Inclusion flotation-driven channel segregation in solidifying steels.
Nat Commun 2014;
5:5572. [PMID:
25422943 PMCID:
PMC4263320 DOI:
10.1038/ncomms6572]
[Citation(s) in RCA: 58] [Impact Index Per Article: 5.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/21/2014] [Accepted: 10/15/2014] [Indexed: 11/29/2022] Open
Abstract
Channel segregation, which is featured by the strip-like shape with compositional variation in cast materials due to density contrast-induced flow during solidification, frequently causes the severe destruction of homogeneity and some fatal damage. An investigation of its mechanism sheds light on the understanding and control of the channel segregation formation in solidifying metals, such as steels. Until now, it still remains controversial what composes the density contrasts and, to what extent, how it affects channel segregation. Here we discover a new force of inclusion flotation that drives the occurrence of channel segregation. It originates from oxide-based inclusions (Al2O3/MnS) and their sufficient volume fraction-driven flotation becomes stronger than the traditionally recognized inter-dendritic thermosolutal buoyancy, inducing the destabilization of the mushy zone and dominating the formation of channels. This study uncovers the mystery of oxygen in steels, extends the classical macro-segregation theory and highlights a significant technological breakthrough to control macrosegregation.
A long-term problem in the casting of alloys such as steels is macrosegregation, which are variations in composition of the cast material. Here, the authors observe that the formation and flotation of oxide-based inclusions from light metals represent a mechanism through which macrosegregation occurs in steels.
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