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Existing thermodynamic descriptions of the whole Cr–Fe–P system are insufficiently accurate for understanding the thermodynamic behavior of the Cr–Fe–P materials during the manufacturing process. To construct a more precise and consistent thermodynamic database of the Cr–Fe–P system, thermodynamic modeling of the Cr–P and Cr–Fe–P systems was conducted using the CALculation of PHAse Diagrams (CALPHAD) approach based on critical evaluation of the experimental data. The modified quasichemical model and compound energy formalism were employed to describe the liquid and solid solutions, respectively. The Gibbs energies of stoichiometric compounds Cr3P(s), Cr2P(s), CrP(s), and CrP2(s) were carefully determined based on reliable experimental data. The ternary (Cr,Fe)3P, (Cr,Fe)2P, and (Cr,Fe)P phosphides were modeled as solid solutions considering mutual substitution between Cr and Fe atoms. In addition, the phase equilibria of BCC_A2 and FCC_A1 solutions and the liquid phase of the ternary Cr–Fe–P system were also optimized for more accurate descriptions of existing phase equilibria and thermodynamic properties data. As an application of the present database, the experimentally unexplored thermodynamic properties and phase diagrams of the Cr–Fe–P system are predicted.

Na2O is an alkaline oxide, which can significantly improve the dephosphorization ability of converter slag. The effect of Na2O on the dephosphorization of converter slag was analyzed with a high-temperature dephosphorization experiment in a MoSi2 resistance furnace. We found that the dephosphorization rate increased with the increase of (Na2O) in the dephosphorization slag. The elements of Ca, Si, O, and P in the dephosphorization slag are distributed in the same area, mainly in the form of phosphate minerals, such as Ca2SiO4·0.05Ca3(PO4)2 and 6Ca2SiO4·Ca3(PO4)2. After adding Na2O, part of the Na will replace the Ca in the phosphorus-containing phase to form Ca2SiO4·Ca2Na2(PO4)2. The industrial test showed that the average dephosphorization rate in the early stage of the test heats with the CaO-MgO-FeO-SiO2-0.5%Na2O slag system could reach 62.39%, which was 19.62% higher than that of the conventional heats. The average basicity of the final slag was 0.19% lower than that of the conventional heats, while w(P2O5) increased by 0.36%, and T.Fe decreased by 0.69%. The average consumption of the slagging materials was 35.93 kg/t, which was 7.24 kg/t less than that of the conventional heats. Through thermodynamic calculation, we found that with the increase of (Na2O), the phosphorus distribution ratio between slag and steel increased significantly, the area of the liquid phase zone of the slag system increased continuously, and the viscosity decreased continuously.

In order to reduce the segregation of Cr and Mo and inhibit the precipitates, we added a small amount of B and Ce to traditional S31254 steel. Using an air-cooling and low-temperature diffusion treatment, the purpose was to control B and Ce at the grain boundary. The heat-treatment process could prompt co-segregation of B, precipitate-forming elements, and Ce at the grain boundary at 950 °C. After aging at 950 °C for different amounts of time, the diffusion treatment had an obvious inhibitory effect on the precipitates that caused them to become discontinuous, fine, and serrated. The B-containing serrated precipitates were only rich in Mo, while Cr was homogeneously distributed in the probed volume. A uniform distribution of Cr reduced the Cr-depleted zone in the area adjacent to the phase interface. Ce was observed to be segregated at the grain boundary. This showed that Ce could inhibit the formation of precipitates at the grain boundary. The serrated precipitates had an obvious resistance to intergranular corrosion.

Focusing on the serious volatilization of MoO3 in super austenitic stainless steel with a high Mo content, the influence of B on the formation of oxide film and the distribution of Cr and Mo was investigated at 900 °C and 1000 °C. Without the addition of B, Mo tends to diffuse to the surface, forming porous Cr/Mo-rich oxides, causing the volatilization of Mo. The addition of B can inhibit the diffusion of Mo to the surface, facilitate the diffusion of Cr to the surface and combines with O, providing conditions for the nucleation of Cr2O3. A large amount of Cr2O3 accumulated on the surface to form a dense passive film, which inhibited the diffusion of Mo to the surface, reduced the loss of Mo, and formed Mo/Cr-rich precipitates at grain boundaries that are close to the surface. However, it was difficult to form Mo-rich precipitates at the grain boundaries of a sample without B, which aggravated the volatilization of Mo from grain boundary to surface. Therefore, the addition of B can improve the oxidation resistance of 254SMO and inhibit the volatilization of Mo.

The effects of the Al2O3 content and basicity of CaO–SiO2–Al2O3–10 wt.% MgO refining slag on inclusions removal in 55SiCr spring steel were investigated. The viscosity of slag was studied using a viscometer, while the microstructure investigation involved using a water-quenching furnace and a Fourier-transform infrared spectrometer. The influence mechanism of the slag adjustment on inclusions was explored through thermodynamic calculations and kinetic analysis. The results indicated that the viscosity of the molten slag increased gradually with the content of Al2O3 increasing due to it increasing the degree of polymerization of the slag network structure, especially the [AlO4]5− and [Si-O-Si] structures. In contrast, the viscosity of molten slag experienced the opposite pattern, with the basicity of molten slag increasing. This was due to the fact that Ca2+ can significantly reduce the degree of polymerization of a slag network structure, especially the percentages of the [SiO4]4−, [AlO4]5− and [Si-O-Si] network structures. Finally, the changes in physical properties and structure of slag significantly affected the removal effect of the inclusions in molten steel. As a result, the number, size distribution, composition distribution and morphology of the inclusions displayed significant changes when the content of Al2O3 increased from 3 wt.% to 12 wt.% and the basicity of the slag gradually increased from 0.5 to 1.2.

S is a common corrosion medium for austenitic stainless steels. The severe intergranular fracture of austenitic stainless steels occurs in sulfur environments. In this paper, the permeation of S at different atomic positions for three symmetric tilt grain boundary types, i.e., Σ5(210), Σ5(310), and Σ9(114) have been computed using first-principles calculations. S has the strongest segregation tendency in the Σ5(210) grain boundary. A high content of S at the grain boundary indicates harm to the grain boundary. Sulfur segregation in the grain boundaries can weaken the strength of the metallic bond. When Mo and Cr are present at the Σ5(210) grain boundary, the sulfur-induced embrittlement is inhibited. With increased S concentration at the grain boundary, the coexistence of Mo and Cr can suppress the intergranular fracture of S on the grain boundary. The reason why high-Mo stainless steel has excellent sulfur-induced intergranular corrosion resistance is explained at the atomic level.

Herein, a 2D unified model coupling a plasma arc–molten bath–cavity in a direct current electric arc furnace was developed for a characteristic analysis of the fluid flow and heating rate of the molten bath. The ‘local thermodynamic equilibrium–diffusion approximation’ method was employed for the physical phenomenon at the plasma arc/molten bath interface, and the volume-of-fluid method was used to track the free surface. After ensuring model validation, the formation processes of the cavity and the flow field and heating rate of the molten bath were investigated by utilizing the unified model. The numerical results showed that the formation processes of the cavity contained three stages, namely the expansion, compression, and dynamic equilibrium stages. The arc pressure and plasma shear stress both contributed to the cavity formation, and dominated the expansion of the cavity depth and diameter, respectively. Under plasma arc jet impingement, there were two flow patterns inside the molten bath: (i) a clockwise eddy on the top surface and lateral part of molten bath dominated by plasma shear stress, and (ii) a counter-clockwise eddy in the bottom part of the molten bath dominated by the electromagnetic force. Meanwhile, the main heated region of the molten bath with the plasma arc–molten bath–cavity coupling was in the radial range of 0.2–0.6 m, and a high-temperature region was formed on the top surface of the molten bath caused by plasma shear stress.

To clarify the effect of sulfur on inclusions and mechanical properties of Ce-Mg treated resulfurized SCr420H steel. Laboratory experiments were conducted to prepare steels with sulfur contents as 0.01%, 0.06%, and 0.132%. Inclusion evolution in liquid steel, MnS precipitation during solidification, and tensile test results of steel after quenching and tempering were investigated. The results showed that due to the limitation of mass transfer in molten steel, composite inclusion that Ce-O-S wrapped by Ce-Ca-Mg-Al-Si-O, which was named transition state inclusions, can form quickly after adding Ce-Mg lump to the molten steel. As the homogenization of molten steel, the difference of sulfur content in steel can lead to the transition state inclusions transformed into different inclusions. With the increase of sulfur content, the quantity of MnS increased significantly, and the morphology of MnS transformed from “stick” to “dendritic + fishbone”, and then to “fishbone”. Tensile test results and fracture analysis indicate that the decline of inclusion spacing as the increase of sulfur content leads to a shorter physical path of crack propagation in steel. Therefore, the increase of sulfur content can bring about a decrease in the strength and plasticity of the steel. From the perspective of inclusion control, making the MnS inclusion precipitate more dispersive and increasing the distance between inclusions can be considered as a method for preventing the decline of mechanical properties in steel with high sulfur content.

Steel tire cord and steel saw wire represent typical precision pearlitic steel wire rods of wire products; it is a very important solar energy material with a diameter about 50 μm. This paper mainly discusses the research progress of the wire rod drawing process, and its main contents are as follows: First section—the control of the wire rod surface quality is summarized, including the thickness of the surface decarburization layer, the phase composition and thickness of the surface iron oxide scale, and the removal of surface iron oxide scale. Then, the research progress of the wire rod water bath treatment process during sorbitization is summarized. In addition, the development of brass plating technology for steel wire is summarized, including copper plating technology, coating phase composition, etc. Furthermore, the development of steel wire drawing methods is summarized. Finally, the development of the dies used in steel wire drawings is summarized.

In order to study the effect of BaO or B2O3 on the absorption of Ti inclusions, the effects of mold fluxes with different contents of BaO (0~15%) or B2O3 (0~15%) on the mass transfer coefficients of TiO2 or TiN were studied with the rotating cylinder method. The experimental results show that with the addition of BaO in the mold flux, the mass transfer coefficient of TiO2 increases from 4.58 × 10−4 m/s to 6.08 × 10−4 m/s, that of TiN increases from 3.09 × 10−4 m/s to 4.41 × 10−4 m/s, 2CaO·MgO·2SiO2 is transformed into BaO·2CaO·MgO·2SiO2, and the Ti inclusions combine with CaO to form CaTiO3. With the addition of B2O3 in the mold flux, the mass transfer coefficient of TiO2 increases from 4.58 × 10−4 m/s to 7.46 × 10−4 m/s, that of TiN increases from 3.09 × 10−4 m/s to 5.50 × 10−4 m/s, CaO and B2O3 combine to 2CaO·B2O3, and Ti inclusions exist in the form of TiO2. During the experiment, TiN will be transformed into titanium oxide.

In the present study, the effects of rare earth metal (REM) Ce on the number, size distribution and type of inclusions, as well as the grain size, tensile and impact properties of LDX2101 duplex stainless steel, were investigated using thermodynamic analysis, optical microscope, image software, scanning electron microscope, tensile and impact testing machines. The results indicate that when the Ce content in steel is 0%, the main inclusions are irregular and large size Al2O3 and Al2O3-MnS. When the Ce content in steel is 0.005% or 0.02%, the inclusions are mainly spherical and small size inclusions CeAlO3, Ce2O2S and Ce2O3. With the increase in Ce content, the proportion of small size inclusions gradually increases; the number of inclusions per unit area decreases from 122 to 58 and the average grain size reduces from 16 ± 0.7 μm to 12 ± 0.3 μm. Moreover, the mechanical properties of steels are improved, and the tensile strength, yield strength and elongation are elevated by 4.69%, 2.83% and 4.9%, respectively. The impact fracture mode of steel without Ce is cleavage fracture, however, the fracture mode is transformed into a mixed fracture of cleavage and dimple after adding 0.005% and 0.02% Ce.

A comprehensive mathematical model of electroslag remelting with two series-connected electrodes (TSCE-ESR) was constructed based on sequential coupling method. The influence of droplet effect on electroslag remelting process (ESR) was considered in this model. Compared with one-electrode electroslag remelting (OE-ESR), the multi-physics field, droplet formation and dripping behavior, and molten metal pool structure of TSCE-ESR process were studied. The results show that during the process of TSCE-ESR, the proximity effect of the electrodes suppresses the skin effect, and Joule heat is concentrated in the area between the two electrodes of slag pool, making the temperature distribution of the slag pool more uniform. The heat used to melt the electrode in the process of TSCE-ESR accounts for about 34% of the total Joule heat, which is lower than the OE-ESR (17%). Therefore, it makes a higher melting rate and a smaller droplet size in the process of TSCE-ESR. Compared with OE-ESR, TSCE-ESR process can realize the unification of higher melting rate and shallow flat molten metal pool. Compared with the results without droplet effect, it is found that in the simulation results with droplet effect, the depth and the cylindrical section of molten metal pool increased, and the width of the mushy zone is significantly reduced, which is more consistent with the actual electroslag remelting process.

The formation and dripping behavior of droplets in the process of the electroslag remelting with two series-connected electrodes (TSCE-ESR) has an important influence on the optimization of power supply parameters and the purity of the electroslag ingot. In this article, through numerical simulation based on the VOF (volume of fluid) model, combined with the transparent experimental device for physical simulation, the mechanism of metal droplet formation and the effect of the filling rate on its droplet behavior were studied. The results showed that the proximity effect, instead of the skin effect, is a major factor influencing droplet formation in TSCE-ESR process. The proximity effect makes the region inside the two electrode tip melt first, and the molten steel converges at the electrode tips to form a droplet source. The process of droplet formation and dropping can be divided into three stages: formation of molten layer, droplet stretching and necking, and detachment. In the stage of droplet stretching and necking, the increase in the contact area between the droplet and the slag and the instantaneous increase of the current provide good thermodynamic and dynamic conditions for the removal of non-metallic inclusions. After the droplet drops into the slag pool, it promotes the flow of slag and improves the heat and mass transfer efficiency of the slag/metal interface. The relatively large filling rate can form smaller and dispersed droplets, which improves the refining effect. At the same time, the increase of the filling rate can improve the input power and the electrode remelting rate.

The effects of the Y- and Ti-containing inclusions on the tensile and impact properties of reduced activation ferritic martensitic (RAFM) steels were evaluated. Four steels with different Y and Ti contents were produced via vacuum induction melting. The size and quantity of inclusions in the steels were analyzed using scanning electron microscopy, and the oxide particle formation mechanism was clarified. These inclusions helped to enhance the pinning effect of the austenite grain boundaries based on the Zener pinning force. The average prior austenite grain sizes, measured via the linear intercept method, were 12.34 (0 wt.% Ti), 9.35 (0.010 wt.% Ti), 10.22 (0.030 wt.% Ti), and 11.83 (0.050 wt.% Ti) μm for the four steels, in order of increasing Ti content, respectively. Transmission electron microscopy was conducted to observe the fine carbides. The strength and impact properties of the steel containing 0.010 wt.% Ti were improved, and the ductile-to-brittle-transition temperature was reduced to −70.5 °C. The tensile strength and impact toughness of the steel with 0.050 wt.% Ti were significantly reduced due to the coarsening of both the inclusions and grain size, as well as the precipitation of large TiN inclusions. The RAFM steel with approximately 0.015 wt.% Y and 0.010 wt.% Ti exhibited an optimized combination of microstructures, tensile properties, and impact properties among the four steels.

This study investigated the microstructural stability and mechanical properties exhibited by China low activation martensitic (CLAM) steels with different yttrium (Y) contents over 3000 h of aging at 550 °C. Scanning electron microscopy, electron backscatter diffraction analysis, and transmission electron microscopy were employed to investigate the microstructural evolution of the steels. Results indicated that grain boundary migration was slow and the Laves phase precipitation was delayed in Y-containing steels. Grain boundaries at different angles in 0Y and 6Y CLAM steels were significantly affected, and those in 36Y and 71Y alloys exhibited negligible changes during the long-term thermal aging. Moreover, Y contents had appreciable effects on the strength and toughness of the aged steels. The stable microstructure of Y-containing CLAM alloys is responsible for improved strength and impact toughness during aging.

In the present study, the effect of cerium content in the range of 0~0.0676% on oxygen and sulfur content, as well as the quantity, size, distribution, and type of inclusions in C104Cr saw wire steel, were investigated using thermodynamic analysis, metallographic examination, SEM-EDS, and component analysis. The results showed that conducting a vacuum carbon pre-deoxidization process is helpful in preventing the formation of Ce2O3 inclusions in a smelting experiment, and cerium has a beneficial effect in terms of modifying inclusions. When the content of cerium in steel is 0.0136% or 0.0277%, the main inclusions in the steel are Ce2O2S and CeS, and when the content of cerium is 0.0389% or above, the inclusions in the steel are Ce2O2S, CeS, Ce–S–O–P(As), Ce–O–P, and Ce–P(As). The calculation of the segregation model showed that the precipitation of CeP and CeAs in steel takes place at the end of solidification. According to the element mapping distribution diagram of Ce–S–O–P(As) and the layered Ce–O–P inclusions found in steel with high cerium content, two possible mechanisms for the formation of Ce2O3 inclusions distributed in the outer layer of cerium composite inclusions are proposed. The first mechanism suggests that Ce2O3 inclusions are generated from the combination of [Ce] and [O] directly, and the second suggests that Ce2O3 is the product of an oxidization reaction after the formation of CeP.

Inclusion removal and modification of C96V saw wire steel using Na2O- and Rb2O- containing novel low-basicity LF (ladle furnace) Refining Slags have been researched. The results indicated that the addition of Na2O deteriorates inclusion removal; by contrast, the addition of Rb2O seems to significantly enhance inclusion removal. In detail, Rb2O can improve the cleanliness in the as-quenched C96V saw wire steel melts compared to preexisting synthetic LF refining slag compositions: (i) The average inclusion diameter experienced a remarkable decrease after reaction between the liquid steel and the synthetic LF refining slag; (ii) In addition, the number of inclusions also suffered from a dramatic decrease, with the reaction time increasing from 900 to 2700 s (15 to 45 min); (iii) Furthermore, both of the MnO-SiO2-Al2O3 and CaO-SiO2-Al2O3 inclusion system mainly concentrated in the low melting zone when the composition of Rb2O in synthetic refining slag was ≥5.0 wt%. This is mainly because Na2O significantly reduces the viscosity of refining slag, while Rb2O increases it. Then, there are two remarkable influences causing the increase of viscosity of refining slag with the addition of Rb2O: the inclusions can be sufficiently entrained within the slag once absorbed due to the significant increase in the viscosity; and the slag entrapment during refining process weakened dramatically.

Electroslag remelting cladding (ESRC) with a t-shape current carrying mold was adopted to make a compound roll including a working layer and mandrel. A comprehensive coupled transient model was established to reveal the basic phenomena of electromagnetic fields, flow fields, temperature fields, and multiphase flow. Meanwhile, the movement of the mandrel and working layer relative to the slag pool was simulated by dynamic mesh technology to reveal the interface bonding mechanism. The mechanism is as follows: The temperature of the mandrel increases and the mandrel melts slightly when the mandrel passes through the slag pool. The fusion layer is a mixture of molten steel of mandrel and working layer that is the connector between the mandrel and the working layer. Therefore, the interface bonding quality is dependent on a fusion layer that is affected by the voltage/power. The investigation indicates that the fusion layer thickness is between 2 and 4 mm in the condition of 40 V that benefits from obtaining a good interface bonding quality.

In the present study, a new electroslag cladding method by using of the advanced current supplying mold technology was used for manufacturing the high speed steel (HSS)/ductile cast iron (DCI) composite roll. The graphite morphology, matrix microstructure, elements distribution, carbides morphology, and carbides composition have been investigated by means of optical microscope (OM), scanning electron microscope (SEM), and energy dispersive spectroscopy (EDS). With increasing distance from the HSS side, a transition of graphite morphology from naught to existence and from small and dispersed to large and nonuniform was obtained at the interface. It was closely related to the fact that graphite in DCI participated in the phase change and the roll core surface and its nearby positions was heated to a high temperature by the liquid slag during the whole electroslag cladding process. Due to the combined effects of melting and elements diffusion, a significant migration of the alloying elements have occurred through the line scan analysis. Based on this, different types of carbides with the morphology and composition were found at the bonding interface. In addition, no obvious slag inclusions, porosity, shrinkage and other defects at the bonding interface were found. Results of the tensile test also illustrated that the bonding interface had a good quality and it could fully meet the requirements of the roll.

High nitrogen martensitic stainless steel 30Cr15Mo1N plates were successfully welded by friction stir welding (FSW) at a tool rotation speed of 300 rpm with a welding speed of 100 mm/min, using W-Re tool. The sound joint with no significant nitrogen loss was successfully produced. Microstructure, mechanical and corrosion properties of an FSW joint were investigated. The results suggest that the grain size of the stir zone (SZ) is larger than the base metal (BM) and is much larger the case in SZ-top. Some carbides and nitrides rich in chromium were found in BM while not observed in SZ. The martensitic phase in SZ could transform to austenite phase during the FSW process and the higher peak temperature, the greater degree of transformation. The hardness of SZ is significantly lower than that of the BM. An abrupt change of hardness defined as hard zone (HZ) was found in the thermo-mechanically affected zone (TMAZ) on the advancing side (AS), and the HZ is attributed to a combination result of temperature, deformation, and material flow behavior. The corrosion resistance of SZ is superior to that of BM, which can be attributed to less precipitation and lower angle boundaries (LABs). The corrosion resistance of SZ-bottom is slight higher than that of SZ-top because of the finer grained structure.

Removal of non-metallic inclusions to CaF2-based slag is one of the most important functions of electroslag remelting. In this work, the dissolution behavior for alumina-based inclusions in CaF2-Al2O3-CaO-MgO-SiO2 slag has been investigated. Results indicate that the diffusion or permeability capacity of slag components into alumina particles is F−, Ca2+, Si4+, Mg2+, from strongest to weakest, for CaF2-Al2O3-CaO-MgO-SiO2 slag. Alumina inclusions react with F− in liquid slag at first and then react with CaO to form xCaO-yAl2O3 system. Subsequently, MgO substitutes for CaO to form a MgO-Al2O3 system layer surrounding the other product and reactant, and then enters the liquid slag. CaF2 can improve the dissolution capacity of slag to alumina inclusions. A complex region was formed between alumina-based particles and the slag, with different areas dominated by CaF2, CaO-Al2O3, CaO-SiO2 and MgO-Al2O3. The dissolution process of alumina particles in slag is different from the formation of compound inclusions originated from the Al-O deoxidization reaction.

Hot deformation behavior and microstructure evolution of 2707 hyper duplex stainless steel (HDSS) were investigated through hot compression tests in the temperature range of 900–1250 °C and strain rate range of 0.01–10 s−1. The results showed that the flow behavior strongly depended on strain rate and temperature, and flow stress increased with increasing strain rate and decreasing temperature. At lower temperatures, many precipitates appeared in ferrite and distributed along the deformation direction, which could restrain processing of discontinuous dynamic recrystallization (DRX) because of pinning grain boundaries. When the temperature increased to 1150 °C, the leading softening behaviors were dynamic recovery (DRV) in ferrite and discontinuous DRX in austenite. When the temperature reached 1250 °C, softening behavior was mainly DRV in ferrite. The increase of strain rate was conducive to the occurrence of discontinuous DRX in austenite. A constitutive equation at peak strain was established and the results indicated that 2707 HDSS had a higher Q value (569.279 kJ·mol−1) than other traditional duplex stainless steels due to higher content of Cr, Mo, Ni, and N. Constitutive modeling considering strain was developed to model the hot deformation behavior of 2707 HDSS more accurately, and the correlation coefficient and average absolute relative error were 0.992 and 5.22%, respectively.