MgO Al2O3 Research Articles

Effect of ladle-lining materials on inclusion evolution in Al-killed steel during LF refining

Abstract The effect of lining materials (Al2O3 and Al2O3–MgO·Al2O3) of ladle on evolution of non-metallic inclusions in aluminum-killed (Al-killed) steel during ladle furnace refining without Ca treatment was investigated through industrial experiments. The results showed that non-metallic inclusions experienced the changes from Al2O3 → MgO–Al2O3 → CaO–Al2O3. During the refining process using either of the two ladle lining materials, for all non-metallic inclusions, the vast majority are distributed in the high Al2O3 area of the CaO–Al2O3–MgO phase diagram, with very little or none in the low melting point zone. Non-metallic inclusions are mainly smaller than 3 μm, while those larger than 3 μm consisted primarily of MgO·Al2O3 and CaO–Al2O3 inclusions. The use of an Al2O3–MgO·Al2O3-lining ladle is more effective in reducing the number density of inclusions in the steel. However, during the refining process, the Al2O3-lining ladle does not have a significant impact on the presence of MgO–Al2O3 and CaO–Al2O3 inclusions in the molten steel. The Al2O3–MgO·Al2O3-lining ladle does not have a significant effect on MgO–Al2O3 inclusions, but it does promote the formation of CaO–Al2O3 and CaS inclusions in the molten steel.

Microstructure evolution, mechanical characteristics and erosion behavior of Cr2O3–Al2O3–MgO–ZrO2 refractories in molten reduction slag

In order to overcome the serious corrosion problem of furnace hearth refractory materials for smelting reduction ironmaking, the Cr2O3–Al2O3–MgO–ZrO2 refractories were synthesized, and the phase component, microstructure, mechanical characteristics, and slag erosion behavior of composite refractories were investigated and evaluated. The results indicate that the composite refractories mainly consist of Mg(Al, Cr)2O4 spinel phase, (Al, Cr)2O3 solid solution and ZrO2. The content of Mg (Al, Cr)2O4 spinel significantly increases with the increasing MgO content, while the content of (Al, Cr)2O3 obviously decreases. Furthermore, the comprehensive mechanical properties of the MgO modified composite refractories can be obviously enhanced by increasing the MgO content, and sample S4 presents the best mechanical characteristics when the MgO addition is 10 wt%. The corresponding hardness, compressive strength and bending strength are 14.22 GPa, 267.14 MPa and 80.0 MPa, respectively. This is mainly because the formation of Mg(Al, Cr)2O4 significantly improves the densification of composite refractories, and a large number of high-strength Mg (Al, Cr)2O4 spinel “bridge” formed between the large-sized (Al, Cr)2O3 grains. The erosion test results indicate that increasing the MgO content can significantly improve the slag infiltration resistance of composite refractories, because the formation of Mg (Al, Cr)2O4 spinel layer significantly improves the densification of MgO reinforced composite refractories. Although the slag corrosion resistance of Mg(Al, Cr)2O4 is lower than that of (Al, Cr)2O3, the Cr2O3–Al2O3–MgO–ZrO2 refractories still presents good erosion resistance, permeability resistance, and excellent mechanical characteristics.

Bimodal volcanism in the Hegau region (SW Germany): Differentiation of primitive melilititic to nephelinitic rocks produces evolved nosean phonolites

Peculiar bimodal volcanism in the Hegau region (SW Germany) comprises two contrasting SiO2-undersaturated rock suites.(I)Primitive olivine melilitites and melilite-bearing olivine nephelinites (12–9 Ma) are characterized by high MgO, CaO, Fe2O3, TiO2, Ni, V, F, moderate alkalis, Al2O3, P2O5, Ba, Nb, Zr, and low SiO2, Rb, Pb, and U concentrations. The rocks are composed of forsteritic olivine, diopsidic clinopyroxene, melilite, perovskite, Cr-bearing oxyspinel, F- and Ba-rich mica, and fluorapatite. In rare cases, they contain coeval coarse-grained ijolite patches generated by rapid in-situ fractionation in small melt pockets.(II)Evolved nosean phonolites (14–11 Ma) comprise high alkalis, Al2O3, SiO2, Rb, Nb, Zr, U, Pb, S, and low MgO, CaO, Fe2O3, TiO2, P2O5, Ba, Ni, and V concentrations, and contain abundant Ba-bearing alkali feldspar and nosean-haüyne-sodalitess macrocrysts, aegirine-augitic clinopyroxene, as well as accessory apatite, titanite, zircon, and pyrochlore.The melilititic–nephelinitic rocks formed by low degrees of partial melting of a carbonated amphibole ± phlogopite-bearing garnet wehrlite in the uppermost asthenosphere or in the thermal boundary layer and occur also in neighbouring regions. However, their coexistence with evolved nosean phonolites is a unique and so far, unexplained feature in the southern Central European Volcanic Province.Thermodynamic modelling implies that removal of 11–19% oxyspinel, 4–10% olivine, 42–57% clinopyroxene, <3% mica, <9% feldspathoids, <8% feldspar from melilititic–nephelinitic parental melts at upper crustal conditions (∼200 MPa) results in significant amounts of phonolitic residues that are compositionally similar to the exposed nosean phonolites. Strongly negative P and Ti anomalies and a trough of MREE in primitive mantle-normalized trace element patterns of phonolites indicate additional fractionation of titanite and apatite, consistent with the mineralogy of coarse-grained (nepheline) syenitic cumulates, which are present as enclaves in both rock suites. The modelling results suggest crystallization of the (nepheline) syenite cumulates between 1050 and 800 °C and ascent and eruption of the phonolite residues at no less than ∼900 °C with complete solidification of the observed assemblage at >750 °C. Significant crustal assimilation during fractionation appears unnecessary to explain the mineralogical, mineral chemical, and geochemical characteristics of the phonolites. Prolonged upper crustal differentiation of the magmas in one case (nosean phonolites) and fast ascent of primitive melts in the other (olivine melilitites and melilite-bearing olivine nephelinites) can be explained by stress field changes from an extensional to a more compressive regime, the magma ascent becoming thereby increasingly structurally controlled and supported by brittle deformation.

Effects of in situ composite ceramics on the mechanical properties and microstructure of Fe–Cr–Ni alloys

Fe–Cr–Ni composites reinforced with Al2O3–MgO composite ceramics were prepared via reactive hot pressing at 800 °C for 2 h under 30 MPa. The composites primarily comprised Cr0.19Fe0.7Ni0.11, Fe–Cr, magnesium aluminate spinel, Al2O3, and MgO phases. The mechanical properties and microstructure of the metal matrix composites changed with the changing in situ Al2O3–MgO content. The composite ceramic exhibited excellent mechanical properties (Vickers hardness = 5.59 GPa, bending strength = 244.59 MPa, and fracture toughness = 11.66 MPa·m1/2) when Al2O3/(MgO + Al2O3) (mol/mol) was 0.6371 owing to the difference in the residual stress at the interface between the ceramic particles and metal matrix.

The Effect of Ca Pretreatment on the Characteristics of Rare‐Earth Nonmetallic Inclusions in Super‐Duplex Stainless Steel

Rare‐earth treatment enhances steel properties. Nevertheless, this beneficial effect can be counterbalanced by the formation of large‐sized rare‐earth inclusions. To refine and spheroidize these inclusions, Ca pretreatment is employed between Al deoxidation and Ce treatment stages for super‐duplex stainless steel 2507 at 1580 °C, using a vertical tube furnace. A systematic analysis is performed to compare the characteristics of nonmetallic inclusions between the Ca‐untreated and Ca‐treated tests. Prior to Ce addition, Ca pretreatment transforms irregular and clustered MgO–Al2O3 spinel inclusions into spherical CaO–MgO–Al2O3 inclusions. Additionally, Ca pretreatment significantly reduces mean diameter of the inclusions from 2.36 ± 0.54 to 1.27 ± 0.47 μm. After Ce addition, rare‐earth inclusions appear near‐spherical with few clustered inclusions in Ca pretreatment case. Conversely, the absence of Ca treatment results in numerous clustered inclusions, thereby yielding significantly larger rare‐earth inclusions, measuring 2.75 ± 1.66 μm compared to 1.99 ± 1.09 μm. CaO component in CaO–MgO–Al2O3 inclusions is largely reduced by Ce. Consequently, Ca pretreatment only yields slight alterations in chemical composition of rare‐earth inclusions. Ce in situ reduces parent inclusions, initiating from the periphery and progressing toward the center. Therefore, the size and morphology of final rare‐earth inclusions are largely inherited from parent inclusions.

Preparation and characterization of SiO2–Al2O3–MgO–CaO–based ceramic foams mainly from Ca–Mg–rich molybdenum tailings

Molybdenum tailings (MTs) and kaolinite were used as the main materials in the fabrication ceramic foams (CFs) via the high-temperature sintering method, with the addition of SiC as a foaming agent. The effects of MT content on the basic physical properties, pore structure, and chemical characterization were investigated. Results showed that MT enhanced the foaming capability. When the MT content was 60% and the sintering temperature was 1170 °C, the optimum CFs obtained demonstrated bulk density, porosity, water absorption, and compressive strength of 0.55 g/cm3, 77.3%, 6.94%, and 6.74 MPa, respectively, and the pore structure was relatively homogeneous with an average pore diameter of 0.67 mm. The results revealed that SiO2–-Al2O3–-MgO–-CaO system CFs can be prepared from Ca–Mg-rich MT, which provided a feasible strategy for value-added utilization of Ca–Mg-rich MT.

Numerical Understanding on Penetration and Corrosion Behavior of CaO–Al2O3–MeO Slag to Al2O3–MgO Refractory

Numerical Understanding on Penetration and Corrosion Behavior of CaO–Al2O3–MeO Slag to Al2O3–MgO Refractory

Study on the Causes and Control Measures of Mg–Al Spinel Inclusions in U75V Heavy Rail Steel

U75V heavy rail steel production uses an aluminum-free deoxidation process; however, large particles of MgO–Al2O3 inclusions form in the steel, which has a great impact on product quality. In this paper, we try to explain how spinel inclusions, which affect the metallurgical quality of heavy rail steel, are produced by thermodynamic and experimental methods, and then determined measures for avoiding such inclusions. The formation mechanism of spinel inclusions in U75V heavy rail steel was determined through the analysis of nozzle clogging in the pouring process and typical inclusions in steel. The results show that there are two types of spinel inclusions in heavy rail steel: one is pure Mg–Al spinel inclusions and the other is Mg–Al spinel inclusions coated with calcium aluminate. The small, pure Mg–Al spinel inclusions were precipitated during the solidification of the molten steel, and the precipitation temperature was related to the composition of the molten steel. The large spinel inclusions were derived from clogging of the submersed nozzle. Mg–Al spinel inclusions coated with calcium aluminate were transformed from CaO–SiO2–Al2O3–MgO complex inclusions in the steel during cooling, and the formation temperature was related to the content of Al2O3 and MgO in the inclusions. The content of Al2O3 and MgO in the inclusions was the key to the formation of the Mg–Al spinel inclusions. Therefore, in order to control the production of spinel inclusions in steel, it is necessary to strictly control the content of impurity elements such as magnesium and aluminum in the alloy auxiliary materials, to reduce the secondary oxidation of liquid steel and to reduce the erosion of refractory materials.

Relationship between viscosity, foaming, and structure of CaO–SiO2–Al2O3–MgO–FeO slag with the addition of SiO2 and Al2O3

Optimizing the foaming characteristics of slag in electric arc furnaces (EAF) presents a challenging task, affecting electrode heating efficiency and increasing smelting cost. This study explores the impact of adding silicon dioxide (15–35 wt%) and a small quantity of alumina (5–10 wt%) on the viscosity and foaming properties of CaO–SiO2–Al2O3–MgO–FeO slag. Raman spectroscopy and X-ray photoelectron spectroscopy (XPS) were employed to investigate structural changes in the slag melt. The findings reveal that higher levels of silica or a slight increase in alumina content enhance slag polymerization and foaming efficiency. Specifically, a 10 wt% alumina content, in contrast to 5 wt%, leads to high silica content, leading to faster polymerization but relatively lower viscosity. Structural analysis confirms that increasing alumina content, particularly when silica content is high, results in a less stable Al–O–Si structure, causing a shift from Q0 and Q1 units to Q2 and Q3 units, which ultimately reduces viscosity. When the alumina content remains at 5 wt% and silica content increases from 15 wt% to 35 wt%, foaming efficiency improves from 13.06 cm min to 94.97 cm min, a remarkable 627% rise. Moreover, when silica content is 30 wt% and alumina is slightly increased by 5 wt%, there is a notable enhancement in foaming efficiency, rising from 47.11 cm min to 89.16 cm min, while the effect on viscosity is not prominent.

Evolution of MnO–SiO2–Al2O3–MgO inclusions during heat treatment at 1100 °C

Evolution of MnO–SiO2–Al2O3–MgO inclusions during heat treatment at 1100 °C

Reaction mechanism between Al2O3–MgO refractory materials and rare earth high-carbon heavy rail steel

Reaction mechanism between Al2O3–MgO refractory materials and rare earth high-carbon heavy rail steel

Preparation of innovative glass-ceramic materials based on mica schist within the CaO–MgO–Al2O3–SiO2 system

The preparation of affordable glass-ceramic materials by induced crystallization of glass-based mica schists and other natural raw materials (dolomite & limestone), as well as magnesite as a mine waste, was investigated for the first time. Five glass batches were designed based on the eutectic composition of the diopside-anorthite ratio with increasing the enstatite content from 0–40 wt.% within the quaternary CaO–MgO–Al2O3–SiO2 system. After melting at 1400 to 1500 °C, casting into discs & rod shapes, and annealing process, the prepared glasses were subjected to careful heat treatment schedules. Several techniques were used to characterize the applied raw materials, glass, and glass-ceramic materials such as X-ray Fluorescence (XRF), Differential Thermal Analysis (DTA), X-ray Diffraction (XRD), Scanning Electron Microscopy (SEM), and Polarizing-light Microscopy. The produced glass-ceramic from the glass batch with 30 wt% enstatite that was nucleated at 750 °C /2h followed by crystallization at 950 °C /h, displayed the well-developed product on the level of volume crystallization and pore formation.

Enhanced performance of low-pressure sintered CaO–MgO–Al2O3–SiO2–CaCl2 glass-ceramic by using Cr2O3 as the nucleating agent

The sintered glass-ceramic always has an uneven microstructure due to the surface crystallization, which limits the enhancement of its mechanical properties. In the present work, Cr2O3 was added into CaO–MgO–Al2O3–SiO2–CaCl2 glass as the nucleating agent, and the low-pressure (14 kPa) sintering technology was utilized to promote the densification process of the glass frits (0.42–2 mm). It was found that by adding 1 wt% of Cr2O3, the bulk crystallization can be achieved inside the glass particle and the microstructure of the glass-ceramic became more homogeneous. Correspondingly, the bending strength was improved from 127 to 147 MPa, and the Vickers hardness was enhanced from 6.5 to 6.7 GPa, comparing with the Cr2O3-free glass-ceramic. The current study confirmed the positive impact of nucleating agent in the performance of sintered glass-ceramic, which also provided a route for the utilizations of CaCl2-and Cr2O3-bearing wastes.

Colossal permittivity and excellent temperature stability of BaTiO3 based fine ceramics with controlled grain growth

Dielectric materials with colossal permittivity (CP, εr > 104) have attracted the increasing interest of researchers due to their enormous potential in the fields of sensor, capacitor, energy storage, etc. However, for the explored CP materials, their grains are too large to apply. To control grain growth, the sintering aids of MgO–Al2O3–SiO2 (MAS) cordierite glass and common suppression grain growth of MgO have been introduced to BaTiO3-0.004Y2O3-0.006MnO2 ceramics derived from the commercial BaTiO3 powder with the average grain size of 300 nm. After controlling grain growth, the fine grains with the average grain size of dg ∼300 nm and CP are achieved in BaTiO3 based ceramics sintered in reducing atmosphere. Notably, excellent temperature stability with Δεr/εr25°C lower than 17 % is gained for the present BaTiO3 based ceramics in the temperature range of −60 to 155 °C, meeting the X8S specification (ΔC/C25°C ≤±22 %, −55 °C–150 °C). Based on the X-ray photoelectron spectroscopy (XPS) and Raman spectra, the outstanding dielectric properties of the present BaTiO3 based ceramics is ascribed to the electron-pinned defect-dipole (EPDD) effect induced by YTi′−YBa∙, TiTi′−Vo∙∙−TiTi′ and YTi′−Vo∙∙−TiTi′ defect dipoles. The present BaTiO3 based fine ceramics with colossal permittivity (∼2.9 × 104), low loss (∼0.03) at 1 kHz and room temperature, excellent temperature stability and high resistivity of 3.54 × 109 Ω cm is a promising candidate for the multilayer ceramics capacitor (MLCC).

Effect of Mg treatment on inclusion behaviors in 430 ferritic stainless steel during solidification

To understand the effect of Mg treatment on the precipitation, growth, and transformation of inclusions in 430 ferritic stainless steel during solidification, slag refining and Mg treatment experiments with different cooling methods were conducted at 1873 K (1600 °C). Experimental results showed that the oxide inclusions in 430 stainless steel without Mg treatment were mainly Al2O3–SiO2–MnO (slag phase), Al2O3–Cr2O3–MnO (spinel phase), high-Al2O3 (corundum phase) and CaO–SiO2–Al2O3–MnO (slag phase), while all of the oxides except CaO–SiO2–Al2O3–MnO inclusions transformed to MgO–Al2O3–Cr2O3–MnO (spinel phase) after Mg treatment. With water quenching, the average inclusion diameters were about 1.4 μm in both of the Mg-free and Mg-bearing steels, while they increased to approximate 3.1 and 1.9 μm after furnace cooling, separately. With the decrease of cooling rate from 26.2 to 1.24 K s−1, in the Mg-free steel, the average Al2O3 and Cr2O3 contents in the inclusion increased from 19.6 to 42.6 mass% and from 12.22 to 19.44 mass%, respectively, and the average SiO2 content decreased from 43.5 to 17.1 mass%. However, the average composition of inclusions in Mg-bearing steel was relatively stable and independent of cooling rate. A kinetic model was established with the solute micro-segregation model to predict oxide inclusion growth during cooling and solidification. Without and with Mg treatment, under a cooling rate of 1 K s−1, the calculated final sizes of the most stable oxide inclusions were 3.27 and 1.88 μm, respectively. The predicted average compositions and diameters of oxide inclusions were generally consistent with the experimental results.

Effect of NiO, ZrO2 and TiO2 on the formation of glass-ceramic cordierite in the MgO–Al2O3–SiO2–MoO3 system

In glass-ceramic design, the two most crucial factors are composition and microstructure both factors control the ability to form a glass and determines its degree of workability. The composition also determines whether internal or surface nucleation can be achieved. If internal nucleation is desired, as is the case in hot forming glassware, right nucleating agents are melted into the glass as part of the bulk composition. For this reason, this research work focuses on obtaining glass-ceramic cordierite starting from a parent glass of the MgO–Al2O3–SiO2–MoO3 system, using NiO, ZrO2 and TiO2 in a range of 1%Wt to 3%Wt, with the objective of identifying which of the oxides most favors the formation of cordierite. Twelve samples were prepared, which were characterized by thermal gravimetric analysis (TGA), differential thermal scanning analysis (DSC), X-ray diffraction (XRD), Elemental X-ray mapping (SEM), and Infrared spectra using the ATR technique (FT-IR). It was found that NiO is the oxide that most promotes the formation of the cordierite phases, in addition to the use of molybdenum as part of the parent glass, which lowers the crystallization temperature of the crystalline phases obtained. This is determined with the results of phase quantification using the Rietveld method, by XRD, where the samples with NiO add up to a content greater than 90 % of cordierite α and β. And it is supported by the SEM results, where the characteristic hexagonal morphologies of cordierite are identified, the IR characterization results where the bands of the bonds of the phases identified by XRD are identified.

Phase Equilibria and Thermodynamic Modelling of the PbO-ZnO-FeO-FeO1.5-SiO2 system and its subsystems in equilibrium with air/metallic lead/iron

The phase equilibria of the ZnO-“FeO1..5”, ZnO-“FeO1.5”-SiO2, PbO–ZnO-“FeO1.5” and PbO–ZnO-“FeO1.5”-SiO2 slag systems in equilibrium with air or metallic lead/iron were studied as part of the investigation of the 19-component PbO–ZnO–Cu2O–FeO–Fe2O3–CaO–SiO2–Al2O3–MgO–S-(As, Sn, Sb, Bi, Ag, Au, Ni, Cr, Co as minor elements) slag/matte/metal/speiss/gas system, supporting the operation/development of existing and emerging pyrometallurgical processes. In the experimental part of the study, samples underwent high temperature equilibration followed by quenching, and the direct measurement of the lead, zinc, iron and silicon concentrations in the liquid slag, solid oxide, and metal phases by electron probe microanalysis (EPMA). The a) massicot (PbO), b) spinel ((Zn, Fe)Fe2O4), c) zincite ((Zn,Fe)O1+x, 2 polymorphs), d) lead ferrite (Pb2+xFe2O5+x), e) plumboferrite (Pb4Fe22-xZnxO37), f) magnetoplumbite (Pb(Fe2O3,PbFeO2,PbZnO2)Fe10O16), and g) W-ferrite (PbZn2-xFe16+xO27) primary phase fields of the PbO–ZnO-“FeO1.5” system in equilibrium with air were studied between 780 and 1300 °C. The ZnO-“FeO1.5”, ZnO-“FeO1.5”-SiO2 and PbO–ZnO-“FeO1.5”-SiO2 systems in equilibrium with air were studied up to 1745 °C, significantly improving the availability of information on the composition range of the high- and low-Fe zincite ((Zn,Fe)O1+x) phases, and on the liquid slag composition at the boundaries of their primary phase fields. Lastly, the solubilities of iron in larsenite (Pb(Zn,Fe)SiO4) and melilite (Pb2(Zn,Fe)Si2O7) in equilibrium with air or metal were studied between 700 and 800 °C. The newly obtained and existing experimental data were used to develop a self-consistent set of thermodynamic parameters describing all phases in the system using the FactSage computer package.

Crosslinking and pyrolysis of a methyl-silsesquioxane: Effect of heating rate on fabrication of polymer derived mullite ceramics using thermoplastic shaping

Poly-silsesquioxanes have been numerously used to produce SiO2 or SixOyCz ceramics through pyrolysis under different atmospheres. In this study, crosslinking and pyrolysis behavior of a commercial methyl-silsesquioxane, was examined using thermogravimetry analysis and a lower SiO2 yield was observed after pyrolysis at low heating rates of 0.3 and 0.6 K/min under air atmosphere, namely 69.1 and 75.0 wt%, respectively. Using ceramic thermoplastic shaping techniques, a low heating rate, below 2 K/min, is usually required to remove processing additive (e.g., binders) gradually and avoid failures like blisters, pores, and cracks. A mixture of SILRES® MK and γ-Al2O3 was prepared to produce a mullite ceramic with Al2O3/ SiO2 ratio of 60/40 wt%. As expected, the stoichiometric ratio of alumina to silica was altered using a heating rate of 0.6 K/min and mullite ceramic with 61.70/37.70 wt% of Al2O3/ SiO2 ratio was obtained. By mixing above the crosslinking temperature of SILRES® MK, a constant ratio of alumina to silica could be achieved successfully, even at low heating rates. In addition, microstructure indicated the growth of needle-like mullite crystals with some amount of SiO2-rich ternary amorphous phase (MgO–Al2O3–SiO2) between the needle grains. Elemental analysis revealed that MgO sintering additive was mainly in the amorphous SiO2-rich phase.

Modification of Quartz Ceramics by Applying a Sol-Gel Composition of MgO–Al2O3–ZrO2–SiO2 System

Composite sol-gel materials of the MgO–Al2O3–ZrO2–SiO2 system were synthesized and the processes of their thermal evolution and crystallization were studied. Application of sol-gel compositions of the MgO–Al2O3–ZrO2–SiO2 system to the surface of quartz ceramics leads to a significant increase in the mechanical strength of the material. The processes of thermal evolution of the sol-gel composition were studied using IR spectroscopy, X-ray diffraction, electron microscopy, and energy dispersive analysis. It was shown that the formation of the oxide composite structure of materials begins at the stage of wet gels. Treatment of quartz ceramics with composite sols followed by drying and heat treatment up to 1200°C results in modification of the surface layers of the material, which makes it possible to increase the mechanical strength of the material by more than 20%. Sol-gel modifying compositions, upon drying and subsequent heat treatment, form polycrystalline structures bonded to quartz ceramic particles and consisting of various oxide crystals.

Diffusion of Lanthanum/Cerium/Manganese in Rare‐Earth Heavy Rail Steel at the Refractory Interface

One of the key factors determining the degree of erosion in the outlet parts of refractory interfaces is diffusion. By studying the representative diffusion behavior of lanthanum, cerium, and manganese in molten rare‐earth high‐carbon heavy rail steel using different refractory interfaces, the diffusion kinetics mechanism of each alloying element is illustrated. The results show that the concentration of diffused lanthanum, cerium, and manganese in rare‐earth high‐carbon heavy rail steel imparts minor changes on the two aluminum–magnesium refractories used in our experiments, whereas the other four refractories show unstable behavior. Furthermore, it is revealed that the smaller the porosity of a refractory material, the greater the decrease in the diffusion channel of each element in molten steel, which in turn increases the diffusion activation barrier and results in slower diffusion. Overall, the suitability degree of the refractory materials tested in experiments for processing molten rare‐earth high‐carbon heavy rail steel with regard to cost, adhesion strength, and erosion degree is as follows: Al2O3–MgO &gt; Al2O3–MgO–SiO2 coating &gt; Al2O3–SiO2–SiO2 coating &gt; Al2O3–SiO2 &gt; Al2O3 &gt; ZrO2.