Clusters of Al2O3 inclusions in a liquid stainless steel (18/8) and in a clogged ZrO2 nozzle after casting were studied during a pilot plant trial. Samples were taken from the melt at different holding times after an addition of 0.1 mass% Al. The characteristics (composition, size, number, and morphology) of clusters and clustered inclusions in the steel samples and in the clogged nozzle were investigated after electrolytic extraction and etching by using SEM. It was found that the Al2O3 inclusions in the clusters are transformed from a spherical into irregular and regular (with sharp edges) shape during the holding time. Most of the inclusions in the clusters (>80%) after a 6 min holding time are regular inclusions, which have sharp edges and flat faces. The size of the inclusions in clusters in the melt increased on average from 1.0 μm at a 1 min to 5.2 μm at a 12 min holding time. While the sizes of different types of inclusions in the clogged nozzle correspond to those present in the liquid steel at respective time, the frequency of spherical inclusions in the clogged nozzle is about 2–4 times larger (particularly near the nozzle wall) compared to that in the melt. Growth and transformation of Al2O3 clusters in the liquid steel at different holding times after an addition of Al and during casting were considered based on the obtained results.

The characterization of nonmetallic inclusions is of importance for the production of clean steel in order to improve the mechanical properties. In this respect, a three-dimensional (3D) investigation is considered to be useful for an accurate evaluation of size, number, morphology of inclusions, and elementary distribution in each inclusion particle. In this study, the application of various extraction methods (chemical extraction/etching by acid or halogen-alcohol solutions, electrolysis, sputtering with glow discharge, and so on) for 3D estimation of nonmetallic Al2O3inclusions and clusters in high-alloyed steels was examined and discussed using an Fe-10 mass% Ni alloy and an 18/8 stainless steel deoxidized with Al. Advantages and limitations of different extraction methods for 3D investigations of inclusions and clusters were discussed in comparison to conventional two-dimensional (2D) observations on a polished cross section of metal samples.

The characteristics of non-metallic inclusions (such as number, size and volume fraction) in liquid steel samples taken during ladle treatment and casting of industrial heats of two low-alloyed Ca-treated steel grades were evaluated by using the Pulse Distribution Analysis with Optical Emission Spectroscopy (PDA/OES) method. These results were compared to data obtained by Scanning Electron Microscope observations of inclusions after electrolytic extraction from steel samples (the EE method). It was found that the PDA/OES method can be used for a relative estimation of the homogeneity of the distribution of non-metallic inclusions in steel samples. Bottom and middle parts of the steel samples showed more homogeneous results with respect to the characteristics of the investigated Al 2 O 3 , CaO-Al 2 O 3 and CaOAl 2 O 3 -CaS inclusions. The numbers of inclusions in the size ranges 2.0-5.7 μm and 1.4-5.7 μm in samples taken before and after a Ca addition, respectively, showed a relatively good agreement between both methods. Furthermore, the calculated volume fractions for inclusions in the size range 2-13 μm obtained by the PDA/OES method agreed satisfactorily well with those obtained from the EE method. Finally, the minimum sizes of inclusions in steel samples, which can reliably be detected by the PDA/OES method, were estimated for steels with different concentrations of Al in steel and Al 2 O 3 in inclusions.

Liquid steel samples were taken during ladle treatment and continuous casting of 37 heats of two duplex stainless steel grades. These samples were used to study inclusion characteristics and potential process control using the pulse distribution analysis with optical emission spectroscopy method (PDA/OES). In addition, a few samples were chosen for a scanning electron microscope examination. A simplified approach of presenting the inclusion composition in ternary diagrams using the PDA/OES method is discussed. More specifically, by defining an operating window, potential deviations can be identified early in the steelmaking process. The variation of the B factor for Al (B Al ) with process time was presented showing similar tendencies for several heats. For that reason, the B factor is considered to be a reliable parameter to study any process changes with respect to inclusion characteristics. Parameters such as B Al and the number of inclusions per unit volume larger than 4 mm obtained using the PDA/OES method showed a moderate correlation with a slivers index. Statistically, more data have to be collected for further studies. Nevertheless, the PDA/OES method is judged to be a promising tool to determine a slivers risk factor at an early stage of the process.