Analysis of the Kinetics of Devitrification and Crystallization of a Melilite Mold Powder Slag for Medium Carbon Steel Billet Casting

Abstract

High-speed continuous casting of steel billets entails considerable turbulence in the liquid core, which results in significant slag entrapment unless high viscosity slags are used. It has been suggested that such slags remain glassy or crystallize slightly under the prevailing mold cooling, temperature and residence time conditions. Slags whose composition lead to formation of melilite minerals (i.e., to formation of calcium sodium magnesium aluminum iron disilicates), as the main crystalline phase, possess viscosities > 0.5 Pa/s at 1573 K (1300 °C), are low or do not contain F, and incorporate transition metal oxides (e.g., FeO, MnO and TiO) to absorb infrared radiation and soften steel shell-to-mold heat transfer. In this work, a commercial melilite mold powder, for casting medium carbon steels round billets, is selected to carry out detailed analysis of the kinetics of precipitation of crystalline phases from glassy—devitrification—and super-cooled liquid slags—crystallization—under non-isothermal and isothermal conditions. High-temperature confocal laser scanning microscopy is used in both cases and differential scanning calorimetry just in non-isothermal ones. Assessment of amorphous and crystalline phases in treated samples is done by quantitative X-ray powder diffraction analysis. It is found that even after prolonged treatment (» 36,000 seconds) at 1248 K (975 °C) approximately 13 wt pct of the slag remains amorphous. Additionally, the results indicate that nucleation of crystalline phases in super-cooled liquid and glassy slags occurs on the surface. Thus, it is found that crystallization kinetics is strongly influenced by the topography of the surface with which the super-cooled liquid is in contact, as well as, by shearing actions imposed on the liquid slag surface, which contribute by developing nucleation sites. Devitrification tends to be stronger on surfaces contacting foreign walls and over cracks. Moreover, it is found that predictions of the kinetic model, developed for estimating time–temperature–transformation diagrams from non-isothermal differential scanning calorimetry data, portray reasonably well experimental results of crystallization, as well as devitrification of consolidated samples.