Inclusion Behavior During the Electron Beam Button Melting Test

The high mechanical performance of alloys developed for the manufacture of turbine disks depend upon the size and the number density of the inclusions. The electron beam button method has been practiced since the 1980s as a technique to quantify the cleanliness of the superalloys as well as to identify the nature and the size of the inclusions. The technique involves melting the sample into a hemispherical water-cooled crucible and the low density inclusions (mainly oxides) are concentrated by a combination of Marangoni and buoyancy forces into an area at the top surface of the button referred to as the raft. We have experimentally studied the behavior of oxide inclusions in special steels using both high definition video and infrared cameras. We have observed the inversion of the Marangoni effect due to the presence of sulfur, which leads to a positive temperature coefficient of the surface tension. A mathematical modeling has been carried out to simulate the turbulent fluid flow associated with the temperature field in the metallic pool of the button. The surface temperature profile has been successfully compared with the measured data. A post-processor numerical tool calculates the inclusion trajectories taking into account the turbulent fluctuation velocity by a stochastic approach. Hence, the behavior of a population of inclusions has been statistically studied, and the dependence of the capture efficiency on the inclusion size has been analyzed.