Slag Inclusions Research Articles

PROSES PENGECORAN ADAPTOR PADA BUCKET TEETH UNTUK EXCAVATOR DENGAN MENGGUNAKAN METODE PEMBUATAN CETAKAN FURAN

The following paper was made to understand the process, and defects from metal casting of Low Carbon Steel GS-25 CrMo 4 Bucket Teeth Adaptor for Excavator with furan molding method and how the results of the Chill Test on the product. Metal casting process of making objects by melting metal and pouring it into a mold cavity. Metal casting has been discovered and continues to be developed, one of which is Sand Casting, where there are various types of methods in making molds including the Furan, Disamatic, and Jolt Squeeze methods. The method used in this research is the Furan method which can be used to make objects with complex shapes such as the Adaptor component used in the Bucket Teeth for Excavators. The casting material used in this casting is GS-25 CrMo 4 steel which has strong and tough properties. All manufacturing processes are carried out through several stages, namely; design, model and core making, mold making, smelting, pouring, fettling and finishing, and quality control. From the results of the research that has been carried out, it can be seen that several rejections from these products include: cold shut, missrun, inoculant inclusion, slag inclusion, and sand inclusion.

Testing of Carbon Steel Pipe and Stainless Steel Duplex Pipes of Welding Joints : A Cost and Time Perspective

In the welding process, it is not uncommon for a defect or discontinuity to occur in the welding results. Common defects on the surface are undercut, concavity, incomplete penetration, spatter, burn-through, and mismatch. While defects in internal welds that are often found during testing are porosity, worm holes, slag inclusions, incomplete fusion, and cracks, To obtain pipeline results that comply with the specifications set by the welding engineer and ASME or ASTM standards, it is necessary to test surface cracks and inside cracks using the non-destructive test (NDT) method, namely the dye penetrant test and radiography test, to determine the results of welding at pipe joints. In addition, it is also necessary to know the time and cost required for each method in the testing process. The results of the radiography test and penetrant test on carbon steel pipe welding joints showed porosity welding defects 1 mm long. Weld defects in duplex stainless steel pipes were not found. Then the results of the total testing time using the radiography test take 18% longer than testing using the penetrant test. Furthermore, the total costs that need to be incurred during the test are found to be 2~3 times more expensive than the cost of the penetrant test.

Study on mechanism of the effect of Al element on the arc shape and molten pool fluctuation pattern in flux bands constricting arc welding (FBCA)

Herein, to investigate dynamic penetration control in ultra-narrow gap grooves, the effect of Al addition at a fraction of 0.2 %–1 % in flux bands on welding arc shape changes and molten-pool fluctuations in flux bands constricting arc (FBCA) welding is examined via a high-speed camera and side glass observation system. The influence mechanism of Al on weld formation is analyzed based on the weld depth-to-width ratio. Results reveal that as the Al content increases, the profile of the welding arc shifts from a divergent spherical shape to a contracted ellipsoidal shape, and the arc-burning position changes from the middle to the lower section of the groove. In addition, Al changes the side flow morphology of the molten pool from a shallow concave to a deep single-V shape, thus accelerating the molten pool flow and resulting in a humped molten pool. As Al in the flux bands changes the molten-pool Marangoni convection modes, the weld formation is affected significantly. When the Al addition is at 0.80 %, the weld depth-to-width ratio reaches a maximum of 1.32, and the joint presents the best welding quality. Meanwhile, at 0.92 % Al addition, fluctuations in the weld depth-to-width ratio increase, porous slag inclusions are observed, and the welding quality degrades. This occurs because Al3+ vapor is preferentially ionized, deoxidation within the arc induces further contraction of the arc, and the arc force impact on the bottom of the molten pool increases. In addition, Al2O3 is regenerated in the molten pool and accumulates on the surface, thus resulting in the highest levels of flow and solidification in the molten pool. However, when excess Al is added to intensify the molten pool reaction, the weld deteriorates.

Revealing the iron skeleton of Notre-Dame de Paris. Methodologies and issues of archaeological and analytical investigations following the blaze

The fire at Notre-Dame de Paris led to the discovery of several series of previously unknown iron armatures, which were systematically recorded. Amongst them, several iron staples from the top of the eaves walls, lead crest reinforcements and a sample of the tie rods used in the choir in the 19th century were analysed by metallography and tensile tests in order to determine their nature and mechanical characteristics. These results can be put into perspective with previous studies on such monuments. The chemical analysis with SEM-EDS of the slag inclusions contained in the matrix of these ferrous alloys makes it possible to determine the technical processes used for their production throughout the construction and restoration of the building, highlighting several differences depending on the typologies of the iron armatures. This information is complemented by a series of radiocarbon dates currently being carried out to better understand the periods of use of these ferrous reinforcements. When compared with those of other materials, these dates could be used to recalibrate the phasing of the building.

Analysis of the process of qualifying the welding technology of S355JR structural steel using the submerged arc welding method

This paper presents the issue of welding technology qualification using the example of structural steel S355JR with a plate thickness of 25 mm and 100 mm, bevelling V. The main objective of this work was to attempt to perform a full qualification of the submerged arc welding process in accordance with the requirements of PN EN ISO 15614. Particular attention was paid to the issue of the qualification of welding technology. The samples were subjected to non-destructive testing, i.e. visual and penetrant testing, as well as ultrasonic testing and heat treatment. This was followed by destructive testing, including macroscopic testing and hardness testing. According to the proposed procedure for the recognition of submerged arc welding technology, once the necessary tests had been carried out and the protocols with positive results had been obtained. The documentation had been completed, the analysis needed to obtain certificates of conformity for factory production control and welding quality was carried out.Submerged arc welding is often used for highly responsible butt joints, particularly when joining thick components. This has been achieved through the proper design of the preparation of the parts to be welded and the development of a welding technology that practically eliminates the pre-phase that occurs in traditional technology, thereby eliminating the risk of it affecting the quality of the welded joint.During the implementation of submerged arc welding, a number of technological problems were encountered. The first test joints contained many defects, i.e. sticking and slag inclusions inside the welds. In addition, obtaining welds with the correct profile and removing the slag from the weld groove was difficult. These obstacles were eliminated experimentally by carrying out successive tests using different parameters and welding groove geometries.The correct implementation of any welding process depends on its input parameters. These parameters include welding current, welding speed, welding current, wire diameter, welding voltage and many others. Submerged arc welding (SAW) is widely used in the industry for manufacturing as it is more reliable, provides deep penetration in the work, ensures a smooth finish on objects, and results in high productivity.The technology was developed for a company that manufactures control discs for steam turbines.

Thixotropic characterisation of slag modified 3D printable metakaolin based geopolymer composite

Geopolymer concrete (GPC) is a substitute for ordinary Portland cement (OPC) in 3D concrete printing for sustainable construction. However, poor structural build-up arising from a slow chemical reaction rate of a two-part GPC is a limitation to buildability. Therefore, slag (0, 5, 10, and 15% by weight of metakaolin), and fibre (0.5% by volume of mix) inclusion in metakaolin (MK)-based GPC composite could improve structural build-up and enhance buildability. This paper presents the rheological thixotropic characterisation of static and dynamic yield stresses, Rthix (re-flocculation rate), and Athix (structuration rate), of slag-modified fibre-reinforced MK-based geopolymer for 3D printing of concrete using an ICAR rheometer at selected resting times of 0 to 2700 s depending on mix behaviour. The printability of the GPC is validated with a 3D concrete print of a 250 mm diameter column for each mix. The results show that the reference, M1, with 0% slag content is more workable than M2 with 5% slag; however, M2 exhibits better thixotropic properties. Slag inclusion in M2 improved the buildability of validated 3D prints by 36% compared to M1. The 3D prints of M1 and M2 columns are buildable up to 27 and 42 layers, respectively, before plastic yield and collapse. Slag inclusion beyond 5% had too little open time than required for printing, leading to a significant and early increase in stiffness and clogging of the printer hose.

Notre-Dame de Paris: The first iron lady? Archaeometallurgical study and dating of the Parisian cathedral iron reinforcements.

The study of iron reinforcements used in the construction of Notre-Dame de Paris offers a glimpse into the innovation that took place on this building site in the mid-12th century, adapting metal to create a novel architecture. The restoration of the monument after the 2019 fire offered unique possibilities to investigate its iron armatures and to sample 12 iron staples from different locations (tribunes, nave aisles and upper walls). Six of them were dated thanks to the development of an innovative methodology based on radiocarbon dating. They reveal that Notre-Dame is the first known Gothic cathedral where iron was massively used as a proper construction material to bind stones throughout its entire construction, leading to a better understanding of the master masons' thinking. Moreover, a metallographic study and slag inclusion chemical analyses of the staples provide the first study of iron supply for a great medieval Parisian building yard, renewing our understanding of iron circulation, trade and forging in the 12th and 13th century capital of the French kingdom. The highlighting of numerous welds in all iron staples and the multiple provenances sheds light on the activity of the iron market in this major medieval European city and the nature of the goods that circulated, and questions the possible importance of recycling.

Fracture Analysis of Butt Welding Area of 5″ Drill Pipe Internal Thread End in an Oilfield

This paper tested fracture morphology analysis, mechanical properties and chemical, metallographic analysis and micro analysis to find out the factors of fracture in the butt welding area of the internal thread of the 5″ drill pipe, which is made of S135 in the casing pulling process of an oilfield. The results show that the chemical element, tensile strength and yield strength, impact performance, metallographic structure, inclusions in microstructure and grain size of the Fracture drill pipe meet the relevant data of the oilfield and industry standards, but the hardness of the fracture does not meet the requirements of the national standard. The important reason of the fracture of the drill pipe is that the oxide skin was not cleaned before the drill pipe joint was welded with the body. During welding, the oxide skin entered the molten weld metal, and large slag inclusions formed in the weld resulted. The secondary cause is improper subsequent heat treatment of drill pipe weld, which leads to increased weld brittleness and accelerated crack growth. This paper puts forward corresponding countermeasures to improve the quality of the drill pipe’s weld and prevent the failure accidents of drill pipe.

Nugget zone characterization of friction stir welded hypereutectic Al-Si alloy

Despite excellent properties of aluminium silicon (Al-Si) alloys in several aircraft and automotive applications, its usage is limited because near net shape casting of Al-Si alloys may cause several defects like surface pinholes and grooves. Fabrication of components and then welding them via fusion-based welding processes imposes issues like porosity and slag inclusions which may severely degrades its properties. Thus in present study, friction stir welding (FSW) was employed for welding of hypereutectic Al-Si cast alloy. The nugget zone (NZ) of welded alloy and its as-cast counterparts were characterized for their performance in terms of mechanical and tribological behaviour. The results depicted fragmentation of α-Al dendrites, refinement and redistribution of acicular Si particles as a result of stirring with high strain rate, and improvement in mechanical properties such as ultimate tensile strength, yield strength, ductility, hardness and wear resistance as compared to as-cast alloy. It is also shown that disparate wear mechanisms occured in friction stir welded (FSWed) and as-cast alloys. A sizeable amount of adhesion with plastic deformation and delamination pits were observed for as-cast alloy, while the dominant mechanism in FSWed alloy was peeling with little adhesion.

Analysis of Lead Smelting Technology in the Early Bronze Age Based on Smelting Slag from the Central Plains of China

To explore the source of Pb in Bronze Age artefacts from the Central Plains (Zhongyuan) in China, we investigated non-ferrous minerals from the Qingyuan archaeological site in Yuanqu County near the Zhongtiao Mountains. Fragments of smelting slag from the Erlitou cultural layer were collected. The smelting slag was investigated by scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS), X-ray photoelectron spectroscopy (XPS), X-ray diffraction (XRD), and lead isotope analysis. The SEM and EDS results confirmed that the slag contained Pb, Pb–As, and Cu–Pb–Sn inclusions and non-metal impurities such as low-Zn spinels. The XRD results signified that the bulk of the slag comprised Fe–Mn–Si phases. The chemical state of Pb was mainly Pb–O with some metallic Pb, as identified by XPS. The theoretical melting point was calculated using FactSage7.1 based on the composition and phase characterisation. The calculated temperature was 1100–1200 °C, which agreed well with the actual melting point of 1114–1354 °C. The slag composition and inclusion phases indicated that Pb–Zn–O ores with Mn and As were added during reduction smelting in Qingyuan. The raw materials of smelting included crude Pb with minor amounts of Cu, As, and Sn. Lead isotope analysis revealed that the lead materials produced in Qingyuan were likely transferred to Yanshi City in the Shang Dynasty. The findings of this study provide significant clues for exploring lead mineral production in the Central Plains during the Early Bronze Age.

Electroslag heating and additional melt feed of steel ingots of semi-continuous casting

The issues related to the continuous compensation of metal shrinkage during its crystallization are studied. Based on the evaluation of ways to reduce the size of the shrinkage shell, aimed at maintaining the liquid phase for a long time, the most effective ways to reduce the size of the shrinkage shell and reduce the head trim are selected. The influence of electroslag heating and recharge technology on the length of the shrinkage shell and the quality of the metal of the sub-shrinkage area of semi-continuously cast ingots has been studied. The study was carried out on ingots with a diameter of 500 mm weighing 3.5 tons of carbon and alloy steels. The installation consisted of 3 electrodes with a diameter of 75–100 mm, connected to the transformer TSH-3000-3. The transformer power was 570 kVA, the current per phase was 1000–3000 A, the voltage on the electrodes was 40–60 V. Temperature measurements were carried out in the copper sleeve of the mold. For comparison, the temperatures in the walls of the mold were recorded during the cooling of the ingot in the mold without heating. The cooling curves showed that the process of electroslag heating does not cause overheating of the mold walls. This is explained by the appearance of a side metal crust in the upper part of the ingot, which does not melt with liquid slag and protects the walls of the mold. The surface of the ingots had no visible defects (crust inversions, film and slag inclusions). Additional surface treatment (stripping, stripping) was not required. The macrostructure of the ingots is dense, without visible defects, including in the axial zone. Sulfur liquation on sulfur prints according to Bauman was not detected. Electroslag heating had a significant impact on the length and shape of the shrinkage shell. The results obtained show that electroslag heating with graphite electrodes, feeding with consumable steel electrodes of the same composition with the resulting ingot and electroslag casting of steel can improve the structure, density and chemical homogeneity of cast metal, reduce the content of non-metallic and gas inclusions and significantly increase the yield of usable compared to conventional casting.

Making Copper: Processing in Early Bronze Age Arslantepe (VI B2)

This paper presents results of archaeometallurgical finds from Arslantepe VI B2 and observations and geoscientific analyses of ores and ore deposits in East Anatolia which are connected with this site. Function and technology of Early Bronze Age crucible smelting in a small scale domestic mode of production are discussed. Ore and rock inclusions in slag and lead isotope analyses are consistent with the origins of various copper sources on the Black Sea coast in the north (Artvin/Murgul, Trabzon) and in the south (Ergani Maden, Upper Mesopotamia) and broadens the Early Bronze Age trade of the Kura Araxes cultural network. The petrology of slags also from Çayönü Tepesi and Nevali Çori shows their formation by partial (eutectic) smelting processes and the non-liquation of refractory materials. The model of deliberate fluxing in smelting copper is proven to be disputable. Smelting of copper was performed in portable crucibles of surprisingly large size with air supply from below.

Design and Test of Duckbill Welding Robot for Cotton Seeder

To improve the automation, welding efficiency, and welding quality of duckbill welding of the cotton seeder, this study designed a cotton seeder duckbill welding robot. According to the characteristics of the duckbill weldment and welding requirements, the overall structure of the welding robot was determined, including the girdle feeding mechanism, static duckbill feeding mechanism, hinge feeding mechanism, welding fixture, welding actuator, and control system. To realize the continuous automatic feeding, positioning, fixing, welding, and unloading of the workpiece in the duckbill welding, the feeding mechanism adopts the method of cooperative cooperation of inductive proximity switch, electromagnet, and cylinder. The main body of the welding fixture adopts the pneumatic clamping method; the welding actuator adopts the synchronous belt module electric drive so that the welding torch can move in a straight line along the X axis and the Z axis. The welding process of the duckbill was simulated by Simufact Welding software, and the deformation and stress changes of the weldment were compared and analyzed when the single-sided single welding, the bilateral symmetrical double welding torch, two welding forms, and two welding process parameters were used to determine the welding process parameters of the welding robot. The prototype was made and the welding test was carried out. The test results show that the duckbill welding robot of the cotton seeder has stable feeding, solid clamping, accurate positioning, and high welding efficiency. According to the national standard, the appearance of the duckbill weld is inspected. The surface of the duckbill weld and the heat-affected zone has no cracks, incomplete fusion, slag inclusion, crater, and porosity. The forming quality of the welded parts is good. The design of the duckbill welding robot for cotton seeder is helpful in solving the problems of cumbersome positioning and clamping and low efficiency in manual and semi-automatic duckbill welding robots, which provides a strong guarantee for the large-scale and standardized welding production of the dibbler duckbill.

Numerical simulation of mould filling process using ansys

ABSTRACT Filling of moulds with molten metal and solidifying it affects the cycle time, casting’s interior quality and the amount of material required throughout the process. Blow holes, slag inclusions, cold shut, shrinkage, and other casting faults are all linked to the mould filling process. Industry demands the simulation of filling and solidification process before the actual operation begins. The simulation helps to examine the molten metal’s free surface variations, temperature distribution, and gas pouring problems to reduce filling-related defects and benefited to the industrial sector by eliminating the wastage of raw resources, money, labour and time. CFD analysis was carried out to investigate the impact of VOF and air entrapment in the casting part at subjected velocities to uncover pouring flaws of the casting part generated in response to the applied velocities.

Wall thickness measurement and defect detection in ductile iron pipe structures using laser ultrasonic and improved variational mode decomposition

A reliable non-destructive evaluation technique that accurately assesses the wall thickness and slag inclusions of ductile iron pipes prior to annealing is crucial to reducing costs in subsequent operations. The rough outer layer of the produced ductile iron pipes leads to considerable background noise, limiting the probability of detection of laser ultrasonic testing equipment. In this study, an improved variational mode decomposition approach based on particle swarm optimization is suggested initially to increase the signal-to-noise ratio. This technique develops a fitness function suitable for processing ultrasound signals. A scanning laser ultrasound technique is designed for simultaneous measuring wall thickness and finding slag inclusions in ductile iron pipes based on excitation locations and flight time. A finite element analysis simulation model is established to assess the feasibility of this scanning method. This experiment is conducted on a 4.2 mm thick sample with slag inclusion defects and a 6.2 mm thick sample without slag inclusion flaws. Experimental results demonstrate that the developed denoising technique may enhance the average signal-to-noise ratio from 34.83 dB to 43.15 dB; the accuracies of thicknesses measurement for two ductile iron pipes are 96.90% and 99.52%, respectively, and the slag inclusion defects can be recognized by ultrasonic amplitude or energy distribution in different B-scan images. It has potential implications for in-service inspection of ductile iron pipe structures.

Performance of Self-Compacted Geopolymer Concrete Containing Fly Ash and Slag as Binders

Geopolymers can replace cement and help reduce the environmental impact of concrete construction, but research is needed to ensure their mechanical properties, durability and practicability. The aim of this investigation is to examine the influence of ground granulated blast furnace slag (slag) content on the performance, at the fresh and hardened states, of fly ash (FA) based self-compacted geopolymer concrete (SCGC). For this purpose, four SCGC mixtures containing 450 kg/m3 of total binder were examined. The alkaline-to-binder ratio was 0.5 for all mixes. FA was substituted with slag at 0%, 30%, 50%, and 100% of the total binder content. The fresh properties in terms of flowability, passing ability, viscosity, and segregation resistance, as well as the mechanical properties in terms of compressive strength and splitting tensile strength, were quantified. The durability behavior of SCGC was also studied to determine sorptivity and long-term free drying shrinkage. The results confirm that slag adversely affects the workability of SCGC mixtures except for the resistance to sieve segregation. Performance of SCGC in hardened states is in general enhanced with slag inclusion but at increased shrinkage strain. Predictions of splitting tensile strength were made using the ACI 318, ACI 363, Eurocode CEB-FIB, and Lee and Lee models. The ACI 363 and Eurocode CEB-FIB models were found to be inaccurate, except for the 30% slag mix. Predicted values obtained from the Lee and Lee model were very close to the actual values of the FA-based SCGC mix. The results of this work could lead to more sustainable concretes using geopolymers instead of OPC.

Research on the Effects of Welding Defects on the Strength Performance of Expandable Profile Liners and Approaches to Improve Welding Reliability

Summary Expandable profile liner (EPL) technology (EPLT) provides an effective solution for lost circulation trouble control without wellbore diameter loss or sacrificing completion and production performance. However, the reliability and stability of the welding seams determine the overall bearing capacity of the EPL string. The application of EPLT in more complicated conditions requires increasing the overall performance of the EPL string welding seams. In this study, we considered four types of artificial welding defects, including cracks, pores, slag inclusions, and incomplete penetration in EPL string samples, and performed internal pressure limit tests to obtain the ultimate failure strength of EPL strings with different welding defects. Abaqus was used to quantitatively assess the influence of welding defects on the strength performance of the EPL string. The critical dimensions and safety evaluation curves of various defects, under a working pressure of 30 MPa (safety factor 1.5), were obtained using a combination of numerical simulations and experiments. Using the latest welding defect identification and detection methods and relevant evaluation procedures, the type, size, and position of welding defects in EPL string can be identified quickly. The new welding process and integrated automatic welding equipment improved the welding quality and reliability of the EPL string. The new research on EPL welding seam defects and recent advancements in EPLT can bring significant economic benefits, thus promoting the application of EPLT to meet future application challenges. The technical innovations presented in this study provide an effective solution for drilling engineering staff to solve the drilling troubles associated with lost circulation and borehole instabilities and are also conducive for oil companies to address the future challenges of exploitation and development of unconventional oil and gas resources.

Characteristics of various non-metallic inclusions in ancient cast iron and solid-state decarburized iron products from a government-run iron workshop during the Han Dynasty in Dongpingling Ruins, Shandong Province

With low content of impurity elements and the near absence of large slag inclusions, ancient Chinese cast iron used to be viewed as a kind of pure iron material. Thus, some crucial non-metallic inclusions in cast iron had been missed in previous studies. Here, we dedicated to analyze a series of pig iron and solid-state decarburized iron implements excavated from a Han dynasty official iron workshop at the Dongpingling site, and proposed to reveal the characteristics of non-metallic inclusions in these iron products. Judging by low impurity elements, the iron samples were identified with 5 categories of non-metallic inclusions, including silicate inclusions, sulfide inclusions, silica inclusions, endogenous oxide inclusions (agglomeration of multiple oxide) and those recombined by them. In addition, formation mechanism of each inclusion has been discussed as well.

First Archaeometrical Approach of the Examinations of Iron Age Ferrous Fragments from Regöly and Bükkábrány (Hungary) – The Inception of Iron Working in the Carpathian Basin?

The emergence, spread and development of iron working in the Carpathian Basin is an essential and interdisciplinary research field, an important stage of which being the results of the archaeometallurgical-archaeomaterial examinations presented in this article. The excavation site of Regöly (Hungary) represents a special source from the earliest Iron culture of the Carpathian Basin, and using the results of metallographic analysis our aim is to place the examined objects in their proper context with regard to the process of iron working. One fragment found in the tumulus of Regöly during the excavation 2011–2012 has been presumed part of an iron bloom; this may be the earliest example of iron working in the Carpathian Basin (630–600 BC). From both an historical and technological point of view this raises several questions. One aim of our study is to characterise the fragments in order to figure out what kind of processing has been applied and ultimately see how the ‘iron bloom’ fragment can be connected in any way to the other iron objects found at the site. Examinations were carried out by optical microscopy (OM) and scanning electron microscopy (SEM-EDS) on both the iron objects and the bloom fragment. Metallographic analysis revealed a very specific microstructure, indicating that the bloom fragment is not a direct product that came directly from the bloomery furnace; it could be a secondary or even tertiary product (prefabricated) instead. However, regarding the bloom fragment, there is evidence of a forging method. During the tests, slag inclusions were also examined. The results from Regöly were also compared with other finds from a Celtic workshop-type site (Bükkábrány, 320–200 BC). Although a direct connection between the examined iron objects and the iron bloom fragment (as possible raw material) cannot be confirmed, the iron artefacts and fragments of Regöly might easily have been made from some basic material as represented by the fragment of an iron bloom or bar. Even though the find from Regöly does not definitively provide the earliest evidence for iron smelting technology in the Carpathian Basin area, it does give evidence for some form of iron forging from a semi-finished product.

A novel approach to predict the inclusion removal in a billet caster mold with the use of electromagnetic stirrer

Use of in-mold electromagnetic stirrer (M-EMS) in continuous casting (CC) mold has been an effective means to get clean steel. However, at times their application results in slag entrainment and inclusion particles from the meniscus due to improper positioning of the stirrer along the length of the mold. More importantly, the inclusion particles coming through the tundish outlet pose a great challenge as they are likely to get trapped in the swirl flow developed due to the stirrer and finally move towards the mold outlet. In this study, a multiphase model involving solidification, slag-metal interface and inclusion transport is developed in the billet continuous casting process. The multiphase study involves the study of slag metal interface as well as the inclusion transport in the billet caster mold. For inclusion removal at the interface, a new realistic approach based on volume fraction criterion is adopted and incorporated using user defined function. The numerical results reveal that both intensity and size of the recirculation loop decrease on shifting the EMS away from meniscus. Tangential velocity increases significantly in the presence of EMS. Stirring generated due to EMS decreases the temperature and increases the uniformity in liquid fraction in the region above the stir. This region becomes wider as EMS moves downwards. Stirring pulls down most of the interface originated 2 μm and a few 100 μm in the mold, which is otherwise trapped back in slag layer when EMS is off. Moreover, this effect diminishes with shifting the EMS down.