In this paper, the CaO-SiO2-FetO-P2O5 dephosphorization slag system during the premier and middle stage of the converter process was studied, the effect of slag composition on the distribution ratio and activity coefficient of P in the n·2CaO·SiO2-3CaO·P2O5 (recorded as nC2S-C3P) solid solution phase and liquid slag phase in the slag system was studied used by the high temperature experiment in laboratory, the theoretical calculation of thermodynamics, and the scanning electron microscope and the energy dispersive spectrometer (recorded as SEM/EDS). The research results show that when the FeO content in the liquid slag increases from 32.21% to 50.31%, the distribution ratio of phosphorus (recorded as LP) in the liquid slag phase increases by 3.34 times. When the binary basicity in the liquid slag increases from 1.08 to 1.64, the LP in the liquid slag phase decreases by 94.21%. In the initial slag, when the binary basicity increases from 2.0 to 3.5, the LP decreases by 70.07%. When FeO content increases from 38.00% to 51.92%, the LP increases by 6.15 times. When P2O5 content increases from 3.00% to 9.00%, the LP increased by 10.67 times. When the FeO content in the liquid slag increases from 32.21% to 50.31%, the activity coefficient of P2O5 in the liquid slag phase (recorded as γP2O5(L)) increases by 54.33 times. When the binary basicity in the liquid slag increases from 1.08 to 1.64, γP2O5(L) decreases by 99.38%. When the binary basicity increases from 2.0 to 3.5, the activity coefficient of P2O5 in the solid solution phase (recorded as γP2O5(SS)) in the solid solution phase decreases by 98.85%. When P2O5 content increases from 3.00% to 9.00%, γP2O5(SS) increases by 1.14 times. When the binary basicity decreases from 3.5 to 2.0, n decreases from 0.438 to 0.404. When the FeO content increases from 38.00% to 51.92%, n decreases from 0.477 to 0.319. When the P2O5 content increases from 3.00% to 9.00%, n decreases from 0.432 to 0.164. The decrease of binary basicity and the increase of FeO and P2O5 content in the initial slag can reduce the value of n and enrich more phosphorus in the solid solution phase. The results can not only provide a theoretical basis for industrial production, but also lay a theoretical foundation for finding more effective dephosphorization methods.
The solution heat treatment (SHT) of the third generation of single crystal (SC) Ni-based superalloys required up to 45 h and was expensive. In this study, SHT based on liquid metal cooling (LMC) was optimized to greatly reduce processing time. The experimental and simulation results showed that residual segregation was evidently reduced, e.g., from 2.12 to 1.22 for the most heavily segregated Re. This led to a 16.7% increase in creep life, more uniform microstructures, and a decrease in solidification and homogenization porosity by a factor of 3.4. Structural refinement, approximately 0.32 times, served as the underlying mechanism for this optimization, which reduced diffusion distance and increased homogenization efficiency during SHT.
The roles of traveling magnetic fields (TMFs) within the transport phenomena during the directional solidification of nickel-based superalloys were simulated. The evolution of thermal field, flow field and solid-liquid interface morphology during the solidification process under both natural and forced convection conditions were also simulated and compared. The strength of TMFs window that suppresses the flow of the interfacial front in the melt was quantified. The association between flow velocity at the interface front and defect formation was discussed.
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