Proceedings of the 2nd International Conference on advances in Steel, Power and Construction

Technology (ICASPCT-2016)
17-19 March, 2016, Raigarh, India

Paper No. 74

STUDY OF THE NON METALLIC INCLUSIONS AND THEIR EFFECT ON THE

PROPERTIES OF STEEL

Deepak Patel
M.Tech Metallurgy
(Steel Technology)
CSVTU, Bhilai Chhattisgarh, India
Email: - dp.metallurgy@gmail.com
Contact No. : - 09981260497

Dr. Varsha Chaurasia

PhD, H.O.D. Metallurgy,
U.P.U. Govt. Polytechnic Durg,
Chhattisgarh, India
Email: - polyedudurg@gmail.com
Contact No. : - 09424118289

Shagufta Hina
Assistant Professor, MGIT,
Hyderabad
Email: shaguftahina@rediffmail.com

ABSTRACT
Mainly the presence of aluminium oxide inclusions is
considered as detrimental both for the production process
itself and for the steel properties [A. GHOSH et al., 2000] [8].
These inclusions take shape during deoxidation of the steel,
which is basic for continuous casting. Thus non-metallic
inclusions vary from the precipitates that are already present
in the liquid steel, though precipitates that are formed at stage
of solidification. Partial elimination of the non-metallic
inclusions during secondary metallurgy and reoxidation of
the steel melt stimulates nozzle clogging at the SEN in
continuous casting. The accretion of clogged material
constitutes significant clusters of NMI. Its thickness is linked
to the volume of steel cast along with the cleanliness of the
steel. Nozzle clogging lead to a declined production, due to
slower casting rate (since the decreasing diameter) and due
certain simultaneous casting disruptions [R. Dekkers et al.
2002] [10]. In the course of rolling, dendrites and aggregates
fractures, frequently next to the necks and subgrains by virtue
of which elongated strings of fragmented particles forms. At
high strains often voids are detected amongst these
fragmented particles, causing fatigue of the steel [S.K.
Choudhary, 2011] [5]. As a generalization, inclusions have
been found to be harmful to the mechanical properties and
corrosion resistance of steel. This is more so for highstrength steels for critical applications. As a result, there is a
move to produce clean steel. However, no steel can be totally
free from inclusions. The number of inclusions has been
variously estimated to range between 1010 and 1015 per ton
of steel. Again, the yardstick for cleanliness depends on how
one assesses it. For example, most of the inclusions are
submicroscopic. Therefore, a microscopic examination
cannot faithfully assess cleanliness. [A. GHOSH et al., 2000]
[8]
.

Non-metallic inclusions are a major issue during the

production clean steels, as they influence the microstructure
and structural properties effectively. They are often
considered as harmful to the final product quality and to the
steel processing productivity; therefore many industrial
efforts are directed towards improving inclusion removal.
Another way is to use non-metallic inclusions to produce
steels with enhanced properties. In both cases, the key issue
is to control the characteristics of the inclusion population in
the liquid steel, such as quantity/limit, composition, physical
appearance or morphology, shape, size and distribution. The
application of new secondary refining techniques and nonmetallic inclusion reduction techniques in steel production
processes has greatly reduced the size and amount of
nonmetallic inclusions remaining in molten steels and steel
products due to which inspection of inclusions is very
difficult. The influences of inclusions on the properties of
steels are discussed. As inclusions have influence on several
properties of steel, such as formability, toughness, and
machinability and corrosion resistance. In general, the less
severe the inclusions, the higher quality of steel. This is the
reason for, analysing and assessment of non-metallic
inclusions is important for quality control. The main part of
this work has been a literature survey, reviewing the main
methods used for the characterization of inclusions in clean
steels, experimental reports for information on how steel
cleanness is evaluated today, and how the steel cleanness is
related to the performance of clean steels as a product.
Keywords: nonmetallic inclusions, clean steel, inclusion
characterization, inclusion rating, clean steel
1. INTRODUCTION

1.1 ROLE OF NMI IN STEEL MAKING

In the global steel scenario aimed at superior properties,

control and cleanliness of steel turn out to be more and more
dynamic. Challenges like tweaking the chemical
composition and the homogeneity have been replaced by
troubles triggered by the presence of non-metallic inclusions.

Non-metallic inclusions are naturally occurring and

typically undesired products that are formed into various
types depending on their favorable thermodynamic
conditions in almost all treatment practices involving
molten steels [A. GHOSH et al., 2000][8].

Proceedings of the 2nd International Conference on advances in Steel, Power and Construction
Technology (ICASPCT-2016)
17-19 March, 2016, Raigarh, India

Paper No. 74

Apart from some applications where inclusions are supposed

to be demanded, like sulphides for improving machinability
(that could be argued with recently available cutting
machines and tools), they usually deteriorate mechanical
properties and surface quality of steel products and could
cause nozzle clogging and disruption of steelmaking and
forming processes. It is widely believed that due to the
presence of sulphide and oxide inclusions some of the
mechanical properties of steel like ductility, toughness,
anisotropy, and formability might be negatively affected.
The harmful effects of non-metallic inclusions on fatigue
properties of steel parts are because they can act as potential
sites of stress concentration that can initiate cracks under
cyclic loadings[Kiessling & N. Lange et al., 1978] [9].

analytical techniques such as scanning electron microscope

(SEM) and energy dispersive x-ray spectroscopy (EDS).
Quantitative assessment involves the inclusion detection and
size determination, which ultimately leads to the
construction of inclusion particle size distribution by image
analysis method. The experimental approaches are
summarized in fig 2-1.

1.2 CLEAN STEEL

The word clean steels is uncertain in class and commonly
indicates steel with very low contents of phosphorus, sulfur,
oxygen, nitrogen, and hydrogen and non-metallic inclusions.
Steel cleanliness is used to refer relative freedom from the
entrapped nonmetallic particles of solid ingot. In some steels
this is the most important criteria in judging their quality. The
fact that it is nonmetallic and, therefore, incongruent with the
metal lattice, has often been considered prima facie evidence
of its undesirability. [R.H. Tupkary, 2012][1]. Inclusions are
the source of many defects. Several applications limits the
maximum size of inclusions therefore size distribution of the
inclusions is significant. Steel cleanliness is optimized by an
extensive choice of operating practices right through the
steelmaking practices. These consist of the phase and
position of deoxidation and alloy additions, the pros and cons
of secondary metallurgy refining, stirring and transfer means,
covering systems, tundish geometry and casting methods
.
2.

Fig 2-1: - Schematic Diagram of the experiment

2.2 QUANTITATIVE ASSESSMENT

A complete assessment of steel cleanliness not only

consists of qualitative information, but also quantitative
information such as inclusion length, inclusion width, a
complete assessment of steel cleanliness not only consists
of qualitative information, but also quantitative information
such as inclusion length, inclusion width, number of
inclusion per unit area, volume fraction, mean free path, etc.
Using as-polished metal samples, quantitative assessment
involves a combination of a microscopic technique to
provide images of the sample surface (image acquisition)
and an image analysis system to accurately measure the
inclusion size.

EXPERIMENTAL ASPECTS AND

METHODOLOGY

2.2.1 Image Acquisition

Image acquisition is a crucial part in the process of
quantitative analysis. The ideal technique for providing
images of the sample surface must offer accurate
representation of inclusion distribution. Analytical
instruments involved in this research project consist of the
following:

2.1 OVERVIEW
The main purpose of this study was to characterize the nonmetallic inclusions found in high strength low alloy steel for
structural applications and to track the development of
inclusions throughout the melting and casting operations. To
do this, the experimental approach was divided into two
parts: qualitative and quantitative aspects. Qualitative
assessment involves inclusion morphology examination and
inclusion type determination by sample preparation and

1. Light optical microscope:

Prior to the advent of electron microscopy, light-optical
microscopy was used to quantify and characterize
inclusions based on morphology. The best-possible spatial

Proceedings of the 2nd International Conference on advances in Steel, Power and Construction
Technology (ICASPCT-2016)
17-19 March, 2016, Raigarh, India

Paper No. 74

resolution of a light-optical microscope, which is

approximately 0.3m, is limited by the fixed
wavelength of light ( 0.5m) [ASTM, 2003] [2]. As the
magnification increases, the light intensity decreases,
which results in darker image. Therefore it becomes rather
difficult to utilize the best-possible resolution of light in a
conventional light-optical microscope.

2.2.3 Sample Preparation

In the following steps:
1.

2. Scanning electron microscope:

SEM and EDS are among the most employed methods of
inclusion investigation mainly due to the following
advantages: high resolution, high sensitivity, quantifiability,
minimal sample preparation and ease of operation. The
secondary electron mode of a SEM provides an improved
spatial resolution of 5~20 nm [4].
The three modes used are secondary electron (SE),
backscattered electron (BSE) and EDS modes. Using the
SE mode, the images formed are topographical
representations of the specimen. Since secondary electrons
have a very small escape depth, the signals received will
reflect the surface structures of the specimen. However,
using SE mode to locate inclusions in a polished sample,
given the topography of the specimen is flat, will be rather
difficult when inclusion size is small. The BSE mode, on the
other hand, utilizes backscattered electrons to create
images showing elemental contrast, thereby revealing the
locations of non-ferrous inclusions in the ferrous matrix.
BSE images are also able to provide information on the
homogeneity of inclusions. In the current investigation, SE
mode was used to image inclusions on polished and SPEED
etched surfaces for inclusion morphology study.
Inclusion type determination was performed by EDS
mode simultaneously. For inclusion quantification, the
BSE mode was used in conjunction with image analysis
software.

2.
3.
4.
5.

2.2.4
1.
2.

2.2.2 Image Analysis

Detection and discrimination of inclusions utilize the
difference in gray level intensity between each inclusion
species and un-etched matrix steel. Measurements are made
based on counting the number of picture point elements
(termed pixels) that satisfy the user-defined gray level
threshold. The dimension of each image pixel is
dependent on both microscope magnification setting and
image resolution. The images for the purpose of quantitative
analysis in this study are taken with the following
parameters [6]:
Magnification: 100X
Image resolution: 512 X 676 pixel
Dimension of each pixel: 1.742 m/pixel

3.
4.
5.

A 20mmX20mmX10mm sample is cut from the

standard location of the 60-100mm long rail sample,
as per IS: 4163 by using Abrasive Cutter Machine.
The polished area of the specimen shall be
approximately 200mm2. It shall be parallel to the
longitudinal axis of the product. It shall be located
halfway between the outer surface and the center.
Rough filing is done on the surface to be polished by
using stone grinder to remove the cut marks.
The specimen is polished by using coarse emery
papers of size 180, 240, 320, 400 & 600 to get the
surface free from scratches [7].
Again it is polished by using fine emery papers of size
1/0, 2/0, 3/0 and 4/0 to get further smooth and scratch
free surface [7].
Fine polishing of the rail sample is done by using
Cloth Polishing Machine where the polishing media is
Alumina powder to get mirror surface. Then it is
washed with water and dried by using blower.
Determination of Content of Inclusion
Inclusion content determination is done by using
Optical Microscope at 100X magnification.
The following types of inclusion are determined in
this method [6].
Group A (Sulphide Type) highly malleable,
individual grey particles and generally rounded
ends.
Group B Alumina - Numerous and nondeformable, angular, black or bluish particles (at
least 3) aligned in the deformation direction.
Group C Silicate - highly malleable, individual
black or dark grey particles and generally sharp
ends.
Group D Globular Oxide non deformable,
angular or circular, black or bluish randomly
distributed particle.
The image is projected on the ground glass and a clear
plastic overlay is placed over the ground glass
projection screen.
The image within the test square is compared with the
standard chart diagrams of IS: 4163 Specification.
Entire polished surface is examined. Randomly any
ten numbers of worst fields are chosen and each field
is compared with the standard chart for each type of
inclusion.

Proceedings of the 2nd International Conference on advances in Steel, Power and Construction
Technology (ICASPCT-2016)
17-19 March, 2016, Raigarh, India

Paper No. 74

6.

In each worst field, for each type of inclusion, total

length of the inclusion is measured and
corresponding severity number is noted down from
the comparison chart of IS: 4163 specification.

To confirm that the inclusions are of sulphide type, SEMEDS analysis was also carried out.
SEM-EDS analysis confirms the results of inclusion rating
and reveals that the inclusions are Manganese Sulphide
(MnS) stringers. The control of sulphur and its associated
level of sulphide inclusions in rail steel is a challenge in
spite of RH-degassing. This can be attributed to the silicon
killing practice adopted in rail steels and RH-degassers
limitations for desulphurization understanding the effect of
secondary refining parameters on desulphurization and
inclusion removal.

3. RESULT AND DISSCUSSION

Rail steel needs to conform to stringent quality standards
described in the standards owing to its critical nature of its
application. Chemical composition range of Grade 880,
which is a common rail grade as per IRS-T12, is shown in
Table 3-1.
Table 3-1: Chemical composition of Grade 880 rails as per
IRS T-12 2009 specifications

Grade
880

Grade

%C %Mn %Si

%S

%P

%Al %Nb

0.60- 0.80- 0.10- 0.03 0.03

0.80 1.30 0.50 max max

0.01
5
max

(a)

H in
ppm
1.6
max

Hydrogen in rail is restricted to a maximum of 1.6 ppm

which makes degassing necessary. As far as inclusions are
concerned, it is well known that they are detrimental to rails.
IRS T-12 2009 specifies that the inclusion rating level of
rails, when examined as per IS: 4163, shall not be worse
than 2.5 A, B, C, D thin or 2.0 A, B, C, D thick.
This study assesses the level and type of inclusions in rail
steels produced at JSPL, Raigarh CG India, and tries to
minimise the inclusion level by carrying out appropriate
modifications in steel making & simultaneously carrying
out the comparative study between VD & RH processed
heat.

(b)

Table 3-2 Inclusion Rating Results

T Thin, T - Thick
Heat
A type
ID
T
T
1
1.5
2
1.0
Group A
(SULPHIDE)
(Thin)
1.5

B type
T
T
0.5
-

Group B
(ALUMINA)
(Thin)
0.5

C type
T
T

Group C
(SILICATE)
(Thin)
-

D type
T
T
1.0
0.5

Group D
(OXIDE)
(Thin)

Fig. 3.1: (a) SEM image of inclusion in Heat ID 1 at 799X

magnification. (b)EDS spectrum of point 3 shown in image.

1.0

Proceedings of the 2nd International Conference on advances in Steel, Power and Construction
Technology (ICASPCT-2016)
17-19 March, 2016, Raigarh, India

Paper No. 74

4.

CONCLUSION

REFERENCES

Four different image acquisition techniques were

evaluated for the quantitative analysis of inclusions and
it was found that SEM-backscattered electron imaging
mode is the most suitable choice.
Presence of non-metallic inclusion can negatively affect
both properties of product and subsequent processing.
Throughout the melting and casting operations,
inclusion species tend to develop from simple primary
oxides to complex binary and ternary oxides. With
reoxidation minimized by gas shrouding between ladle
and tundish, steel cleanliness improvements were
achieved.
Large inelastic inclusions, such as those comprising of
Ca, Al, Si and O tends to act as a nucleation site for crack
growth below the surface of the rail head. These
inclusions which are themselves brittle in nature; under
the influence of stresses can shear in a brittle manner;
thus leading to loss of serviceability. Rail industry has
been constantly working in this regard to lower down
the Size & amount of inclusion prevailing. MnS
inclusions can become crack initiators as they deform in
a non-uniform manner to produce long thin inclusions.
Studies reveal that MnS inclusions, present in the
material are considerably elongated by the loading of the
rail in service and contribute to spontaneous cracking,
subsequently resulting in failure.
Typically problems are faced during desulphurization of
high carbon silicon killed steels due to the low sulphide
capacities of CaO-SiO2 slags. Final slag composition is
controlled by a wide range of operating practices
throughout the steelmaking processes. These include the
time and location of deoxidant, lime and alloy additions,
the extent and sequence of secondary metallurgy
treatments, stirring and transfer operations etc.

[1] Tupkary R.H.: Introduction to Modern Steel Making

Khanna Publisher, Delhi 7th Edition 4th reprint 2012, Pp. 6369,
[2] Astm International, E45 Test Methods for Determining
the Inclusion Content of Steel, Annual Book of Astm
Standards, Astm, Philadelphia, USA, 2003, Vol. 03
55
[3]
http://www.matter.org.uk/steelmatter/casting.htm,
Entrapment of Non- Metallic Inclusions, Corus Corp. And
Matter, Date Accessed: June 16, 2015
[4] W.D. Callister, Materials Science And Engineering An
Introduction, John Wiley & Sons, Inc., New York, Ny, 2003,
6th Edition, P.336
[5] S. K. Choudhary, Influence of Modified Casting
Practice on Steel Cleanliness, ISIJ International, vol. 51,
no. 4, pp. 557565, 2011
[6] IS 4163:2004, Method for Determination of Inclusion
Content in Steel by Microscopic Method, India, edition
2004
[7] ISO 4967:1998, Steel Determination of Content of
Nonmetallic inclusion Micrographic Method using
Standard Diagrams.
[8] A. Ghosh: Secondary steelmaking: principles and
applications, CRC Press, Boka Raton, FL, (2000). Pp. 248290
[9] R. Kiessling and N. Lange, Non-Metallic Inclusions in
Steel, The Institute of Materials (London), 1978, vol. 2 Pp.
40-85, 100-105
[10] R. Dekkers: Non-metallic inclusions inl iquid steel,
Ph.D . Thesis, Katholieke Universiteit Leuven, Leuven,
(2002).

ACKNOWLEDGEMENT

Technical Services Department, RUBM,

Jindal Steel and Power Ltd. Raigarh, Chhattisgarh,
India, 496001