Quantitative Evaluations of Surface Cleanliness in IF Steel Slabs at Unsteady Casting

Macro-inclusions in the surface layer of slabs are mainly responsible for the sliver defects in IF steel sheets. In the present work, macro-inclusions in six kinds of unsteady cast IF steel slabs involving four unsteady states (casting start, ladle change, nozzle change and casting end) in one casting sequence were quantitatively characterized using an automatic inclusion analyzer with a total detection area of 238,048 mm². The cleanliness of corresponding normal slabs was also evaluated as the benchmark study, and the number density (ND) of inclusions > 50 µm was used to describe the surface slab cleanliness. Generally, alumina-based and mold powder inclusions were detected, and the former type was further subdivided into alumina clusters, alumina associated with bubbles, refractory-related alumina, Al-Ti complex oxides and CaO-Al₂O₃-MgO. Several large-sized alumina-based inclusions were detected in the normal slabs with an average ND of 0.31 N/cm², although they had very low total oxygen (TO) contents (10~13 ppm). No mold powder inclusions were found in normal slabs. For all the unsteady slabs, alumina-based and mold powder inclusions were both observed, and the percentage of the former kind was ≥ 90 pct. The average density of macro-inclusions for the first slab was 1.621 N/cm², whose cleanliness was much worse than any of the other unsteady slabs. The first slab should be downgraded. For the second slab, the ND of macro-inclusions was 0.385 N/cm², which was still larger than the normal slabs because of the lasting effect of the re-oxidation. For the penultimate, cap-off and SEN changed slabs, the density of macro-inclusions fluctuated from 0.25~0.35 N/cm², which was close to the average level of normal slabs. However, mold flux-originated inclusions were frequently observed in these slabs because of flow pattern variations due to the casting speed change. In terms of the slab during the ladle change process, mold powder inclusions were frequently detected even though the casting speed remained constant. A mold powder entrapment mechanism was proposed, which showed the entrapment occurred owing to the flow pattern change induced by forming/dropping of SEN clogs due to re-oxidation by FeO in the ladle slag and tundish steel temperature variations during the ladle change practice. The severity of powder entrapment and re-oxidation was also given for different kinds of unsteady slabs, which provides a direct guide to treating these slabs in the steel plant.