Motion and removal behavior of inclusions in electrode tip during magnetically controlled electroslag remelting: X-ray microtomography characterization and modeling verification

doi:10.1016/j.jmst.2021.05.003

Abstract

Abstract:

Detailed three-dimensional (3D) microtomography characterizations of inclusions in electrode matrix, mushy zone (MZ) and liquid melt film (LMF) were performed to elucidate the motion and removal behavior of inclusions in electrode tip during magnetically controlled electroslag remelting (MC-ESR) process. A transient 2D numerical model was also built to verify the experimental results and proposed mechanisms. The number and size of inclusions exhibited an obvious increasing trend from edge to mid region in LMF, while remained almost the same in electrode matrix and MZ. The inclusions in LMF migrated from edge to mid region of LMF, accompanied with removal process. In addition, the kinetic conditions for inclusion migrating to LMF/slag interface (LSI) were enhanced during MC-ESR process, thereby improving the inclusion removal efficiency in LMF. This work highlights the 3D characterization and motion/removal mechanisms of inclusions in electrode tip, as well as sheds new light on preparing high purity materials.

Key words: Inclusion motion, Inclusion removal, Electrode tip, MC-ESR, X-ray microtomography

Yifeng Guo, Zhibin Xia, Qiang Li, Mingyue Sun, Weifeng Liu, Shaogang Wang, Zhe Shen, Tianxiang Zheng, Biao Ding, Yunbo Zhong. Motion and removal behavior of inclusions in electrode tip during magnetically controlled electroslag remelting: X-ray microtomography characterization and modeling verification[J]. J. Mater. Sci. Technol., 2022, 96: 1-10.

Figures/Tables 12

Table I. Chemical compositions of the consumable electrode (GCr15 steel) used in this study (mass percentage, %).

C	Si	Cr	Mn	Al	S	P
0.990	0.250	1.430	0.300	0.014	0.006	0.006

Fig. 1. (a) Schematic diagram of the remelting apparatus (1 mechanical apparatus, 2 consumable electrode, 3 water-cooled mold, 4 MF generator, 5 slag pool, 6 droplets, 7 metal pool, 8 ESR ingot, 9 water-cooled baseplate), (b) The obtained electrode tip and ESR ingot, (c) Schematic diagram of sampling method for macro/micro-structure and inclusion detection (type) in electrode tip, (d) Schematic diagram of sampling method for 3D characterization of inclusion in electrode tip, (e) Schematic diagram of the 3D X-ray experiment, respectively.

Fig. 2. Macrostructures of the longitudinal section of the electrode tip under different experimental parameters, (a) 700A without ASMF, (b) 700A with ASMF respectively.

Fig. 3. The enlarged views of the featured areas in electrode tip, (a) Electrode matrix, (b) MZ and LMF, (c) 3D characterization of the shrinkage porosity in MZ, respectively.

Fig. 4. 3D characterization of inclusions at different regions in LMF (with or without ASMF) in this study, (a) Mid region without ASMF, (b) Half-radius region without ASMF, (c) Edge region without ASMF, (d) Mid region with ASMF, (e) Half-radius region with ASMF, (f) Edge region with ASMF, respectively.

Fig. 5. Statistical results on the number of inclusions (different size) in different regions of LMF (with or without ASMF) in this study, (a) Mid region without ASMF, (b) Half-radius region without ASMF, (c) Edge region without ASMF, (d) Mid region with ASMF, (e) Half-radius region with ASMF, (f) Edge region with ASMF, respectively

Fig. 6. Statistics results on the probability of inclusions (different size) in different regions of LMF (with or without ASMF) in this study, (a) Mid region without ASMF, (b) Half-radius region without ASMF, (c) Edge region without ASMF, (d) Mid region with ASMF, (e) Half-radius region with ASMF, (f) Edge region with ASMF, respectively.

Fig. 7. 3D characterization of inclusions at different regions in MZ (with or without ASMF) in this study, (a) Mid region without ASMF, (b) Half-radius region without ASMF, (c) Mid region with ASMF, (d) Half-radius region with ASMF, respectively.

Fig. 8. 2D morphologies and types of the inclusions in Matrix, MZ and LMF (with or without ASMF) in this study, (a) (b) and (c) SiO2, (d) and (e) Al2O3, (f) TiN, respectively.

Fig. 9. Schematic diagrams of microstructure evolution and motion behavior of inclusions in electrode tip in this study, (a) Without ASMF, (b) With ASMF, respectively.

Fig. 10. Schematic diagram of the FS driving inclusions to LSI and geometric model adapted in this study, MLI: MZ/LMF interface, LSI: LMF/slag interface, VLSI: flow velocity of LSI, FD: drag force, FB: buoyancy force, GI: gravity force, FS: Saffman force, respectively.

Fig. 11. Simulation results of the motion trajectory of inclusions (in different size, type or density, release position of MLI) in LMF in this study, (a) SiO2 in ESR, (b) SiO2 in MC-ESR, (c) Al2O3 in ESR, (d) Al2O3 in MC-ESR, (e) TiN in ESR, (f) TiN in MC-ESR, respectively.

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