Review on desulfurization in electroslag remelting

Abstract

Electroslag remelting (ESR) gives a combination of liquid metal refining and solidification structure control. One of the typical aspects of liquid metal refining during ESR for the advanced steel and alloy production is desulfurization. It involves two patterns, i.e., slag-metal reaction and gas-slag reaction (gasifying desulfurization). In this paper, the advances in desulfurization practices of ESR are reviewed. The effects of processing parameters, including the initial sulfur level of consumable electrode, remelting atmosphere, deoxidation schemes of ESR, slag composition, melting rate, and electrical parameters on the desulfurization in ESR are assessed. The interrelation between desulfurization and sulfide inclusion evolution during ESR is discussed, and advancements in the production of sulfur-bearing steel at a high-sulfur level during ESR are described. The remaining challenges for future work are also proposed.

Keywords

electroslag remelting / desulfurization / sulfide inclusions / sulfur-bearing steel / gasifying desulfurization / desulfurization mechanism

References

[1] Morinaga M, Murata Y, Hashizume R, Sawaragi Y. Remarkable improvement in steam oxidation resistance due to the presence of sulfur in high Cr ferrtic steels. ISIJ Int., 2001, 41(3): 314.

[2] Kizu T, Urabe T. Hot ductility of sulfur-containing low manganese mild steels at high strain rate. ISIJ Int., 2009, 49(9): 1424.

[3] Li QL, Zhang HR, Gao M, Li JP, Tao TX, Zhang H. Mechanisms of reactive element Y on the purification of K4169 superalloy during vacuum induction melting. Int. J. Miner. Metall. Mater., 2018, 25(6): 696.

[4] Bai XF, Sun YH, Chen RM, Zhang YM, Cai YF. Formation and thermodynamics of CaS-bearing inclusions during Ca treatment in oil casting steels. Int. J. Miner. Metall. Mater., 2019, 26(5): 573.

[5] Shi CB. Deoxidation of electroslag remelting (ESR)—A review. ISIJ Int., 2020, 60(6): 1083.

[6] Mehrabi K, Rahimipour MR, Shokuhfar A. The effect of slag types and melting rate on electro-slag remelting (ESR) processing. Int. J. Iron Steel Soc. Iran, 2005, 2(1): 37.

[7] Hou D, Jiang ZH, Wang DY, Qu TP, Tian J, Wang HH. Transfer phenomenon study of slag-metal reaction during electroslag remelting process. Proceedings on Liquid Metal Processing & Casting Conference 2019, 2019 139.

[8] Hlineny J, Buzek Z. Desulphurization in electro-slag melting. Hutnicke Listy, 1966, 8, 524.

[9] Mattar T, EI-Fawakhry K, Haifa H, Eissa M. Effect of nitrogen alloying on sulphur behaviour during ESR of AISI M41 steel. Steel Res. Int., 2008, 79(9): 691.

[10] Shi CB, Zheng DL, Guo BS, Li J, Jiang F. Evolution of oxide-sulfide complex inclusions and its correlation with steel cleanliness during electroslag rapid remelting (ESRR) of tool steel. Metall. Mater. Trans. B, 2018, 49(6): 3390.

[11] Steel Res. Int., 2017, 88(11)

[12] Narita K, Onoye T, Ishii T, Kusamichi T. A metallurgical study of oxide-base slag used for electroslag remelting. Tetsu-to-Hagané, 1978, 64(10): 1568.

[13] Shi CB, Chen XC, Guo HJ, Zhu ZJ, Ren H. Assessment of oxygen control and its effect on inclusion characteristics during electroslag remelting of die steel. Steel Res. Int., 2012, 83(5): 472.

[14] Shi CB, Yu WT, Wang H, Li J, Jiang M. Simultaneous modification of alumina and MgO·Al₂O₃ inclusions by calcium treatment during electroslag remelting of stainless tool steel. Metall. Mater. Trans. B, 2017, 48(1): 146.

[15] Detrois M, Jablonski PD, Hawk JA. Evolution of tantalum content during vacuum induction melting and electroslag remelting of a novel martensitic steel. Metall. Mater. Trans. B, 2019, 50(4): 1686.

[16] Yang QK, Shen P, Zhang D, Wu YX, Fu JX. Analysis on composition and inclusions of ballpoint pen tip steel. Int. J. Miner. Metall. Mater., 2018, 25(4): 420.

[17] Xie ZB, Shao QL, Zhang GP, Wang K, He N. Research on quality of high speed steel M35 bearing sulfur remelting by acid slag. Special Steel, 2019 27.

[18] Cooper CK, Ghosh D, Kay DAR, Pomfret RJ. IronSteel Society of AIME. ESR reaction sites. The 28th Electric Furnace Conference, 1970 8.

[19] Mellberg P, Sandberg H. On the mechanism of desulphurization during a.c. and d.c. electroslag remelting. Scand. J. Metall., 1973, 2(3): 121.

[20] Holzgruber W, Petersen K, Schneider P E. Comparison of products and economics from large VAR, AC-ESR and DC-ESR ingots. Transaction of the International Vacuum Metallurgy Conference, 1968 499.

[21] Plöckinger E. Electroslag remelting—A modern tool in metallurgy. J. Iron Steel Inst., 1973, 211(4): 533.

[22] Shi CB. Behaviour and Control Technique of Oxygen and Inclusions during Protective Atmosphere Electroslag Remelting Process, 2012, Beijing, University of Science and Technology Beijing, 95.

[23] Kato M, Hasegawa K, Nomura S, Inouye M. Transfer of oxygen and sulfur during direct current electroslag remelting. Trans. Iron Steel Inst. Jpn., 1983, 23(7): 618.

[24] Wang Q, He Z, Li GQ, Li BK, Zhu CY, Chen PJ. Numerical investigation of desulfurization behavior in electroslag remelting process. Int. J. Heat Mass Transfer, 2017, 104, 943.

[25] Hou D, Jiang ZH, Dong YW, Li Y, Gong W, Liu FB. Mass transfer model of desulfurization in the electroslag remelting process. Metall. Mater. Trans. B, 2017, 48(3): 1885.

[26] Eissa M, EI-Mohammadi A. Effect of physical properties of slag on sulphur removal mechanism during ESR process. Steel Res., 1998, 69(10–11): 413.

[27] Mattar TMT, Fathy AM, El-Faramawy HSR, Eissa MM, El-Fawakhry KAR. Optimization of desulphurization of tool steels during EAF and ESR processes. Metal 2001, 2001 1.

[28] Padki GM, Balasubramanian MSN, Gupt KM, Krishna Rao P. Effect of ESR and carbon content on mechanical properties of a high-strength steel (15CDV6) for aerospace applications. Ironmaking Steelmaking, 1983, 10(4): 180.

[29] Shi CB, Chen XC, Guo HJ, Zhu ZJ, Sun XL. Control of MgO·Al₂O₃ spinel inclusions during protective gas electroslag remelting of die steel. Metall. Mater. Trans. B, 2013, 44(2): 378.

[30] Shi CB, Park JH. Evolution of oxide inclusions in Si-Mnkilled steel during protective atmosphere electroslag remelting. Metall. Mater. Trans. B, 2019, 50(3): 1139.

[31] Shi CB, Wang H, Li J. Effects of reoxidation of liquid steel and slag composition on the chemistry evolution of inclusions during electroslag remelting. Metall. Mater. Trans. B, 2018, 49(4): 1675.

[32] Steel Res. Int., 2018, 89(10)

[33] Cooper CK, Kay DAR. Behaviour of sulphur during ac electroslag remelting. J. Iron Steel Inst., 1970, 208(9): 856.

[34] Ahmadi S, Arabi H, Shokuhfar A, Rezaei A. Evaluation of the electroslag remelting process in medical grade of 316LC stainless steel. J. Mater. Sci. Technol., 2009, 25(5): 592.

[35] Chen XC, Wang F, Shi CB, Ren H, Feng D. Effect of electroslag remelting process on desulphurization of GH4169. J. Iron Steel Res., 2012, 24(12): 11.

[36] Chang LZ, Shi XF, Cong JQ. Study on mechanism of oxygen increase and countermeasure to control oxygen content during electroslag remelting process. Ironmaking Steelmaking, 2014, 41(3): 182.

[37] Radwitz S, Scholz H, Friedrich B, Franz H. Influencing the electroslag remelting process by varying fluorine content of the utilized slag. Proceedings of European Metallurgical Conference 2015, 2015, 2, 887.

[38] Radwitz S, Scholz H, Friedrich B, Franz H. Process and refining characteristics of ESR using MgO containing slag systems. International of Symposium on Liquid Metal Processing & Casting 2015, 2015 153.

[39] Kang CP, Liu FB, Jiang ZH, Yu J, Chen K. Study on desulfurization kinetics model of electroslag remelting under different atmosphere. Proceedings of 2018 China Special Metallurgical Technology Meeting, 2018 68.

[40] Ballantyne AS. The capabilities and benefits of argon shrouding during electroslag remelting. Medovar Memorial Symposium Proceeding, 2001 113.

[41] Stein G, Menzel J. High pressure electroslag remelting—A new technology of steel refining. Int. J. Mater. Prod. Technol., 1995, 10(3–6): 478.

[42] Pant P, Dahlmann P, Schlump W, Stein G. A new nitrogen alloying technique—A way to distinctly improve the properties of austenitic steel. Steel Res., 1987, 58(1): 18.

[43] Yu J, Liu FB, Li HB, Jiang ZH, Li Y, Kang CP, Wang A, Zhang WC, Feng H. Numerical simulation and experimental investigation of nitrogen transfer mechanism from gas to liquid steel during pressurized electroslag remelting process. Metall. Mater. Trans. B, 2019, 50(6): 3112.

[44] Sekiya A, Nakayama S, Taketsuru T. Deoxidation of stainless steel on vacuum electroslag remelting process. Denki-Seiko, 1995, 66(1): 47.

[45] Huang XC, Li BK, Liu ZQ, Jiang TC, Chai YY, Wu XX. Oxygen transport behavior and characteristics of nonmetallic inclusions during vacuum electroslag remelting. Vacuum, 2019, 164, 114.

[46] Liu Y, Wang XJ, Li GQ, Wang Q, Zhang Z, Li BK. Role of vacuum on cleanliness improvement of steel during electroslag remelting. Vacuum, 2018, 154, 351.

[47] Li SJ, Cheng GG, Miao ZQ, Chen L, Jiang XY. Effect of slag on oxide inclusions in carburized bearing steel during industrial electroslag remelting. Int. J. Miner. Metall. Mater., 2019, 26(3): 291.

[48] Dong YW, Jiang ZH, Cao YL, Yu A, Hou D. Effect of slag on inclusions during electroslag remelting process of die steel. Metall. Mater. Trans. B, 2014, 45(4): 1315.

[49] Shi CB, Li J, Cho JW, Jiang F, Jung IH. Effect of SiO₂ on the crystallization behaviors and in-mold performance of CaF₂-CaO-Al₂O₃ slags for drawing-ingot-type electroslag remelting. Metall. Mater. Trans. B, 2015, 46(5): 2110.

[50] Hou D, Wang D, Qu T, Tian J, Jiang Z. Sulfur content and inclusion control during electroslag remelting of die steel. Chin. J. Eng., 2018, 40(Suppl.1): 19.

[51] Zheng DL, Li J, Shi CB, Zhang J, Geng RM. Evolution of TiN and oxide inclusions in Ti-containing Fe-25Ni-15Cr alloy during electroslag remelting. ISIJ Int., 2020, 60(8): 1577.

[52] Reyes-Carmona F, Mitchell A. Deoxidation of ESR slags. ISIJ Int., 1992, 32(4): 529.

[53] Mitchell A, Reyes-Carmona F, Samuelsson E. The deoxidation of low-alloy steel ingots during ESR. Trans. Iron Steel Inst. Jpn., 1984, 24(7): 547.

[54] Medina SF, Cores A. Thermodynamic aspects in the manufacturing of microalloyed steels by the electroslag remelting process. ISIJ Int., 1993, 33(12): 1244.

[55] Baligidad RG, Prakash U, Rao VR, Rao PK, Ballal NB. Electroslag remelting of Fe-28 at.%Al intermetallic alloy. Ironmaking Steelmaking, 1994, 21(4): 324.

[56] Xiang DL, Zhu XW, Wang KW. Production of ultralow sulphur big ESR ingots. Iron Steel, 1993, 28(6): 421.

[57] Chatterjee M, Balasubramanian MSN, Gupt KM, Rao PK. Inoculation during electroslag remelting of 15CDV6 steel. Ironmaking Steelmaking, 1990, 17(1): 38.

[58] Fraser ME, Mitchell A. Mass transfer in the electroslag process: Part 1 mass-transfer model. Ironmaking Steelmaking, 1976, 3(5): 279.

[59] Tang XW, Zhu R, Li C, Liu W. Effect of ESR technology on desulfurization of high nitrogen steel. J. Iron Steel Res., 2015, 27(6): 24.

[60] Kojima Y, Kato M, Toyoda T, Inouye M. The formation of liquid droplet and the behavior of oxygen in direct current electroslag remelting process. Trans. Iron Steel Inst. Jpn., 1975, 15(8): 397.

[61] Kawakami M, Nagata K, Yamamura M, Sakata N, Miyashita Y, Goto KS. Profiles of temperature, voltage and local heat generation in slag phase and metal pool of ESR unit under operation. Tetsu-to-Hagané, 1977, 63(13): 2162.

[62] Kawakami M, Takenaka T, Ishikawa M. Electrode reactions in dc electroslag remelting of steel rod. Ironmaking Steelmaking, 2002, 29(4): 287.

[63] Paar A, Schneider R, Zeller P, Reiter G, Paul S, Würzinger P. Effect of electrical parameters on type and content of non-metallic inclusions after electro-slag-remelting. Steel Res. Int., 2014, 85(4): 570.

[64] A. Mitchell, Electrochemical aspects of the ESR process, IOP Conf. Ser. Mater. Sci. Eng., 143(2016), art. No. 012001.

[65] Aksenov IA, Matveeva MA, Chumanov IV. Influence of the ESR parameters on the removal of sulfur. Russ. Metall., 2019, 2019(6): 601.

[66] Zhang JW, Guo PM, Li ZB. Study on electro-capillary oscillation in ESR system. Iron Steel, 2000, 35(5): 23.

[67] Holzgruber W, Plöckinger E. Metallurgical and technological foundations of electroslag re-melting of steel. Stahl Eisen, 1968, 88(12): 638.

[68] Qi YF, Li J, Shi CB, Wang H, Zheng DL. Precipitation and growth of MnS inclusion in an austenitic hot-work die steel during ESR solidification process. Metall. Res. Technol., 2019, 116, 322.

[69] Ma Q, Sun CL, Feng GP, Zhang XL. Process practice for improvement of B-type inclusions in ESR sulfur-bearing steel 34CrNiMo6. Special Steel, 2017, 38, 39.

[70] Wang LG, Jia XB, Li YQ, Zhao WY, Bi LG, Yun X, Shang Guan CJ. Study on the control of sulfur and aluminum element during electroslag remelting process. Proceedings of 2016 China Special Metallurgical Technology Meeting, 2016 233.