Regulating the Non-Metallic Inclusions by Pulsed Electric Current in Molten Metal

doi:10.11900/0412.1961.2019.00391

Acta Metall Sin

2020, Vol. 56

Issue (3): 257-277 DOI: 10.11900/0412.1961.2019.00391

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Regulating the Non-Metallic Inclusions by Pulsed Electric Current in Molten Metal

ZHANG Xinfang(

),YAN Longge

State Key Laboratory of Advanced Metallurgy, School of Metallurgical and Ecological Engineering, University of Science and Technology Beijing, Beijing 100083, China

Cite this article:

ZHANG Xinfang, YAN Longge. Regulating the Non-Metallic Inclusions by Pulsed Electric Current in Molten Metal. Acta Metall Sin, 2020, 56(3): 257-277.

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Abstract

Non-metallic inclusions generally reduce the properties of steels, such as reducing transverse mechanical properties, initiating cracks, reducing fatigue life and inducing corrosion. Reducing the number and changing the morphology of inclusions can significantly improve the performance of steels. Therefore, inclusion removal and its morphology control in steel have always been the focus issue. Although the bottom-blown argon, electromagnetic stirring and filtration can remove inclusions to a certain extent, these methods are difficult to effectively remove inclusions smaller than 20 μm in size and cannot effectively control the morphology of the inclusions. Recently, electric current has become a new method for inclusion removal and morphology control. This article briefly reviews the hazards of inclusions and their control methods, and reviews the effects of current on the removal, orientation and morphological evolution of inclusions in metal melts in detail, and introduces three mechanisms of current-controlled inclusion separation: electrophoresis, electrical free energy driving and electromagnetic repulsion. Electrophoresis theory believes that inclusions in the melt are charged, and they migrate parallel to the direction of the current under the action of the electric field force. While the electrical free energy driving and electromagnetic repulsion hold that inclusions migrate perpendicular to the direction of the current. The current waveforms significantly affect the removal efficiency of inclusions. Compared with direct current and alternating current, the pulsed electric current has a stronger ability to remove inclusions, especially pulsed electric current can effectively separate inclusions with a size larger than 5 μm in the molten steel. In addition, the pulse current can not only control the orientation and morphology of the inclusions, but also affect the morphology of the bubbles; the inclusions tend to be refined, spheroidized and arranged parallel to the current under the action of the pulse current. Finally, the research status of current-controlled inclusion separation is summarized, and future research trends are analyzed. At the same time, the application and prospect of pulsed current in anti-clogging of submerged entry nozzle was also analyzed. Due to the low energy consumption, excellent inclusion removal efficiency and easy process equipment, pulsed current separation technique is expected to become a new technology for removing inclusions and suppressing nozzle blockage in the future.

Key words: electropulsing inclusion removal inclusion morphology submerged entry nozzle clogging

Received: 15 November 2019

ZTFLH:

TF704.7

Fund: National Natural Science Foundation of China(U1860206);National Natural Science Foundation of China(51874023);National Natural Science Foundation of China(51601011);Fundamental Research Funds for the Central Universities(FRF-TP-18-003B1);Recruitment Program of Global Experts

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https://www.ams.org.cn/EN/10.11900/0412.1961.2019.00391 OR https://www.ams.org.cn/EN/Y2020/V56/I3/257

Fig.1 Schematics of typical current forms(a) alter current (b) attenuating pulsed current(c) sharp waves (d) rectangular waves

Fig.2 Electrode insertion methods(a) horizontal (b) vertical

Fig.3 Separation of inclusions by electromagnetic repulsive (F—electromagnetic body force, B—magnetic intensitie, F_p—electromagnetic force acting on a spherical inclusion)

Fig.4 Migration of inclusions with different charges toward to the electrodes

Fig.5 Current distributions without inclusion (a) and around inclusion (b) in molten metal

Fig.6 Migration of inclusions in the direction of perpendicular to current

Fig.7 Molten salt electrolyte process (1—cathode, 2—metal liquid, 3—flow, 4—refining slag, 5—anode, 6—tundish)

Fig.8 Trajectory of nonmetallic inclusions in molten metal treated by electric current(a) diagram of inclusion migration(b) distribution of SiC particles(c) SiC particles migration to edge from centre by applying current

Fig.9 Circular pipe (a) and square pipe (b) (I—electric current, v—velocity of liquid metal in pipe)

Fig.10 Comparisons of effects of circular pipe and square pipe on efficiency of inclusion removal under electric current (d—diameter of the inclusion)^[56]

Fig.11 Three effects of inclusion driven by electric current^[49](a) electric free energy change when the inclusion is located at different positions (η=σ_p/σ_m, σ_p is conductivity of inclusion, σ_m is the conductivity of matrix, and η is conductivity ratio)(b) the force acting on inclusion (P—pushing, T—trapping, E—expelling)

Fig.12 Number distributions of inclusions in liquid metal without and with current treatment^[49]

Fig.13 The number distributions of Al₂O₃ (a, b) and MnS (c, d) in steels without (a, c) and with (b, d) pulse current treatment^[67]

Fig.14 Particle size distributions of MgO inclusions on the middle part of the sample before and after electric pulse treatment

Fig.15 Schematic configurations of MnS particle before and after application of an electric current^[74](a-1~a-3) strip inclusions rotate parallel to current(b-1~b-3) chain-like inclusion by aggregation of three smaller inclusion(c-1~c-3) spherical inclusions become strip inclusions

Fig.16 Fatigue crack initiation from different configurations of the MnS particles^[74](a) cracks are along single ellipsoidal MnS inclusion when the load axis is perpendicular to the sulphide(b) cracks emanates from the chain-like type MnS inclusions when the load axis is perpendicular to the sulphides(c, d) no crack emanates from the sulphide when the load axis is parallel to the particles

Fig.17 Ellipsoidal particles suspended in melt metal^[77]Color online(a) only one particle submerged in the matrix with angle of inclination θ to electric field direction and the normal vector n(b) 173 ellipsoidal particles with random orientation(c) 173 particles with some extents of preferred orientation toward vertical direction(d) 173 aligned particles along current flow direction

Fig.18 Property changes during the rotation of ellipsoidal particle(a) the electric-current-induced torque is dependent on θ^[77](b) changes of electrical resistivity and electric current free energy during the rotation of ellipsoidal particle

Fig.19 Interaction between inclusions caused by electric current(a) position of the inclusions in polar coordinates (j—current density; P(ρ, θ_t)—coordinates of inclusion in polar coordinates; P(0, 0)—origin coordinates of another inclusion; θ_t—angle between the arrangement direction of the inclusions and the current direction)(b) fore induced by current (F_et—tangential force acting on inclusions; F_er—radical force acting on inclusions)^[79]

Fig.20 Schematic of inclusions interaction^[79](a) interaction mechanism of inclusion in current fields(b) attraction and rotation resulting in the agglomeration of inclusions(c) inclusions apart from each other by repulsion in rotation

Fig.21 The morphologies and distributions of inclusion in steel^[79]Color online(a) the spherical MnS in sample untreated by pulsed electric current(b) the chain like MnS in sample treated by pulsed electric current

Fig.22 Schematics of morphological evolution of MnS in steel after pulsed electric current treatment and rolling(a) randomly oriented inclusions and its evolution after rolling(b) inclusions MnS with specific orientation by applying pulsed electric current during solidification and its evolution after rolling

Fig.23 Distributions of inclusions in steel^[49,87]

Fig.24 Analysis of force acting on inclusions on bubble surface(a) surface force acting on inclusion (collision and sliding) without current (F_s—surface force caused by the deformation of the bubble surface)(b) forces acting on inclusion with current (F_d—driving force induced by electric current)

Fig.25 Changes of relative density and the inclusions layer thickness along with the applying of pulse current^[108]

Table 1 Summary of parameters for current removal inclusions^{[34,45,49,51,52,53,55,57,58,59,62,66,69,72,108,109]}

Fig.26 Inclusion removal efficiency of different current types^{[34,49,54,56,57,58,68,69]}

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