Xiaofen
Zhang
ab,
Yunhai
Jia
*a,
Zhigang
Yang
*c,
Liang
Sheng
a,
Baibing
Li
b,
Yong
Lyu
ab,
Shanshan
Xu
b,
Chunyan
Zhang
c and
Zhihao
Tang
c
aBeijing Advanced Innovation Center for Materials Genome Engineering, Central Iron and Steel Research Institute, Beijing, 100081, China. E-mail: jiayunhai@ncschina.com
bUniversity of Science and Technology Beijing, Beijing, 100083, China
cBeijing Key Laboratory of Metal Materials Characterization, The NCS Testing Technology Co., Ltd., Beijing, 100081, China. E-mail: yangzhigang@ncschina.com
First published on 12th December 2023
Based on the original position statistic distribution analysis technique, the characterization method of segregation for large-size metal materials gives significant guidance to the research of material properties and production. However, random errors are inevitably brought into the calculation of segregation degree for materials characterization by the Spark Mapping Analysis for Large Sample (SMALS) technique, resulting in a misguide of the segregation degree. In this paper, we present the lower limit of segregation degree (Ds(L)) method to distinguish the random error from metal material segregation for large-size samples over the SMALS method. The random error of standard material in the 95% confidence interval was utilized as Ds(L) and the method has been applied for macro-segregation quantitative analysis. The precision correlation between Spark Atomic Emission Spectrometry (Spark-AES) and SMALS was established. Furthermore, the functional relationship between the Ds(L) and element content C can be obtained in the SMALS method. The Ds(L) method as the criterion can be used to not only characterize the minimum limit of the segregation degree but also the segregation existence for large-size samples. Applying to low-alloy steel can illustrate the effective performance of the Ds(L) method. Results on both spark mapping analysis and Spark-AES verify the substantial consistency.
OPA and SMALS methodologies have been introduced to obtain better analytical results.15–18 For example, Wang15 used the OPA technique to carry out statistical distribution analysis for low-alloy steel continuous casting billets and calculate the maximum segregation degree. The difference between an equiaxed sample and a columnar sample was quantitatively compared. Sheng11 characterized the multiple elements composition distribution of high-speed rail axle casting billets in 1000 mm × 250 mm by SMALS, and compared with other characterization methods, which proved the accuracy of SMALS results. However, the evaluation criteria of segregation degree for large-size samples are rarely studied. Wang19 proposed two judgment models: the total weight ratio of carbon contents within the permissive content range (C0 ± R) of statistical distribution and the confidence extension ratio of the median value (K) at 95% of the confidence limit of the weight ratio, which characterize the segregation degree of continuous casting quality billets by OPA. Zhang20 proposed a segregation degree evaluation method for large-size metal materials using the SMALS technique, which formulates the upper limit equation of segregation degree by the 95% prediction interval limit of the regression equation of permissible deviation and element content. However, there is almost no research on the lower limit of segregation degree for large-size samples by SMALS.
Firstly, the reference material normally contains no segregation because of better homogeneity but still shows a small segregation value due to the random error in detection. This random fluctuation has an impact on the results of segregation degree using calculation methods for the segregation degree. Next, the two-dimensional or three-dimensional contour map uses a color scale for qualitative judgment of sample segregation in most studies. Due to no definite specification for setting the color scale, visual error and misjudgment possibly are caused by color difference. Therefore, it is necessary to introduce the Ds(L) as the criterion for large-size sample by SMALS, and the random error limit of the reference material can be set as the low segregation limit. Fig. 1 shows the derivation process of the Ds(L) formula based on SMALS. SMALS and Spark-AES were used to analyze carbon steel and low-alloy steel. The correlation between the two methods was investigated, and the Ds(L) equation about the content of each element was obtained based on the SMALS method.
Item | Value |
---|---|
Spark excitation frequency/Hz | 500 |
Excitation capacitance/μF | 7.0 |
Pre-burning voltage/V | 360 |
Integration voltage/V | 190 |
Argon flow rate/L min−1 | 8 |
Tungsten electrode | Diameter 6 mm with sharp end 90° |
Wavelength range/nm | 160 to 650 |
PMT diameter/mm | 13 |
PMT sensitivity/μA lm−1 | 40 |
1 | 2 | 3 | 4 | 5 | 6 | |
---|---|---|---|---|---|---|
C | 0.215 | 0.424 | 0.082 | 0.634 | 0.008 | 0.036 |
Si | 0.135 | 0.244 | 0.487 | 0.333 | 0.643 | 0.786 |
Mn | 0.268 | 0.139 | 0.435 | 0.652 | 1.281 | 1.739 |
P | 0.017 | 0.026 | 0.049 | 0.037 | 0.006 | 0.041 |
S | 0.006 | 0.03 | 0.025 | 0.037 | 0.024 | 0.014 |
Cr | 0.76 | 0.369 | 1.451 | 0.991 | 0.119 | 1.71 |
Ni | 0.977 | 1.595 | 0.692 | 1.383 | 0.444 | 0.136 |
Mo | 1.06 | 0.501 | 1.192 | 0.141 | 1.16 | 0.70 |
Cu | 0.236 | 0.054 | 0.433 | 0.138 | 0.182 | 0.319 |
V | 0.298 | 0.407 | 0.077 | 0.231 | 0.526 | 0.069 |
Nb | 0.209 | 0.045 | 0.096 | 0.284 | 0.15 | 0.219 |
Al | 0.055 | 0.536 | 0.099 | 0.259 | 0.381 | 0.007 |
The six standard samples were analyzed by SMALS and Spark-AES, as shown in Fig. 2(a) and (b). The SMALS mapping area is 36 mm × 36 mm, and the effective excitation spot is 4 mm. A total of 12 spectral analyses were performed by Spark-AES on every sample surface. A large-size low-alloy steel sample was selected as the application sample. The steel was taken for SMALS full-scale surface analysis, where the mapping diameter is 124 mm (Fig. 2(c)). 20 spectral analyses were performed at uniformly distributed locations on the sample surface by Spark-AES (Fig. 2(d)).
The segregation value of the finished product is the content of a position (x, y) or the average content of an area C minus the total average content of the finished product , eqn (1) as follows:
(1) |
The segregation degree is divided into positive segregation degree (Ds(P)) and negative segregation degree (Ds(N)), as shown in eqn (2) and (3).
(2) |
(3) |
Any analysis method will have a random error, and the random error cannot be corrected, and increasing the number of parallel experiments may reduce the random error fluctuation. At the same time, the random error in testing from the instrument cannot be regarded as material segregation, so the composition change introduced by segregation must be greater than the random testing error of the standard material, otherwise measurement error will be confused with segregation. The random error has a normal distribution, and the absolute value of the error will not exceed a certain limit under a certain confidence probability (where α = 0.05). This limit value can be used as the lower limit of segregation degree of large-size metal materials. The lower limit value of segregation can be expressed by formula (4):
Ds(L) = 1.96sr/C | (4) |
(5) |
The functional relationship between Ds(L) and r can be obtained by substituting sr derived from formula (5) into formula (4). Moreover, the precision data in ASTM E415-15 Standard Test Method for Analysis of Carbon and Low-Alloy Steel by Spark Atomic Emission Spectrometry gave the values corresponding to the repeatability limits r and content C of each element in carbon steel and low-alloy steel measured by Spark Atomic Emission Spectrometry. Since the contents of several standard materials of V and Al exceeded the content range given by ASTM E415-15, the precision equations of GB/T 11170-2008 Stainless steel—Determination of multi-element contents-Spark discharge atomic emission spectrometric method were added. The regression equations of the repeatability limits r of each element by Spark-AES to content C were calculated, as shown in Table 3.
Element | Content range C/% | Repeatability limit r/% | R 2 |
---|---|---|---|
C | 0.02–1.1 | r = 0.0133C + 0.0036 | 0.926 |
Si | 0.02–1.54 | r = 0.0147C + 0.0005 | 0.921 |
Mn | 0.03–2.0 | r = 0.0186C − 0.0016 | 0.849 |
P | 0.006–0.085 | r = 0.1478C + 0.0017 | 0.916 |
S | 0.001–0.055 | r = 0.1581C − 0.0003 | 0.867 |
Cr | 0.007–8.14 | r = 0.0089C + 0.0004 | 0.967 |
Ni | 0.006–5.0 | r = 0.0133C + 0.0004 | 0.982 |
Mo | 0.007–1.3 | lgr = 0.854lgC − 1.648 | 0.968 |
V | 0.003–0.3 | r = 0.0248C + 0.0006 | 0.989 |
0.04–2.5 | r = 0.0222C + 0.0028 | ||
Al | 0.006–0.093 | r = 0.0724C − 0.0001 | 0.87 |
0.02–2.0 | r = 0.0305C + 0.002 | ||
Ti | 0.001–0.2 | r = 0.0809C − 0.00004 | 0.975 |
Cu | 0.006–0.5 | r = 0.0823C + 0.000006 | 0.915 |
Nb | 0.003–0.12 | r = 0.0879C + 0.00008 | 0.95 |
Sb | 0.006–0.027 | r = 0.0699C + 0.0007 | 0.912 |
N | 0.01–0.055 | r = 0.035C + 0.0007 | 0.888 |
Zr | 0.01–0.05 | r = 0.2448C + 0.00006 | 1 |
As | 0.003–0.1 | r = 0.1041C + 0.0004 | 0.996 |
Sn | 0.005–0.061 | r = 0.0767C − 0.0003 | 0.919 |
The linear functional relationship between r and C of repeatability limits of C, Si, Mn, P, S, Cr, Ni, Mo, V, Al, Ti, Cu, Nb, Sb, N, Zr, As, Sn elements and the logarithmic function relation of Mo element are obtained in ASTM E415-15. The correlation coefficient R0.05,11 = 0.553 was used to check the significance for the regression equation of each element, and the R for all elements was greater than R0.05,11, indicating that the regression line determined was meaningful.
Because the repeatability limit was measured by standard materials, sr is the measurement error of Spark-AES. According to the relationship between Ds(L) and r, the functional relationship between the lower limit of segregation degree Ds(L) and the content C of each element can be obtained, and the results are shown in Table 4.
Element | Content range (quality score) C/% | Ds(L) |
---|---|---|
C | 0.02–1.1 | Ds(L) = 0.0025/C + 0.0094 |
Si | 0.02–1.54 | Ds(L) = 0.0004/C + 0.0104 |
Mn | 0.03–2.0 | Ds(L) = 0.0011/C + 0.0132 |
P | 0.006–0.085 | Ds(L) = 0.0012/C + 0.1045 |
S | 0.001–0.055 | Ds(L) = 0.0002/C + 0.1118 |
Cr | 0.007–8.14 | Ds(L) = 0.0003/C + 0.0063 |
Ni | 0.006–5.0 | Ds(L) = 0.0003/C + 0.0094 |
Mo | 0.007–1.3 | Ds(L) = 0.0159C−0.146 |
V | 0.003–0.3 | Ds(L) = 0.0004/C + 0.0175 |
0.04–2.5 | Ds(L) = 0.0020/C + 0.0157 | |
Al | 0.006–0.093 | Ds(L) = −0.00007/C + 0.0512 |
0.02–2.0 | Ds(L) = 0.0014/C + 0.0216 | |
Ti | 0.001–0.2 | Ds(L) = 0.00003/C + 0.0572 |
Cu | 0.006–0.5 | Ds(L) = 0.000004/C + 0.0582 |
Nb | 0.003–0.12 | Ds(L) = 0.00006/C + 0.0622 |
Sb | 0.006–0.027 | Ds(L) = 0.0005/C + 0.0494 |
N | 0.01–0.055 | Ds(L) = 0.0005/C + 0.0247 |
Zr | 0.01–0.05 | Ds(L) = 0.00004/C + 0.1731 |
As | 0.003–0.1 | Ds(L) = 0.0003/C + 0.0736 |
Sn | 0.005–0.061 | Ds(L) = 0.0002/C + 0.0542 |
The lower limit segregation equation is for the Spark-AES method and applies only to carbon and low-alloy steels. The content ranges are listed in Table 4, with Ds(L) corresponding to each content. If the maximum positive and negative segregation of the sample measured by Spark-AES is less than Ds(L), it indicates no segregation or the segregation is so small as to be negligible. The correlation of the standard deviation sr between the SMALS method and the Spark-AES method will be established. The lower limit of segregation degree will be used as the criterion to judge segregation existence in the sample for the SMALS method. If the positive and negative segregation degree of an element in a large sample is less than the Ds(L), no segregation of the element in the sample will occur.
Fig. 3 Standard deviation fitting curves of the Spark-AES method and the SMALS method for elements C, Si, Mn, P, S, Cr, Ni, Mo, V and Al. |
The linear regression equation and determination coefficient R2 of the standard deviation of the SMALS results and Spark-AES results of a series of large-size standard samples are shown in Fig. 3. The correlation coefficient R0.05,4 = 0.811 was used to conduct significance tests for the regression equations of C, Si, Mn, P, S, Cr, Ni, Mo, V, Nb and Al elements. The correlation coefficient R of all elements was greater than R0.05,4, indicating that the regression line determined was meaningful.
The regression equations obtained from standard deviations of C, Si, Mn, P, S, Cr, Ni, Mo, V, Al and the functional relationship between the Ds(L) and C of Spark-AES are substituted into the formula (4) to obtain the functional relationship between the Ds(L) and C of SMALS for each element, as shown in Table 5.
Element | Content range (quality score) C/% | Ds(L) |
---|---|---|
C | 0.02–1.1 | Ds(L) = 0.0052/C + 0.0096 |
Si | 0.02–1.54 | Ds(L) = 0.0042/C − 0.0012 |
Mn | 0.03–2.0 | Ds(L) = 0.0037/C + 0.0107 |
P | 0.006–0.085 | Ds(L) = 0.00006/C + 0.0049 |
S | 0.001–0.055 | Ds(L) = −0.00002/C + 0.0576 |
Cr | 0.007–8.14 | Ds(L) = 0.0047/C + 0.0019 |
Ni | 0.006–5.0 | Ds(L) = 0.0031/C + 0.0041 |
Mo | 0.007–1.3 | lgDs(L) = −0.6205lgC −3.054 |
V | 0.04–2.5 | Ds(L) = 0.0001/C + 0.0001 |
Al | 0.02–2.0 | Ds(L) = 0.0015/C + 0.0047 |
The C, Si, Mn, Cr, Mo, V and Al composition content distributions are heterogeneous at the surface, and C, Si, Mn, Cr, Mo have pattern segregation. The phenomenon's main reason may be that in the condensation process of the ingot, the surface temperature is lower than the interior, the outer region cooling speed is fast. Alloying elements such as Mn, Cr, Mo, V solidified too late to diffuse at 3/4 R (scanning diameter is R), resulting in the formation of columnar crystal and negative segregation in the interior region. During the cooling process, Fe and a large number of alloying elements form a solid solution or interstitial solid solution with C and Si elements. Therefore, the location of segregation behavior of C and Si elements is consistent with that of heavy metals. The internal heat is dissipated at the surface through diffusion, and the internal cooling rate is slower, then forming coarse equiaxed crystals. The outer columnar crystals of crystallization growth pushes the unsolidified low-melting point segregation elements and impurities to the central region. As the temperature of the molten steel in the core tends to be uniform and drops below the supercooling temperature, coarse equiaxed crystals form in the central region. Al has low solid solubility in steel, and most Al exists in the form of inclusions. Under the condition that the crystallization process is sufficient, it cannot exist between the cells and moves to the liquid phase until the core part is completely solidified and remains in the center, so these elements are mainly distributed in the center of the sample. Al elements form a large number of point segregations in the center, indicating central segregation. The formation of this non-uniform layered structure is closely related to the compositional segregation during its thermal processing.
The total amount of single sparks was 1562298 by mapping the section surface of large-size low-alloy steel. These over of thousands of spectral signals can picture the probability density statistical distribution map of the element content in each original position and determine the element segregation through the peak pattern. Moreover, given the content of elements, the calculated repeatability limit r of each element is converted to repeatability standard deviation sr by formula (5), obtaining the probability density of normal distribution for each element content, which is the normal distribution for analyzing the random error of standard samples (non-segregation). According to the definition of the lower limit of segregation degree, the content value of the standard sample random error sr under 95% confidence is exceeded which illustrates element segregation existence.
As shown in Fig. 5, the probability density statistical distribution diagrams of elements C, Si, Mn, Cr and Al for the applied samples all have peak shape widths that exceed the 95% confidence interval of normal distribution of the standard samples, with negative segregation on the left and positive segregation on the right.
Fig. 5 Probability density statistical maps of C, Si, Mn, Cr, Al elements in the low-alloy steel by the SMALS method. |
The Ds(L) of the SMALS method was used as the evaluation method for segregation existence, and the average contents of elements C, Si, Mn, Cr, Ni, Mo, Cu, V and Al were substituted into the Ds(L,SMALS) equation of each element. The analysis statistical results are shown in Table 6.
Element | Content average wt/% | 95% confidence interval of content wt/% | Ds(N-max)/% | Ds(P-max)/% | Ds(L)/% | |
---|---|---|---|---|---|---|
C | 0.313 | 0.2931 | 0.336 | −6.36 | 7.35 | 2.61 |
Si | 0.297 | 0.2811 | 0.3134 | −5.35 | 5.52 | 1.28 |
Mn | 0.702 | 0.6819 | 0.7218 | −2.86 | 2.82 | 1.60 |
Cr | 1.086 | 1.0649 | 1.1089 | −1.94 | 2.11 | 0.62 |
Ni | 1.09 | 0.924 | 1.2319 | −15.23 | 13.02 | 0.70 |
Mo | 0.237 | 0.2236 | 0.2509 | −5.65 | 5.86 | 0.22 |
Cu | 0.048 | 0.0446 | 0.0514 | −7.08 | 7.08 | 0.23 |
V | 0.034 | 0.0208 | 0.0471 | −38.82 | 38.53 | 0.30 |
Al | 0.03 | 0.0251 | 0.0382 | −16.33 | 27.33 | 5.42 |
The maximum positive and negative segregation degrees of C, Si, Mn, Cr, Ni, Mo, Cu, V and Al are all greater than the Ds(L,SMALS) in Table 6, indicating that segregation exists in the sample. Moreover, the two-dimensional composition distribution of each element shows the segregation behavior. The calculated results are consistent with the content distribution diagram and probability density statistical map.
The large-size low-alloy steel was analyzed at 20 points by Spark-AES, which was evenly distributed on the full surface. The probability density distribution of each element content was obtained by Gaussian fitting of these spectral points. The average contents and sr with ASTM E415-15 of C, Si, Mn, Cr, Ni, Mo, Cu and Al were used to picture the normal distribution in Fig. 6.
Fig. 6 Probability density statistical maps of C, Si, Mn, Cr, Ni, Mo, Cu, Al elements in the low-alloy steel by the Spark-AES method. |
Compared with the statistical distribution maps of the two methods, the different peak shapes of the applied samples have two main reasons. One is the unequal analysis areas, the failure in full-scale scanning with Spark-AES, and the original position information of materials cannot be completely obtained. Another one is a different excitation pattern for two methods, Spark-AES adopts preignition for 10 s and integrates for 10 s. However, the peak width on both sides of the probability density statistical distribution diagram of elements C, Si, Mn, Cr, Ni, Mo, Cu, and Al of the applied sample exceeds the 95% confidence interval of normal distribution of the standard sample, indicating that segregation exists in the sample. The results of the SMALS method are consistent with the results of the Spark-AES method. Therefore, it has further demonstrated that Ds(L) can quantitatively determine the minimum limit of segregation degree and segregation existence using the SMALS technique.
The effectiveness of the Ds(L) equations was demonstrated through successful application to low-alloy steel with the SMALS methods. The two-dimensional content distributions of C, Si, Mn, Cr, Ni, Mo, Cu elements indicate pattern segregation and center segregation of Al. In mapping data, the Ds(L) of SMALS is less than the maximum segregation in the sample which is consistent with Spark-AES data, meaning that the Ds(L) equation can be a criterion of the segregation degree and segregation existence.
Moreover, combined with the upper limit of the segregation degree equation, the Ds(L) is proposed to improve the segregation evaluation system for SMALS. Due to the Ds(L) analytical method, the qualitative analysis of the segregation for large-size samples is upgraded to quantitative characterization, and each content has a corresponding Ds(L) value one by one. This method can be used as a reference for advanced characterization technology and other steels.
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