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non-metallic non-metallic reviewed, reviewed,

2) 2)

process process micro micro

In In

Traditionally, Traditionally,

regarded regarded

deoxidation deoxidation

ferroalloys ferroalloys recognised; recognised;

recently, recently,

terms terms

3) 3)

solidification solidification

basis. basis.

iron

modification modification new new

customers' customers'

overriding overriding

as as 1) 1)

presented presented

industry industry

the the development development

about about

crystal crystal

demonstrated. demonstrated.

from from

rely rely

product product Many Many

This, This,

ferroalloys. ferroalloys.

in in

impurities impurities

control, control,

iron iron

inoculants inoculants

the the

potential potential

Department Department

Department Department

Elkem Elkem

Trondheim, Trondheim,

and and

on-going on-going

structure structure

ferroalloy

in in

much much

of of

of of

new new

In In

and and

structure. structure.

present present

tum, tum,

1. 1.

quality quality

the the

steel

composition, composition,

the the

and and

towards towards

in in

the the

with with

of of

as as

ASA, ASA,

and and

steelmaking steelmaking

concern concern

ABSTRACT ABSTRACT

specifications specifications

particularly particularly

ideas ideas

in in

success success and

important important

of of

different different

has has

on on

Process Process

inclusions inclusions

and and

and and

manufacturing manufacturing

particular particular

Some Some

paper, paper,

and and

academia academia

research research

bulk bulk

heterogeneous heterogeneous

particular particular

INTRODUCTION INTRODUCTION

iron iron

the the

minor minor

shifts shifts

affect affect

product product

Norway. Norway.

ferroalloys ferroalloys

paper paper

of of

of of

an an

This, This,

c/o c/o

the the

improved improved

about about

in in grain grain

0ystein 0ystein

Metallurgy, Metallurgy,

Materials Technology Technology Materials

inclusion inclusion

impact impact

has has

collaboration collaboration

principal principal

evolution evolution

products products

Elkem Elkem

end. end.

and and

results results

the the

in in

elements elements

size size

role role

alloying alloying

in in

projects, projects,

are are

the the

developments developments

their their

of of

been been

refiners refiners

The The

ferroalloy ferroalloy

that that

ferrous ferrous

on on

developments developments

emphasis emphasis

tum, tum,

the the

and and

solid solid

the the

supplied supplied

steel steel

and and

the the

on on

of of

Grong

future future

Thamshavn, Thamshavn,

has has

a a

chemistry chemistry

ability ability

are are

compositional compositional

guidelines guidelines

ferroalloys ferroalloys

ferroalloys ferroalloys

have have

form form

Future Future

to to

approach approach

demands demands

has has

costs. costs.

to to

content content

where where

multilateral multilateral

where where

nucleation. nucleation.

KTH, KTH,

elements elements

state state

metallurgy metallurgy

been been

has has

through through

presented presented

meet meet

be be

1

resulting resulting

between between

, ,

role role

on on

brought brought

product product

through through

Par Par

to to

during during

during during

Iron Iron

added added

More More

by by

been been

been been

fully fully

both both

how how

S-100 S-100

acts acts

and and

and and

the the

the the

are are

are are

Role Role

for for

J0nsson

of of

in in

in in

of of

in in

a a

a a

1

PO PO

. .

and and

and and

44 44

Box Box

of of

Electroch~mistry, Electroch~mistry,

2 2

Stockholm, Stockholm,

Steel Steel

Ferroalloys Ferroalloys

and and

the the

refiners refiners

terms terms

on on

greater greater

production, production,

The The

presented presented

clearly clearly

made made

alloy

and and

in in

finished finished metallic metallic

further further

fabrication fabrication

thermomechanical thermomechanical

resulting resulting

can can

transformations transformations

create create

solidification solidification

producer producer

different different

opportunity opportunity

authors authors

The The austenite

materials materials

properties properties

11. 11.

inoculants inoculants

ensure ensure

in in

castings castings

2. 2.

10, 10,

ferrous ferrous

accordance accordance

the the

future future

The The

act act

Ole-Svein Ole-Svein

N-7301 N-7301

present present

steelmaker steelmaker

modifications modifications

of of

demand demand

in in

background background

derive derive

that that

or or

uniformity uniformity

as as

working working

and and

essence essence

REFINING REFINING GRAIN

), ),

opinion opinion

inclusions inclusions

for for

to to

below below

role role

developing developing

stricter stricter

types types

heterogeneous heterogeneous

materials materials

mechanical mechanical

with with

Sweden. Sweden.

introduce introduce

of of

the the

products products

and and

modify modify

is is

paper paper

wrought wrought

without without

for for

Orkanger, Orkanger,

iron iron

from from

iron iron

shaped shaped

of of

and and

with with

Klevan

overall overall

in in

NTNU, NTNU,

derive derive

steadily steadily

of of

of of

for for

ferroalloys ferroalloys

because because

optimum optimum

(e.g. (e.g.

grain grain

the the

this this

quality quality

to to

processing processing

summarises summarises

and and

these. these.

of of

and and

the the

ranging ranging

subsequent subsequent

or or

and and

in in

the the

microstructures microstructures

the the

steel steel

castings castings

standard standard

inoculants inoculants

innovative innovative

submicroscopic submicroscopic

the the

higher higher

represents represents

3 3 possibly possibly

performance performance

from from

the the

graphite, graphite,

higher higher

compromising compromising

problem problem

properties. properties.

refiners refiners

existing existing

by by

Norway Norway

N-

nucleation nucleation

future future

steel steel

steel. steel.

specifications specifications

needs needs

products. products.

the the

becoming becoming

7 7

liquid liquid

combination combination

be be must

from from

a a

491 491

and and

OF OF

broad broad

and and

purity. purity.

requests requests

means means

the the

performance performance

demand demand

making making

new new

stocks stocks

The The

is is

solid solid

of of

qualities qualities

in in

and and

ferrite ferrite

welding welding

ferroalloy ferroalloy

STEELS

ferroalloy ferroalloy

a a

steel steel

slabs slabs

progress progress

either either

the the

sites sites

is is

interest interest

In In

viewed viewed

shaped shaped

golden golden

grades grades

during during

Thus, Thus,

ideas ideas

grain grain

more more

more more

non­

state state

iron iron

and and

that that

for for

the the

for for

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for for

for for

for for

of of

or or

to to

to to

of of

to to

l- 56~ 56~

;563 ;563

Typically, Typically,

resulting resulting

commercial commercial MnO MnO

is is

the the

reactions reactions

Mn Mn

conventional conventional

during during

These These inclusions inclusions

about about

oxygen oxygen MnS MnS

commonly commonly

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distribution distribution

former former

FeMn, FeMn,

14, 14, casting casting

2.1.1 2.1.1

customers' customers'

composition

regarded regarded

overriding overriding Traditionally

2. 2.

production production

designed designed

heavily heavily

new new distribution distribution

inclusion inclusion ferroalloy ferroalloy

of of

are are

refiners refiners

and and

and and

microstructure microstructure

available available

by by

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critical. critical.

. .

15 15

1 1

is is

rather rather

the the

present present

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. .

thus thus

aluminium

and and

resulting resulting

p or or

well well

0.5 0.5

cooling cooling

systems systems

1gure 1gure

· ·

final final

produced produced

group group

Alloy Alloy

and and

solubility solubility

Ferroalloys Ferroalloys

development development

property property Characteristics Characteristics

the the

MnS MnS

Since Since

on on

size size

between between

methods, methods,

interesting interesting

grain grain

(or (or the the

% %

for for

form form

coarse; coarse;

as as

chemical chemical

found found

used used

established established the the

industry, industry,

by by

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in in

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FeCr FeCr

specifications specifications

the the

products products

0 0

of of

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resulting resulting

casting casting

distribution distribution

size size

being being inoculants) inoculants)

oxide oxide

steels, steels,

cleanliness cleanliness

the the

MnO-SiOi-MnS MnO-SiOi-MnS

the the

refiner. refiner.

a a

shows shows

bulk bulk

by by

are are

during during

mechanical mechanical

size size

naturally naturally to to

oxides oxides

alloys alloys

12 12

chances chances

profile profile

ferroalloys ferroalloys

late late

by by

in in

and and

rate rate

. .

alloys. alloys. mould mould in in

and and

weight weight

0 0

grain grain

control control

characterised characterised as as

and and

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commercial commercial

marked marked

has has

At At

means means

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contain contain

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composition composition

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addition addition

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costs

products products

4

examples examples

operation

mechanical mechanical

' '

FeMn FeMn

where where

that that

shown shown

opposed opposed

13

can can

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size size

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a a

present, present,

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liquid liquid

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casting casting

. .

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of of

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both both

or or

full are are

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. .

properly properly

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with with

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in in

higher) higher)

properties, properties,

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sulphides, sulphides,

-

important important

microstructure microstructure inclusions inclusions

is is

such such

success success

of of

scale scale

an an

commercially commercially

conventional conventional

have have

. .

to to

prior prior

steel steel

Cr

in in

state state represents represents

of of

Cr Cr

where where

MC MC

between between

to to

be be

is is

Candidate Candidate

respect respect

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by by owing owing

inclusions inclusions

inclusions inclusions

2

FeCr FeCr

properties properties

meet meet 0

no no

and and

complex complex

remedies remedies

specially specially

low, low,

Fig. Fig. cast cast

be~ause be~ause intrinsic intrinsic

obtained obtained

adjusted adjusted

3

Si Si

controls controls

14

a a

to to

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for for

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relies relies

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stee

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size size

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2. 2.

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to to

to to

2 5 5

a a

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l l

inclusion inclusion

ferroalloy ferroalloy

solidification solidification

dissolution dissolution

considering considering

characteristics, characteristics,

applied applied

identity, identity,

ferroalloy ferroalloy

liquid liquid

transferred transferred

of of liquid liquid

When When

a a 15

2.1.2 2.1.2

LC LC

Fig

inclusions inclusions

unsuitable unsuitable

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. .

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0

0.6% 0.6%

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0.9% 0.9% the the

. .

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and and

2 2

50µm 50µm

steel steel

,-

a a

ferroalloy, ferroalloy,

MC MC

inclusions inclusions

distribution distribution

Dissolution Dissolution

Size Size

properly properly

steel, steel,

-

but but

coarsening. coarsening.

A A

prior prior

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14

their their

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B B

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Ferromangan

0 0

D D • •

• •

of of

behaviour behaviour

refining refining

ferroalloy ferroalloy liquid liquid

possible possible

on on

DP DP

the the

DH DH

DT DT DM DM

c c

dissolution dissolution

inclusions inclusions

deoxidation deoxidation

inc eventually eventually

( (

(3.4-6

( (

(6.7-1

ferroalloy ferroalloy

>26

1

as as

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ese ese

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µm) µm)

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time time

µm) µm)

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µm) µm)

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of of

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to to

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Sjoqvist Sjoqvist

non

control control

of of

such such

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is is

rate rate

loose loose

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excessive excessive

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addition addition

practice practice

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11

metallic metallic

-~ -~

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15

the the

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be be

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of of

to to

14 • •

r r

r r

r r

2.1.3 2.1.3

will will

Controlled Controlled

Ce

Fig. Fig.

ferrous ferrous

and and

shown shown

alloying alloying

elements elements temperature, temperature,

properties. properties.

quenched quenched but but

Therefore, Therefore,

After After

Fig

inclusions inclusions

supersaturated supersaturated

inclusions inclusions become become

in in

inclusions inclusions

submicroscopic submicroscopic

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1600°C. 1600°C.

Fig. Fig.

2

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::;; ::;;

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m m

c:: c::

0

3 3

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coarsening coarsening

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occur occur

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3 3

Grong Grong

.

3 3

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5 5

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30

20 20

that that

\ \

Data Data

alloy alloy

Inclusion Inclusion

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detrimental detrimental

technique technique

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gradually gradually

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solution solution

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laboratory laboratory

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experiments experiments

min min

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1.5 1.5

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1

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2.1.4 2.1.4

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casting casting

future future

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ferroalfoys ferroalfoys

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and/or and/or

distribution distribution

enormous. enormous.

ferroalloy ferroalloy oxides oxides

desirable desirable

oxides oxides direction direction

performance performance

castings castings

number number

weldability weldability

marked marked of of

austenite austenite

of of

has has costs. costs.

undercoolings. undercoolings.

presented presented

2.2.1 2.2.1 As-cast As-cast

potential potential

away away depend depend

microstructures microstructures

microstructure microstructure

coarse coarse materials materials solidification solidification

requirements requirements

800 800

steels steels

• •

the the

ferrite ferrite

shown shown

been been

exploit exploit

million million

is is

deep deep

too too

world-wide world-wide

demand demand

sulphides sulphides

readily readily

are are

by by

technique. technique.

and and

Potential Potential

rates rates

developments developments

In In

may may

As-cast As-cast

Grain Grain

for for

on on

density density

columnar columnar

upon upon

and and

of of

to to

with with

steels steels

or or

for for

that that

above above

or or

during during

where where

known known

much much

by by

in in

retained, retained,

qualities, qualities,

sulphides sulphides

such such

increase increase

the the a a

practice, practice,

austenite austenite

tonnes tonnes

is is

involved involved

exceed exceed

the the

can can

systematically systematically

can can

wrought wrought

microstructure. microstructure.

modification modification

delta delta

achieved achieved

3

Size Size

the· the·

Fig

these these

understanding understanding

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for for

process process

the the

soft soft

Both Both 21

has has

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of of

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22

the the

steel steel

circumstantial circumstantial

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grain grain

also also

Control Control

finely finely

. .

4, 4,

iron. iron.

enabled enabled

and and

per per

strength strength

for for

ferrite ferrite

characteristics characteristics

grain grain

10

promote promote

in in

toughness, toughness,

possible possible

alloys alloys

the the

3

as as

in in

prime prime

REM REM

properly properly

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where where

be be

these these

steel steel

8 8

properties properties

owing owing

in in

accordance accordance

A A

production production

all all

steels steels

year, year,

treatment treatment

particles particles

well well

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of of

A A

ability ability

where where

be be

steel steel

of of

met met

similar similar

dispersed dispersed

new new

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of of

in in

major major

contain contain

at at

structure structure

products. products.

the the

an an

without without

(Ce (Ce

the the

to to

homogeneous homogeneous

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In In

examples examples

as as

contradictory contradictory

obtained obtained

Steels Steels

the the

by by

1

weld weld

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1

at at

very very

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appropriate appropriate

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point point

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20

with with

steelmaker steelmaker

Zr Zr

general, general,

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in in

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designing designing

minimum minimum

per per

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objective objective

and and

evidence evidence

balanced balanced

achieved achieved

potential potential

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of of

product product

property property

nucleate nucleate

with with

In In

existing existing

number number

metals, metals,

of of

overall overall

and and

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oxides oxides

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about about

small small

mm

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good good

view view

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high high

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La) La)

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Ti Ti

of of

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1s 1s

3

a a

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. . 56L 56L

565 565

significantly significantly

further further initial initial sheet, sheet,

quality quality

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Due Due

phase phase

• •

• •

• • observed: observed:

• •

their their

solidification solidification

in in

- carbon-manganese

quite quite microstructures microstructures

Experience Experience

hot hot grain grain

line line

formation

Depending Depending

override override

improved improved equiaxed equiaxed

Fig. Fig.

equiaxed equiaxed heterogeneous heterogeneous

equiaxed equiaxed shown shown

presence presence

of of

potent potent

inevitably inevitably

Primary Primary

Primary Primary

peritectic peritectic Primary Primary

Primary Primary

chemical chemical

the the

segregation. segregation.

5 5

to to

cracking cracking

of of

higher higher

size size

grain grain

plate, plate,

Grains Grains

Columnar Columnar

transformations, transformations,

different different

the the

steels. steels.

schematically schematically

heterogeneous heterogeneous

of of

working working

grain grain solidifying solidifying

Schematic Schematic

grains grains

13

and and

grains grains

castability castability

grain grain

the the

absence absence

of of

, ,

size. size.

shaped shaped

tube, tube,

austenite austenite

ferrite ferrite

ferrite ferrite

ferrite ferrite

alloy alloy

improved improved

evolve evolve

which, which,

upon upon

has has

transformation transformation

resistance) resistance)

refining refining

.,. .,.

reduced reduced

Both Both

effective effective

ahead ahead

composition. composition.

nucleation nucleation

modes modes

of of

inherent inherent

form form

from from

structure structure

bar, bar,

to to

Grains Grains

Equiaxed Equiaxed

shown shown content content

and and formation formation

or or

formation formation

of of

the the

castings castings

high high

front front

in in

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of of

upon upon

/J.T /J.T

formation formation

in in

(e.g. (e.g.

standard standard low low

subsequent subsequent

wire wire

directly directly

problems problems

by by

nucleation nucleation

austenite austenite in in

columnar columnar

turn, turn,

there there

diagram diagram

those those

Fig. Fig.

castability castability

circumstances, circumstances,

seed seed

"' "'

alloyed alloyed

fully fully through through

a a

alloy alloy

are are

and and

/'iTn /'iTn

that that

are are

hot hot

columnar columnar

and and

may may

and and

reduction reduction

solidification solidification

to to

gives gives

5. 5.

II> II>

II> II>

and and

is is

followed followed Four Four

absent. absent.

in in

of of

austenite austenite

broader broader

crystals, crystals,

austenitic austenitic

ductility ductility

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lO(a), lO(a),

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to to

resulting resulting

·

at at

W0

balanced balanced in in

liquid liquid

c

MgS, MgS,

(e.g. (e.g.

·

of of

Si01 Si01

the the

or or

1 1

complex complex

in in

that that

5wt% 5wt%

'

1 1

'" '"

is is

the the

inoculation inoculation

product product

of of

hexagonal hexagonal

ductile cast cast ductile

ductile ductile

Sr Sr

a a

FeSi. FeSi.

formation formation

4

role role

this this

structure structure

. .

liquid liquid 3

after after

aimed aimed

formers formers

by by

·2Si0

high high

the the

documented documented

CaS, CaS,

Fig

ferrosilicon

4

sulphides sulphides

after after

The The

iron iron

surface surface

' '

the the

heterogeneous heterogeneous

the the

41

reaction reaction

Mg, Mg,

using using

After After

of of

-

additions additions

. .

nature nature

43

cast cast

nodularizing nodularizing

magnesium magnesium

mechanical mechanical

44

dominating dominating

number number

MgO·Si0

lO(b). lO(b).

2 2

inoculation inoculation

. .

castability castability

inclusions inclusions

iron, iron,

the the

. .

at at

after after

It It

chemical chemical

of of

such such

0

iron; iron;

or or

Skaland Skaland

silicate silicate

is is

with with

of of

a a

during during

of of

.

in in

minor minor

5wt% 5wt%

FeSi FeSi

well well

with with

non­

thus thus

iron iron

will will

The The

and and

the the

the the

for for

the the the the

the the

(a) (a)

(X (X

as as

of of

of of

a a

2 2

represent represent

nucleus. nucleus.

recognition recognition principle principle

lattice lattice

interfaces interfaces coheren

graphite graphite

offer offer

illustrated illustrated

definition definition enhance enhance inclusions inclusions

the the

efficient efficient

ferrosilicon ferrosilicon

If If

After After

Fig

nucleus

3.2 3.2

Coherent Coherent

Coherent Coherent

Referring Referring

La La

magnesium magnesium

11 11

into into

alloy, alloy,

i) i)

rare rare

. .

highlight highlight

are are

11 11

three three

minor minor

Skaland Skaland

slightly slightly

/

particularly particularly

substrate substrate

earth earth

.

t/semi-coherent t/semi-coherent

Details Details

Inclusion Inclusion disregistry disregistry

Effects Effects

Type Type

Ca, Ca,

(OOl)c.o·>J2D

--t-r-r-t--r--r--

added added

This This

should should

nucleation nucleation

a a

the the

inoculants inoculants

main main

graphite

in in

to to

in in

graphite/BaO·Si0

between between

of of

with with

good good

Mg

alloy

equation equation

et et

the the

metals metals

Fig. Fig.

ferrosilicon ferrosilicon

Fig. Fig.

elements elements

nucleation nucleation

A A

different different

nucleating nucleating

of of

conforms conforms

al al

categories categories

»2S

, ,

to to

interface interface

be be

fundamental fundamental

4

of of

/

the the

match match

inclusions

, ,

i0

1•1 1•1

Si, Si,

. .

CaO

lb) lb)

respect respect

11, 11,

Formation Formation

2 2

12, 12,

duly duly

the the

JJ JJ

and and

(001)""'"" (001)""'""

5 5

(REM) (REM)

the the

lattice lattice

Ce Ce

favourable favourable

S S

because because

(1)

the the

for for

·A

, ,

they they

inclusions inclusions

liquid liquid

and and

li0

observed observed

in in

for for

Q

QC-a

contained contained

after after . .

theory theory

according according

[ [

substrate substrate

to to

[l!OJ [l!OJ

(001) (001)

and and

4

The The

11 11

Qs

Q

(FSM) (FSM)

3

ductile ductile

to to

2 2

3

arrangement arrangement

potency potency

si-atoms si-atoms

: :

OJ OJ

, ,

·

search search

can can

low low

2Si0

development development

such such

0 0

a a

C-atoms C-atoms

,ra,ru" ,ra,ru"

C•O C•O

which which

i-atom

toms toms

inoculation

importance importance

interface, interface,

results results

graphite

·A>,D3.ZSi02 ·A>,D3.ZSi02

iron iron

small small

these these

La La

as as

basal basal

as as

be be

2 2

s s

1

as as

sites sites

will will

• •

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treatment treatment

the the

iron iron

of of

interface. interface.

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grouped grouped

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in in

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of of

contain contain

to to

energy energy

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planes planes

planar planar

facets facets

. .

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form. form.

main main

; ;

Fig. Fig.

and and

the the

the the

the the

the the

the the

the the

As As

for for

the the the the

(b) (b)

(a) (a)

of of

of of 568 568

569 569

La La

The The iii) iii)

Fig. Fig.

ii) ii)

inclusions

rich rich

3.3 3.3

magnesium magnesium

liquid liquid

and and the the not not

inoculation inoculation

inclusions. inclusions.

I

from from

occurring occurring

inclusions inclusions

Si Si

the the context

inclusions inclusions

are are crystal crystal

solidification solidification illustrated illustrated

a a

formation formation

for for

n n

lower lower

but but

the the

stable stable

therefore therefore

strong strong

take take

12 12

treated treated

La La

inclusions inclusions

graphite graphite

type type

(a) (a)

" "

absence absence

not not

iron. iron.

reactions reactions

43

Mg Mg Type Type

constituent constituent

Type Type

Mg Mg elements. elements.

and and

Grouping Grouping

structure. structure.

Formation Formation

if if

Conditions Conditions

nucleating nucleating

~ ~

, ,

0 0

part part

• •

After After

eutectic eutectic

Ce Ce

these these

and and

(b) (b)

A A

in in

Tn

during during

are are

oxide oxide

stage. stage.

and

La. La.

ductile ductile

and and

The The

treatment treatment

,A ,A

of of

Fig. Fig.

or or

C C

inclusions inclusions

in in

process. process.

Type Type

B B

of of

are are

nucleation nucleation

less less

Ons0ien Ons0ien

(type (type

/or /or

minor minor

inclusions, inclusions,

is is

La. La.

elements elements

the the

Si Si

of of

Ce Ce

inclusions, inclusions,

forming forming

type type

They They

temperature temperature

therefore therefore

13(a) 13(a)

Ce. Ce.

thought thought

the the

occurring occurring

inclusions inclusions

temperature temperature

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elements elements potent potent

B B

Type Type

cast cast

(with (with

'~'"'·~' '~'"'·~'

Finally, Finally,

as as

and and

graphite graphite

C) C)

or or

k k

inclusions

interest interest

B B

As As

the the

et et

without without

and and

final final

Ca, Ca,

may may

stem stem

due due

La, La,

probably probably

iron; iron;

for for

al al

Mg, Mg,

inclusions inclusions

are are

elements elements

sites sites

a a

Ce Ce

main main

at at

43

to to which which

SI, SI,

characterised characterised

the the

and and

the the

the the

. .

to to

S, S,

result, result,

also also

found found

which which

along along

from from

stages stages

formation formation

present present

0 0

be be

La) La)

in in

of of

the the

(a) (a)

, ,

during during

a a

phosphorus­

Tn

temperature temperature

for for

the the

( (

subsequent subsequent

constituent constituent

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the the

just just

favourable favourable

c) c)

absorb absorb

contain contain

,

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B· B·

in in

reactions reactions

ongmate ongmate

Type Type

with with

type type

Mg Mg

graphite graphite

they they

Type Type

contain contain

type type

contain contain

During During

iron, iron,

present present

of of

Ce Ce

below below

in in

and and

and and

and and

the the

the the

the the

Ce Ce

Ce Ce

by by

do do

P P

A A

as as

C C

A A

B B

' '

never never

Fig. Fig.

heat heat

nucleation nucleation

to to

mechanism mechanism

because because

Nevertheless, Nevertheless, inclusions inclusions

conditions conditions the the

supercooled supercooled

When When iron iron

(region (region

solidification solidification

nucleation nucleation additions. additions.

Fig

change change

indicated indicated

this this composition composition

the the reaches reaches

the the

type type

inclusions inclusions

graphite graphite

undercooling undercooling This This count count

a a

graphite graphite

slight slight

. .

the the

total total

A+B A+B

13 13

increase increase

A A

containing containing

implies implies

13(b). 13(b).

energy energy

implies implies

Ce Ce

reach reach

after after

in in

inclusions inclusions

A),. A),.

Schematic Schematic

situation situation

the the

of of nodule nodule

during during

{b) {b)

(•) (•)

After After

nodule nodule

reduction reduction

nucleation nucleation

regime regime

in in

T..m T..m

or or

during during

fe

become become

of of

at at

i

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.

a a

s-~

at at

1-

Fig. Fig.

liquid liquid

-~.,~-~-~--·-

level level

A

solidification, solidification,

.. ..

is is

type type

At At

modification modification

Al!!;

La La

graphite graphite

: :

' '

the the

the the

.~~-·-· .~~-·-·

that that

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-__,.,,_.

the the

and and

type type

not not

solidification, solidification,

count count

count count

barrier barrier

that that

act act

Ce Ce

required required

is is

13(a). 13(a).

A+B A+B

in in

higher higher

solidification, solidification,

resulting resulting

A A

point point

and and

of of

described described

in in

interaction interaction

active. active.

large large

--

the the

added added

in in

representation representation

Fig. Fig.

inclusions increases increases inclusions

A A

as as

crystal crystal

or or

at at

the the

the the

with with

formation formation

increases. increases.

that that

et et

Ce Ce

%Ceor%la %Ceor%la

%Ceor%La %Ceor%La

;

' '

~ ~

At At

the the

inclusions increases increases inclusions

nucleation nucleation

temperature temperature

'"'""" '"'"""

e e

al al

where where

type type

-

La; La;

REM-free REM-free

enough enough

13(b). 13(b).

type type

Ce

against against

or or

increasing increasing

43

to to

'Tn.A 'Tn.A

T,,

low low

This This

of of

.s .s

release release

as as

. .

graphite graphite

both both

/

La La

La La

for for

the the

in in

(a) (a)

their their

conforming conforming

structure, structure,

B B

B B

in in

Ce/La Ce/La

illustrated illustrated

between between

(b) (b)

gives gives

the the

corresponds corresponds

As As

Fig. Fig.

to to

liquid liquid

levels levels

inclusions. inclusions.

ductile ductile

inclusions. inclusions.

Nucleation Nucleation

types types

chemical chemical

Resulting Resulting

iron iron

of of

sites sites

promote promote

Ce Ce

graphite graphite

a a

graphite graphite

of of

type type

nodule nodule

of of

levels, levels,

rise rise

result, result,

latent latent

13(b) 13(b)

or or

iron iron

will will

cast cast

and and

the the

the the

the the the the

for for

La La

as as

to to

of of

B B

to to

in in I I

in in more more

Fig. Fig.

manner, manner,

Hence, Hence,

promotes promotes against against lanthanum lanthanum

net net Although Although

3.4 3.4 increased, increased,

makes makes

concentrations concentrations Ce Ce

experimental experimental inclusions inclusions

illustrated illustrated count count

count count Fig. Fig.

independent independent

sulphide sulphide

compiled compiled

A A

cast cast

additions additions

further further

ductile ductile

or or

effect effect

14 14

~ ~

'O 'O

-5 -5

o; o;

.~ .~

.!!! .!!!

'E 'E

g g 8 8

iron: iron:

14. 14.

difficult difficult

0.0 0.0

0.2 0.2

0.4 0.4

0

0.8 0.8

La La

1.0 1.0

passes passes

1

0.0 0.0

0 0

0.4 0.4

0.6 0.6

0.8 0.8

1.2 1.2

1.0 1.0

.

.

. .

0

6 6

0

2 2

2 2

the the

the the

Practical Practical

Effect Effect

.

the the

.

00 00

00 00

L_~-'----'---'-~~---' L_~-'----'---'-~~---'

r----

lanthanum lanthanum

.

-

.. ..

on on

content content

(b) (b)

is is

nucleation nucleation

(a) (a)

of of At At

8 8

by by

former former

• •

,./

increase increase

in in

Ce Ce

(a) (a)

cast cast

.. ..

use use

more more

sources)

curve curve

·-

graphite graphite

~

0.02 0.02

.1 .1

these these

the the

observed observed

0.02 0.02

Fig. Fig.

.

observations observations

o o

in in

through through

Lanthanum Lanthanum

the the

to to

·

Ons0ien Ons0ien

~ ~

and and

Cerium, Cerium,

in in

Cerium Cerium

of of

of of

shifted shifted

iron, iron,

0 0

-

graphite graphite

achieve. achieve.

of of

the the

13(b) 13(b)

Implications Implications

··-

difficult, difficult,

0

La La

0.04 0.04

is is

changes changes

s s

same same

compared compared -

. .

.04 .04

agreement agreement rare rare

· ·

La La

in in

the the

content content

is is

at at

case case

sharper

co

------, ------,

as as

either either nucleation nucleation

a a

0 0

the the

0 0

n

a a

peak peak

behave behave

type type

(b) (b)

0.06 0.06

(region (region

et et

tent tent

0.06 0.06

iron iron

maximum maximum

an an

earth earth

formation formation

stronger stronger

time time

Both Both

(wt-%) (wt-%)

of of

in in

towards towards

Ce Ce

(wt-%) (wt-%)

is is

al al

alloying alloying

Lanthanum. Lanthanum.

which, which,

alone alone B B

, ,

is is

La, La,

Fig. Fig. 0.08 0.08

0.08 0.08

that that

in in

or or

with with

and and

4

inclusions, inclusions,

progressively progressively metal metal factors factors

3 3

the the

B). B).

in in

0 0

as as

the the

with with

La La

at at

(from (from 14. 14.

the the

oxide oxide

0.10 0.10

0.10 0.10

a a

when when

or or

Thus, Thus,

in in

shown shown

therefore therefore

peak peak

in in

element element

type type

cerium. cerium.

content content

nodule nodule

similar similar

nodule nodule

(REM) (REM)

ductile ductile

in in

weigh weigh

lower lower

tum, tum,

Data Data

and and

two two

the the

the the

the the

the the

of of

as as

in in

A A

refining refining

Possible Possible

present, present,

the the

5. 5.

industry, industry, Future Future

The The

certainly certainly

which, which,

serve serve

the the

but but

characterised characterised

reach. reach.

inclusions inclusions

obtaining obtaining sufficiently sufficiently

during during

resulting resulting

steel, steel, oxide oxide

inoculation inoculation

existing existing

metallic metallic

approach approach combinations combinations

transformations transformations to to

austenite austenite should should

The The different different

solidification solidification steels 4. 4. act act

iron iron performance performance

restore restore Product Product

inoculants inoculants

summarise summarise

containing containing

its its

iron iron

Ce Ce lead lead

form form

create create

ability ability

the the

liquid liquid

purpose purpose as as

within within

improvements improvements

existing existing

. .

as as

of of

inclusions inclusions

concept concept

to to

can can

The The

be be

Thus, Thus,

solidification solidification

most most

developments developments

following following

ACKNOWLEDGEMENTS ACKNOWLEDGEMENTS

heterogeneous heterogeneous

CONCLUDING CONCLUDING

the the

a a

developments developments

the the

inclusions inclusions

), ),

candidate candidate

misch misch

with with

are are

treatment treatment

mechanical mechanical

and and

have have

have have

or or

guiding guiding

continued. continued.

types types

the the

is is

to to

a a

state. state.

and and

the the

treatment treatment

lead lead

essence essence

is is

a a

relevant relevant

potential potential

. .

graphite graphite

of of

introduce introduce

promising promising

without without

also also

fine fine

enhance enhance

FeCr FeCr

it it

by by

sensible sensible

a a

the the

and and

and and

progress progress

not not an an

the the

metal metal

introduction introduction

well-established well-established

theoretical theoretical

grain grain

has has

of of

in in

of of

to to

(e.g. (e.g.

This This

high high

tool. tool.

applicable applicable

a a

improved improved

better better

search search

impact impact

ferroalloys ferroalloys

distribution distribution

present present

the the

in in

yet yet

of of

subsequent subsequent and and

alloys alloys

been been

microstructures microstructures

grain grain

grain grain

late late

properties. properties.

and and

and and

alloys alloys

and and

the the

and and

additions. additions.

nodularity nodularity

within within

refiners refiners

along along

the the

composition composition

the the

provides provides

alloy alloy

oxygen oxygen submicroscopic submicroscopic

been been nucleation nucleation

graphite, graphite,

comprom1smg comprom1smg

element element

made made

FeMn, FeMn,

technical technical

liquid liquid

REMARKS REMARKS

addition addition

in in

comprehensive comprehensive

demonstrated demonstrated

for for

limitations limitations

nodule nodule

on on

problem problem

paper paper

refinement refinement

optimisation optimisation

are are

refinement refinement

these these

after after

for for

framework framework

to to

the the

fully fully

this this

of of

the the

for for

in in

new new

for for

solubility solubility

steel, steel,

iron iron

of of

by by

still still

technology, technology,

In In

This This ductile ductile

a a

has has

solid solid

inoculation inoculation

solid solid

developing developing

which which

steel steel

in in

quenching quenching

ferrite ferrite

new new lines lines

count count

ferroalloy ferroalloy

field field

explored. explored.

basis basis

to to

so

iron iron

sites sites

cast cast

virtue virtue

range range

catalytic catalytic

is is

element element

that that

been been

impure impure

lution

but, but,

during during

within within

makes makes

of of

liquid liquid

either either

state. state.

grain grain

have have

non­

both both

state state

iron iron

will will

that that

cast cast

and and

Ce­

and and

are are

can can

the the the the

for for

for for

by by

43

to to

in in or or to to

of of

of of

is is at at

s s

. . 571 571

571 571

9. 9.

4. 4. 7. 7.

6. 6.

8. 8.

11. 11.

5. 5.

10. 10.

3. 3. 2. 2.

Norwegian Norwegian discussions. discussions.

for for

Casper Casper

(KTH) (KTH) Ferroalloy Ferroalloy

addition, addition, (both (both The The

1. 1.

also also

support support

partly partly

authors authors

many many

. .

van van

Klevan Klevan

Berg Berg

International, International,

Alexis Alexis

SINTEF), SINTEF),

Steelmaking, Steelmaking,

Alexis Alexis Eijk Eijk

Metall. Metall.

26 26

0, 0, Metall. Metall. J. J.

0, 0,

2353. 2353.

64. 64.

Ons0ien Ons0ien

2345. 2345. (1999), (1999),

Institute Institute

Ons0ien Ons0ien

(1999), (1999),

Rev., Rev.,

Norway. Norway.

Ferroalloy Ferroalloy

Ferroalloy Product Product Ferroalloy

Skaland Skaland

Principle Principle Skaland Skaland

of of

to to Grong Grong

Grong Grong

Proc. Proc. (FFF), (FFF),

and and

Grong Grong

6. 6.

Mater. Mater.

from from

they they

Welding", Welding",

(1997), (1997),

14 Research Research

been been

Skaland Skaland

Skaland Skaland

der der

Research Research

C C

Dr. Dr.

111 111

31 31

Int. Int.

H., H.,

pp. pp. J, J,

J, J,

van van

0. 0.

Eijk Eijk

acknowledge acknowledge

fruitful fruitful

1069-1079

1053-1068. 1053-1068.

0, 0,

0, 0,

of of

Trans. Trans.

Trans. Trans.

of of

would would

(1986), (1986),

provided provided

JOnsson JOnsson

Torbj0rn Torbj0rn

MI, MI,

MI, MI,

JOnsson JOnsson

Sci. Sci.

T, T,

T, T,

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Matlock Matlock

Materials. Materials.

der, der,

June, June,

Mr. Mr.

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Guidelines Guidelines

and and

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T. T.

T. T.

2ed, 2ed,

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Metall. Metall.

24A 24A

24A 24A

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27-48. 27-48.

like like

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Ironmaking Ironmaking

P. P.

H, H,

INFACON INFACON

P, P,

Thobias Thobias

1995

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. .

by by

The The

Skaland Skaland

ASA ASA

Scan. Scan.

Morten Morten

DK. DK.

T, T,

Jonsson Jonsson

0, 0,

0, 0,

0, 0, the the

Johansen Johansen

(1993), (1993),

0, 0,

(1993), (1993),

16 16

, ,

to to

Development, Development, the the

, ,

0, 0,

London, London,

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127-139. 127-139.

Trans. Trans. Skaland Skaland

Trans. Trans.

772-

Trondheim, Trondheim,

l l

(2000), (2000),

Norwegian Norwegian

stimulating stimulating

Gundersen Gundersen

Gundersen Gundersen

Int. Int.

Norwegian Norwegian

for for

Grong Grong

Grong Grong

thank thank Walmsley Walmsley

Modelling Modelling

J. J.

and and

(FFF). (FFF).

financial financial

Ons0ien Ons0ien

(Elkem) (Elkem)

Sjoqvist Sjoqvist

Metall., Metall.,

778. 778.

L. L.

Mater. Mater.

7, 7,

2347-

2321-

have have

New New

30A 30A

30A 30A

ISIJ ISIJ

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and and

ST, ST,

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55-

Dr. Dr.

the the

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24. 24.

23. 23.

22

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19. 19.

18 18

17. 17.

16. 16.

15. 15.

14. 14.

13. 13.

12. 12.

. .

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Melt Melt Bramfitt Bramfitt

Research, Research,

Austenitischer Austenitischer

(1970), (1970),

Kornfeinenden Kornfeinenden

Universitat Universitat Eigenshi:iften Eigenshi:iften

Thesis, Thesis, HKDH. HKDH.

Westin Westin Korngrosse Korngrosse

Figenschuh Figenschuh

Stahlgusslegierungen, Stahlgusslegierungen,

Nicholson Nicholson London, London, Properties, Properties,

Honeycombe Honeycombe Chromium Chromium

Ironmaking Ironmaking

Nuri Nuri

Kitamura Kitamura (1986), 53-69. 53-69. (1986),

Wilson, Wilson,

1980, 1980,

408-416. 408-416. Guo Guo

Nuri Nuri 37 37

Kitamura Kitamura Sommerville Sommerville (1999), (1999), 39

Additions Additions

Guo Guo Royal Royal

399-407. 399-407.

(1999), (1999), 39 Inclusions Inclusions

Stockholm, Stockholm,

istics istics

manganese manganese

Kiessling Kiessling

London, London,

Materials. Materials.

Amberg Amberg

Grong Grong 5045-5052. 5045-5052.

Sjoqvist Sjoqvist

Bhadeshia Bhadeshia

1999, 1999,

1992, 1992,

(1985), (1985),

M, M,

M, M,

Inoculation. Inoculation.

Y, Y,

Y, Y,

in in

Swedish Swedish

Department Department

0

1987-1995. 1987-1995.

London, London,

L. L.

Institute Institute

Suito Suito

Edward Edward

Suito Suito

The The

Steels-Microsrtucture Steels-Microsrtucture

.

L. L.

Steel

, ,

Stockholm, Stockholm,

0. 0.

0. 0.

Ohashi Ohashi

Ohashi Ohashi

BL. BL.

36-41. 36-41.

722-729. 722-729.

678-685. 678-685.

on on

in in

T. T.

HKDH. HKDH.

Grain Grain

Berlin, Berlin,

Dahle Dahle

2ed, 2ed,

8 8

WG, WG,

Sweden. Sweden.

Acta Acta

1980, 1980,

and and

Trans. Trans.

Trans. Trans.

and and

Metals Metals

Steel, Steel,

ID. ID.

Nickel

A, A,

, ,

H. H.

Inclusion Inclusion

H. H.

H. H.

R. R.

und und

1995

Effect Effect

RWK, RWK,

Lie. Lie.

Metall. Metall.

Institute Institute

Umwandlungsfreier Umwandlungsfreier

Arnold. Arnold.

und und

Journal Journal

ISIJ ISIJ

Refinement Refinement

Technical Technical

ISIJ ISIJ Mater. Mater. The The

Calcium Calcium

AK, AK,

Germany. Germany. Stee

T, T,

T, T,

of of Zusatzen Zusatzen

Bainite Bainite

Parts Parts

ISIJ, ISIJ,

ISIJ, ISIJ,

, ,

Heaslip, Heaslip,

Gladman Gladman

Einfluss Einfluss

Society. Society.

of of

Techn. Techn.

Type Type

Sweden. Sweden.

Hiromoto Hiromoto

Hiromoto Hiromoto

International, International,

Mechanische Mechanische

International, International,

lmaking

Non-Metallic Non-Metallic

Ons0ien Ons0ien Technischen Technischen

Technology, Technology,

Ferritischer Ferritischer

Institute Institute

Metallurgy, Metallurgy,

of of

I-IV, I-IV,

Dr. Dr.

Character­

46 46

Trans., Trans.,

Bhadeshia Bhadeshia

22 22

22 22

of of

of of

in in

Steel Steel

Carbide Carbide

Report, Report,

Metals, Metals,

(1982), (1982),

(1982), (1982),

(1998)

Metals Metals

Thesis, Thesis,

Ferro­

Steels, Steels,

of of

1978, 1978,

, ,

Ing. Ing.

and and

van van

MI, MI,

auf auf

LJ, LJ,

18 18

by by

13 13

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T, T,

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26. 26.

29. 29. 27. 27.

34

33. 33. 31. 31.

28

32. 32.

35. 35.

30. 30.

36. 36.

. .

. .

Material Material

Process Process

Rolled Rolled US US

Nippon Nippon US US US US

Steel

Nippon Nippon

P, P, Excellent Excellent

US US

Nakajima Nakajima

High High

Structures, Structures,

Dons Dons T

Steel Steel Turkdogan Turkdogan

Steelmaking, Steelmaking,

Hanamura Hanamura

JP JP

(1999), (1999), 589435 589435

Janke Janke 26A 26A

Lange Lange

(2000), (2000), Grong Grong EP EP Institute Institute

589424 589424 or or

(1988)

Construction Construction

177851 177851

Weldability, Weldability,

, ,

Heinen Heinen

Patent Patent

Nagai Nagai

Patent Patent

Patent Patent

Patent Patent

Patent Patent

Patent Patent

PC PC

(1995)

, ,

Strength, Strength,

1987

AL, AL,

, ,

D, D,

0, 0,

Shape Shape

of of

KW. KW.

31-39

53-89. 53-89.

1188-1193. 1188-1193.

Steel. Steel.

Steel. Steel.

for for

Steel Steel

of of

Refractory Refractory

Process Process

H

K. K.

Zhongting Zhongting

8041589A 8041589A

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Bar Bar

4842816 4842816

, ,

T, T,

Containing Containing

A. A.

Fire Fire

Hjelen Hjelen

Materials. Materials.

, ,

5336339 5336339

5421920 5421920

. .

1995, 1995,

4629504 4629504

Said Said

Producing Producing

849372 849372

Nippon Nippon

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525-534. 525-534.

ET. ET.

1994, 1994,

. .

Torizuka Torizuka

Int. Int.

Steel Steel

Shibata Shibata

ISIJ ISIJ

ISIJ ISIJ

Steel Steel

Material Material

l l

High High

996, 996,

Having Having

Nippon Nippon

Resistance, Resistance,

Fundamentals Fundamentals

AO, AO,

Nippon Nippon

Material, Material,

Mater. Mater.

J. J.

International, International,

Material Material

International

High High

for for

Steel. Steel.

Al Al

and and

Having Having

and and

Toughness Toughness

and and

PC PC

Metall

MA

H, H,

London, London,

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Roll

S, S,

Nylund Nylund

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Waseda Waseda

Steel. Steel.

EU EU

Steel Steel

EU EU

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Toughness Toughness

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EP EP

Takanashi Takanashi

Steel. Steel.

Rev

Excellent Excellent

e

Valentin Valentin

d d

. .

Having Having

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e e

Patent Patent Patent Patent

Trans. Trans. Patent Patent

Active Active

Shape Shape

Alloy Alloy

., .,

1993, 1993,

1993

Steel Steel

Wire Wire

HK, HK,

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42. 42.

40. 40.

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41. 41.

44. 44.

39. 39.

38. 38.

37. 37.

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Improved Improved

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Normark Normark

Improvements Improvements

Particles, Particles,

Heat Heat

Ma Ma

Technical Technical

TU TU

Htittenwerke. Htittenwerke.

Killed Killed Ma Ma

Elliott Elliott

Coal Coal Patent Patent

EP EP

EP EP

Ons0ien Ons0ien J0rgensen J0rgensen Metals Metals

Ons0ien Ons0ien

Olsen Olsen

Germany. Germany.

(ESCS), (ESCS),

by by Ons0ien Ons0ien

Cast Cast

Grain Grain

Quality Quality (1999), (1999),

Steel. Steel.

Techniques, Techniques,

147-152. 147-152.

1998

1988, 1988,

Freiberg, Freiberg,

Patent Patent

Patent Patent

Z

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Affected Affected

Z, Z,

Kawasaki Kawasaki

London, London,

Steel Steel

, ,

SE. SE.

e

Res., Res.,

Structure

Alternativ

253-259. 253-259. and and

R. R.

tallic tallic

Steel Steel

of of

Janke Janke

9739157 9739157

MI

Ml

MI

A, A,

K. K.

Franke Franke

Report Report

Continuously Continuously

AFS AFS

Toughn

1997

Cast Cast

Technical Technical , ,

, ,

, ,

839921 839921

by by

906960 906960

10 10

Skaland Skaland

Germany. Germany.

Mater. Mater.

Grong Grong

Grong Grong

Grong Grong

Steel Steel

Inclusions Inclusions

Butterworths. Butterworths.

She

Zone, Zone,

D

1996

of of

(1997), (1997),

Steel. Steel.

, ,

Trans., Trans.,

s s

Oxide Oxide

. .

e e

Iron Iron

e

e

to to

of of

Improvement Improvement

t t

Castability Castability

ss ss

A

TU TU

, ,

Steel Steel

Sci. Sci.

0

0, 0,

Al Al

T. T.

0

, ,

1997, 1997,

Al Al

the the

and and

Commmunity Commmunity

Report, Report,

Continuously Continuously

, ,

, ,

17-26. 17-26.

in in

Deoxidation Deoxidation

Technology, Technology,

105 105

Metallurgy, Metallurgy,

Int. Int.

Skaland Skaland

Skaland Skaland

Cast Cast

Janke Janke

Techn

R0rvik R0rvik

and and

and and

European European

Freiberg

Dillinger Dillinger

Titanium Titanium

Method

Welding Welding

Nippon Nippon

Having Having

(1997), (1997),

J. J.

St

1999

Fin

C

., .,

WO WO

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and and

ast ast

D. D.

G, G,

15 15

T, T,

T, T,

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