Al Alloy Melting Behavior and Interfacial Reactions with Steel Under Natural Convection

The Al alloy melting behavior and interfacial reactions during the steelmaking process of high-Al automotive steel were investigated in this study. The total dissolution time of Al bars (20 × 20 × 80 mm) in molten steel was quite short, decreasing from 21.4 s to 10.0 s with an increase in bath temperature from 1580 to 1620 °C. The Al alloy melting process at the molten steel temperature of 1600 °C included the formation of a solidified steel layer, the latter's rapid melting, and Al alloy normal melting, while at 1600 °C, the process included a second increase in the thickness of the solidified layer. Because steel elements such as [Fe], [C], [O], and [N] could diffuse during the whole Al alloy melting process, an Fe (Al)-FeAl-FeAl₂-Fe₂Al₅-Al diffusion layer along the direction of the Al-rich matrix could be found at the Fe-Al interface. Moreover, Fe_xO, Al₂O₃, and unstable AlN inclusions could be observed in the FeAl layer. This study also investigated how to reduce the number of these easily formed inclusions. Decreasing the pre-heating process time and dissolved oxygen content could be useful in decreasing Fe_xO and Al₂O₃ inclusion formation. Some small-sized AlN inclusions formed in the center of the Al bars where they could not come into contact with the molten steel directly during the melting process; even for the immersion time of only 1 second, these inclusions were not stable in molten steel at the refining temperature and disappeared during the melting process.