New Microscopy System Improves Steel Mill Performance and Allows Production of Higher Quality Steel

Inclusions are particles of insoluble impurities formed during steelmaking and casting operations that are entrapped during solidification of metal. Characterizing inclusions is important because of an increasing demand for cleaner steels with low inclusion (defect) content. The composition, and therefore the properties, of the inclusions can be controlled through the chemistries of the metal and slag. Controlling the properties of the inclusions allows higher quality steel to be made. However, despite the major advances in inclusion control, no rapid and accurate method is available to determine the type, size, and number of inclusions present in steel samples.

RJ Lee Group, Inc., with AMO and steel industry support, has developed the ASCAT, an inclusion analysis tool based on a highly capable scanning electron microscope combined with specially developed hardware and software. The ASCAT provides a way to understand the complicated effects of inclusions in the steel making process and on the resulting properties of steel. The instrument uses an innovative state-of-the art silicon drift detector to acquire x-ray composition information that is about an order of magnitude faster than previously used equipment. The ultimate goal is to develop the system so that analysis time is reduced to 10-15 minutes, which would enable the ASCAT to be used as an "on-line" analysis tool. The ASCAT uses "intelligent" software to emulate specialized knowledge that can be used to evaluate causes of clogging/erosion, slag treatment practices, castability, degasser circulation optimization, and slab disposition. One ASCAT system is now in use at the U.S. Steel Munhall Research and Technology Center.

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<h4>Overview</h4><ul><li>Developed and being marketed by the <a href="http://www.rjlg.com">RJ Lee Group, Inc</a>.</li><li>Commercialized in 2007.</li><li>Employed at the U. S. Steel Munhall Research and Technology Center.</li></ul><h4>Applications</h4><p>Can be used in the steel manufacturing process, including in castability of calcium treated steel; interstitial free degasser grade slag conditioning practice; tundish clogging and erosion minimization; degasser circulation and optimization; quality assessment/steel cleanliness; slab, billet, or bloom disposition; and alloy development.</p><p>&nbsp;</p><h4>Capabilities</h4><ul><li>Collects statistically meaningful data on inclusions in a steel sample and addresses a market need to monitor the effects of inclusions in the steel making process.</li><li>Uses fast inclusion identification software with advanced statistical algorithms to automatically sort inclusions into meaningful classifications.</li><li>Provides intuitive graphics-based output, which can be integrated to plant control rooms and computer databases.</li></ul><h4>Benefits</h4><h5>Energy Savings</h5><p>Improves energy efficiency by minimizing steel rejection and subsequent remelting of the rejected steel.</p><p>&nbsp;</p><h5>Productivity</h5><p>Increases production and reduces downgrades, with significant cost savings.</p><p>&nbsp;</p><h5>Product Quality</h5><p>Allows for the increased production of high-grade steels and alloys.</p><p>&nbsp;</p><h4>Contact Information</h4><p><strong>Gary Cassucio</strong><br />(724) 387-1818<br /><a href="mailto:gcasuccio@rjlg.com">gcasuccio@rjlg.com</a><br /><a href="http://www.rjlg.com">RJ Lee Group, Inc</a>.</p>