid steel is agitated by argon bubbling and/or electromagnetic stirring, turbulent collisions dominate.

EVALUATION OF THE EFFICIENCY OF USING SK30 WIRE IN STEEL PROCESSING AT THE LADLE FURNACE PLANT

The paper presents studies showing the effectiveness of the use of wire with SiCa filler in the out-of-furnace processing of steels. The efficiency of use was evaluated by calculating the contamination with non-metallic inclusions, as well as by determining the phase composition of non-metallic inclusions at the stages of out-of-furnace processing and casting. (installation bucket furnace→vacuum cleaner→continuous casting). The study found that the adjustment of the content of aluminum before casting leads to the formation of refractory inclusions of corundum - (AlO), spinels - (AlO·MgO), which are deposited on the walls of the steel filling path and worsen the spillability of steel. The use of SK30prov with SiCa filler at the final stages of extra-furnace processing (after the introduction of aluminum), leads to the modification of refractory inclusions in low-melting calcium aluminates of the type (CaO·AlO). The presence of low-melting inclusions is more preferable, since this type of inclusions is not deposited on the walls of the filling cup and does not have a negative effect on the contamination of the continuously cast billet and products obtained from them with inclusions.

Heat Conductive Plates from Recycled Niobium Slag

Niobium slag as a waste product from metallurgical production of metallic niobium, containing calcium aluminates mainly, is valuable raw materials for different new products in the building materials industry. Disintegrator milling technology for pretreatment of Nb-slag was used, consisting of following steps: a) precrushing of slag, b) separative milling for extraction of metallic Nb. The yield of metallic Nb with a purity of 90 – 95 % was about 1.0 %; mineral ballast consists mainly (about 98 %) from calcium aluminates. The potential application areas of fine fraction (less 0.3 mm) of calcium aluminates were studied a) as a component in concrete and ceramics and b) as the main component of heat conductive material. The technology, mechanical and thermal properties (strength, thermal conductivity and expansion) of materials were studied. As reference material analogous CPA commercial thermal plates (Cebud, Poland) were studied. In the result of studies of mechanical and thermal properties of calcium aluminate based materials, it was demonstrated that the application of them as heat conductive material is more prospective.

Evaluation of red sludge use efficiency for water purification from sulphates

In this work the reagent purification of aqueous solutions from sulfates with the use of red sludge of the Nikolaev alumina plant processes were investigated. This sludge, according to chemical analysis, contains a sufficiently large amount of alumina (up to 18 %) and calcium oxide (up to 10 %) and along with calcium silicate and iron oxides contains sodium and calcium aluminates. The ability of sodium aluminate to be deposited from a solution of sulfates in the form of calcium sulfoaluminates was used in the work to purify water from sulfate anions. The process takes place when treating the solution with sludge and lime suspension. It is shown that when red sludge is applied in the amount of 1–50 g/dm3 during magnesium sulfate solutions liming, water is purified from sulfate anions. The degree of water purification reaches 50–70 %. It was found that the efficiency of sulfate extraction is significantly dependent on the consumption of lime and increases slightly with increasing sludge consumption over 1 g/dm3. The dependence of the efficiency of sulfate extraction from water on their initial concentration is determined. It was found that at the initial concentration of sulfates up to 1000 mg/dm3 at the expense of lime 3–12 mg-eq/dm3 the residual concentration of sulfates decreases to 236–460 mg/dm3, and at the concentration of sulfate anions about 2000 mg/dm3 their concentration decreases to 550–830 mg/dm3 at a lime consumption of 30 mg-eq/dm3 regardless of the sludge consumption. The degree of extraction of sulfates from solutions reaches 40–73 %.