Cite this article as: |
Cheng-bin Shi, Yi Huang, Jian-xiao Zhang, Jing Li, and Xin Zheng, Review on desulfurization in electroslag remelting, Int. J. Miner. Metall. Mater., 28(2021), No. 1, pp. 18-29. https://doi.org/10.1007/s12613-020-2075-3 |
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.
[1] |
M. Morinaga, Y. Murata, R. Hashizume, and Y. Sawaragi, Remarkable improvement in steam oxidation resistance due to the presence of sulfur in high Cr ferrtic steels, ISIJ Int., 41(2001), No. 3, p. 314. doi: 10.2355/isijinternational.41.314
|
[2] |
T. Kizu and T. Urabe, Hot ductility of sulfur-containing low manganese mild steels at high strain rate, ISIJ Int., 49(2009), No. 9, p. 1424. doi: 10.2355/isijinternational.49.1424
|
[3] |
Q.L. Li, H.R. Zhang, M. Gao, J.P. Li, T.X. Tao, and H. Zhang, Mechanisms of reactive element Y on the purification of K4169 superalloy during vacuum induction melting, Int. J. Miner. Metall. Mater., 25(2018), No. 6, p. 696. doi: 10.1007/s12613-018-1617-4
|
[4] |
X.F. Bai, Y.H. Sun, R.M. Chen, Y.M. Zhang, and Y.F. Cai, Formation and thermodynamics of CaS-bearing inclusions during Ca treatment in oil casting steels, Int. J. Miner. Metall. Mater., 26(2019), No. 5, p. 573. doi: 10.1007/s12613-019-1766-0
|
[5] |
C.B. Shi, Deoxidation of electroslag remelting (ESR)—A review, ISIJ Int., 60(2020), No. 6, p. 1083. doi: 10.2355/isijinternational.ISIJINT-2019-661
|
[6] |
K. Mehrabi, M.R. Rahimipour, and A. Shokuhfar, The effect of slag types and melting rate on electro-slag remelting (ESR) processing, Int. J. Iron Steel Soc. Iran, 2(2005), No. 1, p. 37.
|
[7] |
D. Hou, Z.H. Jiang, D.Y. Wang, T.P. Qu, J. Tian, and H.H. Wang, Transfer phenomenon study of slag–metal reaction during electroslag remelting process, [in] Proceedings on Liquid Metal Processing & Casting Conference 2019, Birmingham, UK, 2019, p. 139.
|
[8] |
J. Hlineny and Z. Buzek, Desulphurization in electro–slag melting, Hutnicke Listy, 8(1966), p. 524.
|
[9] |
T. Mattar, K. EI-Fawakhry, H. Haifa, and M. Eissa, Effect of nitrogen alloying on sulphur behaviour during ESR of AISI M41 steel, Steel Res. Int., 79(2008), No. 9, p. 691. doi: 10.1002/srin.200806185
|
[10] |
C.B. Shi, D.L. Zheng, B.S. Guo, J. Li, and F. Jiang, Evolution of oxide-sulfide complex inclusions and its correlation with steel cleanliness during electroslag rapid remelting (ESRR) of tool steel, Metall. Mater. Trans. B, 49(2018), No. 6, p. 3390. doi: 10.1007/s11663-018-1398-1
|
[11] |
Y. Liu, Z. Zhang, G.Q. Li, Q. Wang, L. Wang, and B.K. Li, Evolution of desulfurization and characterization of inclusions in dual alloy ingot processed by electroslag remelting, Steel Res. Int., 88(2017), No. 11, art. No. 1700058. doi: 10.1002/srin.201700058
|
[12] |
K. Narita, T. Onoye, T. Ishii, and T. Kusamichi, A metallurgical study of oxide-base slag used for electroslag remelting, Tetsu-to-Hagané, 64(1978), No. 10, p. 1568. doi: 10.2355/tetsutohagane1955.64.10_1568
|
[13] |
C.B. Shi, X.C. Chen, H.J. Guo, Z.J. Zhu, and H. Ren, Assessment of oxygen control and its effect on inclusion characteristics during electroslag remelting of die steel, Steel Res. Int., 83(2012), No. 5, p. 472. doi: 10.1002/srin.201100200
|
[14] |
C.B. Shi, W.T. Yu, H. Wang, J. Li, and M. Jiang, Simultaneous modification of alumina and MgO·Al2O3 inclusions by calcium treatment during electroslag remelting of stainless tool steel, Metall. Mater. Trans. B, 48(2017), No. 1, p. 146. doi: 10.1007/s11663-016-0771-1
|
[15] |
M. Detrois, P.D. Jablonski and J.A. Hawk, Evolution of tantalum content during vacuum induction melting and electroslag remelting of a novel martensitic steel, Metall. Mater. Trans. B, 50(2019), No. 4, p. 1686. doi: 10.1007/s11663-019-01614-z
|
[16] |
Q.K. Yang, P. Shen, D. Zhang, Y.X. Wu, and J.X. Fu, Analysis on composition and inclusions of ballpoint pen tip steel, Int. J. Miner. Metall. Mater., 25(2018), No. 4, p. 420. doi: 10.1007/s12613-018-1587-6
|
[17] |
Z.B. Xie, Q.L. Shao, G.P. Zhang, K. Wang, and N. He, Research on quality of high speed steel M35 bearing sulfur remelting by acid slag, Special Steel, 2019, No. 1, p. 27.
|
[18] |
C.K. Cooper, D. Ghosh, D.A.R. Kay, and R.J. Pomfret, ESR reaction sites, [in] Iron and Steel Society of AIME, ed., The 28th Electric Furnace Conference, Warrendale, PA, (1970), p. 8.
|
[19] |
P. Mellberg and H. Sandberg, On the mechanism of desulphurization during a.c. and d.c. electroslag remelting, Scand. J. Metall., 2(1973), No. 3, p. 121.
|
[20] |
W. Holzgruber, K. Petersen, and P. E. Schneider, Comparison of products and economics from large VAR, AC-ESR and DC-ESR ingots, [in] Transaction of the International Vacuum Metallurgy Conference, California, 1968, p. 499.
|
[21] |
E. Plöckinger, Electroslag remelting—A modern tool in metallurgy, J. Iron Steel Inst., 211(1973), No. 4, p. 533.
|
[22] |
C.B. Shi, Behaviour and Control Technique of Oxygen and Inclusions during Protective Atmosphere Electroslag Remelting Process [Dissertation], University of Science and Technology Beijing, Beijing, 2012, p. 95.
|
[23] |
M. Kato, K. Hasegawa, S. Nomura, and M. Inouye, Transfer of oxygen and sulfur during direct current electroslag remelting, Trans. Iron Steel Inst. Jpn., 23(1983), No. 7, p. 618. doi: 10.2355/isijinternational1966.23.618
|
[24] |
Q. Wang, Z. He, G.Q. Li, B.K. Li, C.Y. Zhu, and P.J. Chen, Numerical investigation of desulfurization behavior in electroslag remelting process, Int. J. Heat Mass Transfer, 104(2017), p. 943. doi: 10.1016/j.ijheatmasstransfer.2016.09.022
|
[25] |
D. Hou, Z.H. Jiang, Y.W. Dong, Y. Li, W. Gong, and F.B. Liu, Mass transfer model of desulfurization in the electroslag remelting process, Metall. Mater. Trans. B, 48(2017), No. 3, p. 1885. doi: 10.1007/s11663-017-0921-0
|
[26] |
M. Eissa and A. EI-Mohammadi, Effect of physical properties of slag on sulphur removal mechanism during ESR process, Steel Res., 69(1998), No. 10-11, p. 413. doi: 10.1002/srin.199805573
|
[27] |
T.M.T. Mattar, A.M. Fathy, H.S.R. El-Faramawy, M.M. Eissa and K.A.R. El-Fawakhry, Optimization of desulphurization of tool steels during EAF and ESR processes, [in] Metal 2001, Ostrava, Czech Republic, 2001, p. 1.
|
[28] |
G.M. Padki, M.S.N. Balasubramanian, K.M. Gupt, and P. Krishna Rao, Effect of ESR and carbon content on mechanical properties of a high-strength steel (15CDV6) for aerospace applications, Ironmaking Steelmaking, 10(1983), No. 4, p. 180.
|
[29] |
C.B. Shi, X.C. Chen, H.J. Guo, Z.J. Zhu, and X.L. Sun, Control of MgO·Al2O3 spinel inclusions during protective gas electroslag remelting of die steel, Metall. Mater. Trans. B, 44(2013), No. 2, p. 378. doi: 10.1007/s11663-012-9780-x
|
[30] |
C.B. Shi and J.H. Park, Evolution of oxide inclusions in Si–Mn-killed steel during protective atmosphere electroslag remelting, Metall. Mater. Trans. B, 50(2019), No. 3, p. 1139. doi: 10.1007/s11663-019-01564-6
|
[31] |
C.B. Shi, H. Wang, and J. Li, Effects of reoxidation of liquid steel and slag composition on the chemistry evolution of inclusions during electroslag remelting, Metall. Mater. Trans. B, 49(2018), No. 4, p. 1675. doi: 10.1007/s11663-018-1296-6
|
[32] |
R.S.E. Schneider, M. Molnar, S. Gelder, G. Reiter, and C. Martinez, Effect of the slag composition and a protective atmosphere on chemical reactions and non-metallic inclusions during electro-slag remelting of a hot-work tool steel, Steel Res. Int., 89(2018), No. 10, art. No. 1800161. doi: 10.1002/srin.201800161
|
[33] |
C.K. Cooper and D.A.R. Kay, Behaviour of sulphur during ac electroslag remelting, J. Iron Steel Inst., 208(1970), No. 9, p. 856.
|
[34] |
S. Ahmadi, H. Arabi, A. Shokuhfar, and A. Rezaei, Evaluation of the electroslag remelting process in medical grade of 316LC stainless steel, J. Mater. Sci. Technol., 25(2009), No. 5, p. 592.
|
[35] |
X.C. Chen, F. Wang, C.B. Shi, H. Ren, and D. Feng, Effect of electroslag remelting process on desulphurization of GH4169, J. Iron Steel Res., 24(2012), No. 12, p. 11.
|
[36] |
L.Z. Chang, X.F. Shi, and J.Q. Cong, Study on mechanism of oxygen increase and countermeasure to control oxygen content during electroslag remelting process, Ironmaking Steelmaking, 41(2014), No. 3, p. 182. doi: 10.1179/1743281213Y.0000000114
|
[37] |
S. Radwitz, H. Scholz, B. Friedrich, and H. Franz, Influencing the electroslag remelting process by varying fluorine content of the utilized slag, [in] GDMB Society of Metallurgists and Miners, ed., Proceedings of European Metallurgical Conference 2015, Vol. 2, Düsseldorf, Germany, (2015), p. 887.
|
[38] |
S. Radwitz, H. Scholz, B. Friedrich, and H. Franz, Process and refining characteristics of ESR using MgO containing slag systems, [in] International of Symposium on Liquid Metal Processing & Casting 2015, Leoben, Austria, 2015, p. 153.
|
[39] |
C.P. Kang, F.B. Liu, Z.H. Jiang, J. Yu, and K. Chen, Study on desulfurization kinetics model of electroslag remelting under different atmosphere, [in] Proceedings of 2018 China Special Metallurgical Technology Meeting, Shenyang, 2018, p. 68.
|
[40] |
A.S. Ballantyne, The capabilities and benefits of argon shrouding during electroslag remelting, [in] Medovar Memorial Symposium Proceeding, Kiev, Ukraine, 2001, p. 113.
|
[41] |
G. Stein and J. Menzel, High pressure electroslag remelting—A new technology of steel refining, Int. J. Mater. Prod. Technol., 10(1995), No. 3-6, p. 478.
|
[42] |
P. Pant, P. Dahlmann, W. Schlump, and G. Stein, A new nitrogen alloying technique—A way to distinctly improve the properties of austenitic steel, Steel Res., 58(1987), No. 1, p. 18. doi: 10.1002/srin.198701482
|
[43] |
J. Yu, F.B. Liu, H.B. Li, Z.H. Jiang, Y. Li, C.P. Kang, A. Wang, W.C. Zhang, and H. Feng, Numerical simulation and experimental investigation of nitrogen transfer mechanism from gas to liquid steel during pressurized electroslag remelting process, Metall. Mater. Trans. B, 50(2019), No. 6, p. 3112. doi: 10.1007/s11663-019-01714-w
|
[44] |
A. Sekiya, S. Nakayama, and T. Taketsuru, Deoxidation of stainless steel on vacuum electroslag remelting process, Denki-Seiko, 66(1995), No. 1, p. 47. doi: 10.4262/denkiseiko.66.47
|
[45] |
X.C. Huang, B.K. Li, Z.Q. Liu, T.C. Jiang, Y.Y. Chai, and X.X. Wu, Oxygen transport behavior and characteristics of nonmetallic inclusions during vacuum electroslag remelting, Vacuum, 164(2019), p. 114. doi: 10.1016/j.vacuum.2019.03.014
|
[46] |
Y. Liu, X.J. Wang, G.Q. Li, Q. Wang, Z. Zhang, and B.K. Li, Role of vacuum on cleanliness improvement of steel during electroslag remelting, Vacuum, 154(2018), p. 351. doi: 10.1016/j.vacuum.2018.05.032
|
[47] |
S.J. Li, G.G. Cheng, Z.Q. Miao, L. Chen, and X.Y. Jiang, Effect of slag on oxide inclusions in carburized bearing steel during industrial electroslag remelting, Int. J. Miner. Metall. Mater., 26(2019), No. 3, p. 291. doi: 10.1007/s12613-019-1737-5
|
[48] |
Y.W. Dong, Z.H. Jiang, Y.L. Cao, A. Yu, and D. Hou, Effect of slag on inclusions during electroslag remelting process of die steel, Metall. Mater. Trans. B, 45(2014), No. 4, p. 1315. doi: 10.1007/s11663-014-0070-7
|
[49] |
C.B. Shi, J. Li, J.W. Cho, F. Jiang, and I.H. Jung, 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, 46(2015), No. 5, p. 2110. doi: 10.1007/s11663-015-0402-2
|
[50] |
D. Hou, D. Wang, T. Qu, J. Tian, and Z. Jiang, Sulfur content and inclusion control during electroslag remelting of die steel, Chin. J. Eng., 40(2018), No. Suppl. 1, p. 19.
|
[51] |
D.L. Zheng, J. Li, C.B. Shi, J. Zhang, and R.M. Geng, Evolution of TiN and oxide inclusions in Ti-containing Fe–25Ni–15Cr alloy during electroslag remelting, ISIJ Int., 60(2020), No. 8, p. 1577. doi: 10.2355/isijinternational.ISIJINT-2019-603
|
[52] |
F. Reyes-Carmona and A. Mitchell, Deoxidation of ESR slags, ISIJ Int., 32(1992), No. 4, p. 529. doi: 10.2355/isijinternational.32.529
|
[53] |
A. Mitchell, F. Reyes-Carmona, and E. Samuelsson, The deoxidation of low-alloy steel ingots during ESR, Trans. Iron Steel Inst. Jpn., 24(1984), No. 7, p. 547. doi: 10.2355/isijinternational1966.24.547
|
[54] |
S.F. Medina and A. Cores, Thermodynamic aspects in the manufacturing of microalloyed steels by the electroslag remelting process, ISIJ Int., 33(1993), No. 12, p. 1244. doi: 10.2355/isijinternational.33.1244
|
[55] |
R.G. Baligidad, U. Prakash, V.R. Rao, P.K. Rao, and N.B. Ballal, Electroslag remelting of Fe–28 at.%Al intermetallic alloy, Ironmaking Steelmaking, 21(1994), No. 4, p. 324.
|
[56] |
D.L. Xiang, X.W. Zhu, and K.W. Wang, Production of ultralow sulphur big ESR ingots, Iron Steel, 28(1993), No. 6, p. 421.
|
[57] |
M. Chatterjee, M.S.N. Balasubramanian, K.M. Gupt, and P.K. Rao, Inoculation during electroslag remelting of 15CDV6 steel, Ironmaking Steelmaking, 17(1990), No. 1, p. 38.
|
[58] |
M.E. Fraser and A. Mitchell, Mass transfer in the electroslag process: Part 1 mass-transfer model, Ironmaking Steelmaking, 3(1976), No. 5, p. 279.
|
[59] |
X.W. Tang, R. Zhu, C. Li, and W. Liu, Effect of ESR technology on desulfurization of high nitrogen steel, J. Iron Steel Res., 27(2015), No. 6, p. 24.
|
[60] |
Y. Kojima, M. Kato, T. Toyoda, and M. Inouye, The formation of liquid droplet and the behavior of oxygen in direct current electroslag remelting process, Trans. Iron Steel Inst. Jpn., 15(1975), No. 8, p. 397. doi: 10.2355/isijinternational1966.15.397
|
[61] |
M. Kawakami, K. Nagata, M. Yamamura, N. Sakata, Y. Miyashita, and K.S. Goto, Profiles of temperature, voltage and local heat generation in slag phase and metal pool of ESR unit under operation, Tetsu-to-Hagané, 63(1977), No. 13, p. 2162. doi: 10.2355/tetsutohagane1955.63.13_2162
|
[62] |
M. Kawakami, T. Takenaka, and M. Ishikawa, Electrode reactions in dc electroslag remelting of steel rod, Ironmaking Steelmaking, 29(2002), No. 4, p. 287. doi: 10.1179/030192302225005132
|
[63] |
A. Paar, R. Schneider, P. Zeller, G. Reiter, S. Paul, and P. Würzinger, Effect of electrical parameters on type and content of non-metallic inclusions after electro-slag-remelting, Steel Res. Int., 85(2014), No. 4, p. 570. doi: 10.1002/srin.201300317
|
[64] |
A. Mitchell, Electrochemical aspects of the ESR process, IOP Conf. Ser. Mater. Sci. Eng., 143(2016), art. No. 012001. doi: 10.1088/1757-899X/143/1/012001
|
[65] |
I.A. Aksenov, M.A. Matveeva, and I.V. Chumanov, Influence of the ESR parameters on the removal of sulfur, Russ. Metall., 2019(2019), No. 6, p. 601. doi: 10.1134/S003602951906003X
|
[66] |
J.W. Zhang, P.M. Guo, and Z.B. Li, Study on electro-capillary oscillation in ESR system, Iron Steel, 35(2000), No. 5, p. 23.
|
[67] |
W. Holzgruber and E. Plöckinger, Metallurgical and technological foundations of electroslag re-melting of steel, Stahl Eisen, 88(1968), No. 12, p. 638.
|
[68] |
Y.F. Qi, J. Li, C.B. Shi, H. Wang, and D.L. Zheng, Precipitation and growth of MnS inclusion in an austenitic hot-work die steel during ESR solidification process, Metall. Res. Technol., 116(2019), p. 322. doi: 10.1051/metal/2018114
|
[69] |
Q. Ma, C.L. Sun, G.P. Feng, and X.L. Zhang, Process practice for improvement of B-type inclusions in ESR sulfur-bearing steel 34CrNiMo6, Special Steel, 38(2017), p. 39.
|
[70] |
L.G. Wang, X.B Jia, Y.Q. Li, W.Y. Zhao, L.G. Bi, X. Yun, and C.J. Shang Guan, Study on the control of sulfur and aluminum element during electroslag remelting process, [in] Proceedings of 2016 China Special Metallurgical Technology Meeting, Dalian, 2016, p. 233.
|