1. War in the Micro-World: Identification and Traceability of Endogenous vs. Exogenous Inclusions in Induction Melting
Фокус: Utilizing metallographic atlases and SEM/EDS analysis to distinguish between oxides and sulfides formed during the melting process (эндогенный) and inclusions introduced by refractory spalling or contaminated charge materials (экзогенный).
This section provides precision targeting for root-cause troubleshooting.
Эндогенные включения: Products of internal chemical reactions (например, deoxidation products like $Al2O3$ or sulfides like MnS). Usually small and uniformly distributed.
Экзогенные включения: “Foreign invaders” such as slag entrapment or refractory grains (например, MgAl2O4 spinel from liners). Usually larger with complex, irregular morphologies.
2. More Than Just a Cover: Selection and Timing of Covering Agents (Insulating & Refining Fluxes)
Фокус: An in-depth exploration of the chemical compositions and physical properties of various fluxes. We discuss the “when” и “how much” of additions, and how to select functional agents—for insulation, atmospheric isolation, or inclusion adsorption—based on the specific alloy (например, High Manganese Steel против. Tool Steel).
- Key Insight: Choosing the right basicity ($V$-ratio) and melting point to ensure the flux actively traps floating inclusions rather than just providing thermal insulation.
3. The Filtration Revolution: Application of Ceramic Foam Filters (CFF) in Induction Furnace Tapping Spouts
Фокус: Introducing the integration of filtration units directly into the tapping system to physically intercept microscopic inclusions. We analyze the suitability of different materials (например, Zirconia, Силиконовый карбид) and pore densities (PPI) for various molten metals, as well as their impact on pouring fluidity.
- Механизм: Moving beyond simple physical screening to leverage “Deep Bed Filtration,” where fine inclusions are captured by inertial impaction and Cake Filtration.
