CLEAN STEEL

WHAT IS IT??
• Steel which is free from inclusions.
• Inclusions are non metallic particles
embedded in the steel matrix.
• Practically it is not possible to produce steel
without any inclusion.
• Inclusion size and concentration are most
important.
Inclusion vs clean steel
 Types of Inclusions
Inclusions are chemical compounds of metals like (Fe, Mn, Al, Si,
Ca etc) with non metals (O, S, N, C, H). Different types are:

Types Example
Oxides FeO,Al2O3,SiO2,MnO,Al2O3.SiO2,FeO.Al2O3,MgO.Al2O3,MnO.SiO2

Sulphides FeS,CaS,MnS,MgS,Ce2S3
Nitirides TiN, AlN, VN, BN

Oxysulphides MnS.MnO,Al2O3.CaS
Carbonitrides Titanium/ vanadium/Niobium carbonitirides,
Phosphides Fe3P,Fe2P,Mn5P2
 Types of Inclusions
oxygen inclusions are classified:

Types Example
Free oxides FeO,MnO,Cr2O3,SiO2(quartz)Al2O3 (corundum) and other;

Spinels Ferrites, chromites and aluminates

Silicates SiO2 with a mixture of iron, manganese,
chromium, aluminum and tungsten oxides and
also crystalline silicates.
Inclusion vs steel properties
Morphology of Inclusions
 Morphology of Inclusions
Globular shape is desirable. Certain inclusions like MnS,
oxysulphides, iron aluminates and silicates are globular.

Polyhedral inclusions are not very harmful.

Platelet shape: undesirable. Al deoxidized steels contain MnS in the

form of thin films located along the grain boundaries.
 Morphology of Inclusions

Calcium aluminate in A529 steel

 Morphology of Inclusions

Manganese sulfide in A529 steel

Morphology of Inclusions

Faceted Al2O3 inclusion in steel

 Size of inclusions
There are micro inclusions(size 1−100 μm) and
macro-inclusions (size greater than100 μm).
 Micro inclusions are beneficial as they restrict grain
growth,
 increase yield strength and hardness.
 Micro- inclusions act as nuclei for precipitation of carbides
and nitrides.
 Macro- inclusions must be removed.
 Micro inclusions can be used to enhance strengthening by
dispersing them uniformly in the matrix.
 Properties of inclusions:
i) Thermal expansion.

 An inclusion is a mismatch with the steel matrix. There are

inclusions like MnS, CaS, etc. which have thermal
expansion greater than steel matrix. On heating steel with
these types of inclusions voids or parting of the matrix can
occur. The void can act as cracks.

 On the other hand Al2O3,SiO2 and CaO.Al2O3, etc

inclusions have thermal expansion smaller than steel
matrix. On heating steels with these type of inclusions
internal stresses of thermal origin can develop.
 Properties of inclusions:
II) Density and melting point
 Properties of inclusions:
iii) Plastic deformability

The plastic deformability of an inclusion will govern any

change in its shape under the action of external forces
and will determine the amplitude of stress concentration.

Brittle inclusions are dangerous as they may crack and

cause fracture of the component under the application of
external force. The majority of inclusions belong to
pseudo-ternary system:
CaO−SiO2−Al2O3,MgO−SiO2,−Al2O3 CaO−SiO2−Cr2O3
etc.
 Properties of inclusions:
iii) Plastic deformability

Sulphide inclusions are mainly MnS. Other elements like

Ti, Zr, rare earths, Nb, V etc. usually appear as solid
solutions in existing inclusion phases. The following
classification of inclusions according to kieslling is useful
to the metallographers to determine type of inclusions .
 Properties of inclusions:
I) Calcium aluminates and Al2O3 inclusions in steel are
undeformable at temperatures of interest in steelmaking.
(ii) Spinel type double oxides AOB2O3 (where A is Ca, Fe(l), Mg and
Mn,and B is Al,(Cr etc) are deformable at temperatures greater
than1200℃ .
(iii) Silicates are deformable at higher temperature range. The
extent of deformation depends on their chemical compositions.
Silicates are not deformable at room temperature.
(iv) FeO, MnO and (Fe, Mn) O are plastic at room temperature but
gradually lose plasticity above 400℃.
(v) MnS which is highly deformable at 1000℃ temperature but
becomes slightly less deformable above 1000℃ .
(vi) Pure silica is not deformable up to 1300℃ .
 Inclusion assessment
Inclusion counts are performed to assess their shape, quantity and
distribution to assess about the cleanliness of steel.

Inclusion Analysis
Sample preparation

Qualitative Assessment Quantitative Assessment

• Dissolution of matrix by
SPEED method
• Inclusion species and
morphology study by
SEM and EDS
• Image acquisition by SEM –
Back scattered electron mode
• Inclusion counting by
image analysis
 Inclusion assessment
The energy dispersive x-ray analysis (EDX) attachment for SEM
allows quantitative chemical analysis of inclusion as well as
quantitative mapping of distribution of various elements in and
around the inclusions.

Quantimet has an optical microscope fitted with video screen and

associated microprocessor-based instrumentation. It can scan the
specimen very quickly and provide a variety of information such as
inclusion size, distribution, number, volume fraction, etc.

Total oxide inclusion content of steel can be determined from the

analysis of oxygen by sampling and the use of vacuum /inert gas
fusion apparatus.
Source of Inclusion Formation
Mechanism of inclusion formation:

Indigenous inclusions are formed in liquid,

solidified or solid steel as a result of chemical
reactions (deoxidation, desulfurization) between
the elements dissolved in steel.

Exogenous inclusions are derived from external

sources such as furnace refractories, ladle lining,
mold materials etc.
 Inclusion Source & Control
 Source of Inclusion:

I. Primary inclusions: generated during deoxidation reaction

II. Secondary inclusions: generated due to equilibrium shift
as temperature decreases during vessel transfer, such
as tapping and teeming operations
III. Tertiary inclusions: generated during the process of
solidification, usually characterized by rapid cooling
IV. Quaternary inclusions: generated during solid state
phase transformation, which causes changes in
solubility limits of various constituents
 Inclusion Formation
There are three stages of inclusions formation:

1. Nucleation
Nuclei formed as a result of super-saturation of the solution with the solutes
The nucleation process is determined by surface tension on the boundary
inclusion-liquid steel.
The nucleation process is much easier in the presence of other phase (other
inclusions) in the melt.
2. Growth
Growth of a separate inclusion continues until the chemical equilibrium is
achieved (no super-saturation).
very slow process
3. Coalescence and agglomeration
Motion of the molten steel due to thermal convection or forced stirring
causes collisions of the inclusions, which may result in their
coalescence (merging of liquid inclusions) or agglomeration (merging of
solid inclusions)
 Distribution of Inclusion
 Homogeneous distribution of small inclusions is the
most desirable type of distribution.
 Location of inclusions along the grain
boundaries is undesirable since this type of
distribution weakens the metal.
 Clusters of inclusions are also unfavorable since
they may result in local drop of mechanical properties
such as toughness and fatigue strength.

• Distribution of non-metallic inclusions may change

as a result of metal forming (eg. Rolling).
Distribution of Inclusion
 Control of Inclusion
 Inclusion can be controlled at:
a) During liquid steel processing
stage
b) During solid state processing
 Control of Inclusion
i) Control of inclusion during tapping of steel
• Carry-over slag to be minimized
- Carry over of 1 kg FeO in slag decrease Al by
0.286 kg , which in turn forms 0.51 kg Al2O3
- No. of inclusion are 240 per kg of carry over
FeO of slag
ii) Control of inclusion during treatment of steel
 Stirring of steel bath accelerate the inclusion
float to surface
 Control of Inclusion
iii) Control of inclusion during teeming of steel
• Shrouding of molten steel stream in order to
avoid re-oxidation.
• Proper selection of tundish flux.
• Segregation during solidification to be avoided
iv) Control of inclusion during Solid state
processing.
 Working temp range 800-1200oC.
 Inert atmosphere to avoid oxidation.
 Inclusion Modification
 Depends on application, Inclusion Modification
Technique is based on design of inclusions so
as to minimize their harmful effects on the
product properties.

 Uniformly dispersion of inclusion in the matrix

Requirement for Inclusion Modification
 It should have high chemical affinity for the
inclusion
 It should be able to modify the composition so
that it becomes liquid.
 It should be able to modify the shape i.e sharp
edges and corner of inclusion to spherical.
Ca-treatment for inclusion modification
 It should have high chemical affinity for the
inclusion
 It should be able to modify the composition so
that it becomes liquid.
 It should be able to modify the shape i.e sharp
edges and corner of inclusion to spherical.
Ca-treatment for inclusion modification
• Mainly Al2O3 and MnS inclusions are modified
• Al2O3 inclusions are solid at casting
temperature & brittle in nature. Therefore clog
the nozzle at continuous casting and breaks on
deformation

• MnS inclusion in steel on deformation becomes

stringer type.

• Ca is used widely to modify inclusion

Ca-treatment for inclusion modification
• Ca first modify the oxide inclusion
• Thermodynamically it is easier to form CaO.2Al2O3
Then converted to CaO.Al2O3 and finally liquid
calcium aluminate rich in CaO
• Then Ca desulphurise to very low levels.
• When Ca content reach a certain level (~34ppm),
CaS precipitation begins
• This will result in precipitation of CaS which forms a
duplex inclusion in which CaS-MnS ring surrounds
calcium aluminate core. This type of inclusion is
spherical and does not elongate.
Ca-treatment for inclusion modification

Oxide inclusions found in ladle tap sample: calcium aluminate

 Conclusions
 It not always important to remove the inclusion
from steel, however , the bigger size inclusion are to
be removed.

 Smaller size inclusion is not all the time required

that can be removed, however, if those inclusions
can be modified in terms of their melting point, or in
terms of their sharp edges or corner edges modified
to spherical globule, then it will be good. From
application point of view , they will not have a
harmful effect.