Theoretical precipitation modeling and multidimensional characterization of sulfide inclusions in tellurium-containing steels

This study investigates the precipitation characteristics of sulfide inclusions during the solidification of alloy steels under the combined influence of sulfur (S), manganese (Mn), and tellurium (Te). A multidimensional characterization and comparison of sulfide inclusions in Te-containing steels with varying S content and cooling conditions were performed using X-ray Micro-CT, Raman spectroscopy, and field emission scanning electron microscopy (FE-SEM). Both 2D and 3D analyses confirmed that increasing the S content in Te-containing steels leads to a higher overall number of sulfide inclusions. In particular, the rise in the proportion of small-sized inclusions was analyzed from the perspectives of interfacial dynamics and equilibrium thermodynamics. Regarding inclusion morphology, 2D characterization exhibited significant inaccuracies in assessing large inclusions in high-S, Te-containing steels, while X-ray Micro-CT proved advantageous for evaluating both the spatial distribution and morphology of inclusions. In addition, X-ray Micro-CT was used for the first time in this study to perform a non-destructive analysis of the layered MnS-MnTe structure, expanding the method's application in the metallurgical field. A predictive model based on inter-element activity interaction coefficients was employed to determine the first-order activity interaction coefficient of Te for Mn. Furthermore, a thermodynamic model for sulfide precipitation in Te-containing steels was developed. This study lays a theoretical foundation for better control of sulfide inclusions in future Te-containing specialty steels. •3D non-destructive structure of MnS-MnTe inclusions was presented by X-ray Micro CT in Te-containing steels.•Sulfur-induced increase in nucleation rate during MnS precipitation in Te-containing steels•An equilibrium thermodynamic model for MnS precipitation was developed for Te-containing steels.