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<p>This study aims to control the increase of calcium content in ingots during the electroslag remelting (ESR) process by designing suitable slag compositions. Analysis of industrial data using machine learning identified calcium ion activity in slag and electrode melting rate as the key factors influencing ingot calcium content. Based on industrial practice, a CaF<sub>2</sub>–Al<sub>2</sub>O<sub>3</sub>–CaO–SiO<sub>2</sub>–MgO slag system generated 138,347 slag combinations. Using thermodynamic data and MICT, slag compositions with lower calcium ion activity were identified while maintaining stable melting points, viscosity, and conductivity. ESR experiments with 1.2343 mold steel confirmed that lower calcium ion activity in slag reduces calcium content in ingots, leading to the development of a slag composition (Model-3) with minimal calcium-increasing potential. These results confirmed the correlation between slag calcium ion activity and ingot calcium content, validating MICT's reliability in predicting slag calcium ion activity. To further investigate the effects of slag components, 138,347 slag compositions were ranked on a scale of 0 to 10 based on calcium ion activity, deriving interaction coefficients among the components. A predictive equation for ingot calcium content was also developed, accurately forecasting calcium levels in ESR ingots for various slag compositions and melting rates in 5 to 15 tons furnaces.</p>

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Calculation of Calcium Ion Activity in the CaF2–Al2O3–CaO–SiO2–MgO Slag System and Its Impact on Calcium Content in Steel

  • 期刊论文

  • 发表日期：

    2025年4月15日

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  • Yi-ming Li,
  • Jia-long Tian,
  • Zhou-hua Jiang

摘要

This study aims to control the increase of calcium content in ingots during the electroslag remelting (ESR) process by designing suitable slag compositions. Analysis of industrial data using machine learning identified calcium ion activity in slag and electrode melting rate as the key factors influencing ingot calcium content. Based on industrial practice, a CaF2–Al2O3–CaO–SiO2–MgO slag system generated 138,347 slag combinations. Using thermodynamic data and MICT, slag compositions with lower calcium ion activity were identified while maintaining stable melting points, viscosity, and conductivity. ESR experiments with 1.2343 mold steel confirmed that lower calcium ion activity in slag reduces calcium content in ingots, leading to the development of a slag composition (Model-3) with minimal calcium-increasing potential. These results confirmed the correlation between slag calcium ion activity and ingot calcium content, validating MICT's reliability in predicting slag calcium ion activity. To further investigate the effects of slag components, 138,347 slag compositions were ranked on a scale of 0 to 10 based on calcium ion activity, deriving interaction coefficients among the components. A predictive equation for ingot calcium content was also developed, accurately forecasting calcium levels in ESR ingots for various slag compositions and melting rates in 5 to 15 tons furnaces.