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*Desulfurization Process in Steelmaking *

- Desulfurization is the removal of Sulfur from molten steel.
Sulfur has a bad effect on impact resistance and cold workability of steel and causes hot shortness of rolled steel. It forms an Eutectic structure (FeS) on the Grain Boundaries leading to embrittlement during rolling processes.
Therefore, the sulfur concentration should be as low as possible usually lower than 0.04% S.

- Sulfur is removed at secondary metallurgy stage (LRF) by lime additions to form sulfide compound as the following reaction.
[FeS] + (CaO) → (CaS) + (FeO)

*Factors favoring the Desulfurization*

(1) Basic slag: CaO/ SiO2 ratio should be above 2.5 which are achieved by the addition of sufficient amount of burnt lime. Limestone is not used in sulfur refining because reaction is endothermic and limestone addition will decrease liquid steel temperature which decrease reaction rate.

(2) High temperature: Sulfur refining reaction is endothermic in nature and as the temperature increases rate increases, sulfur refining takes place above 1600°C.

(3) Reducing atmosphere: low oxygen and FeO which is obtained by adding deoxidizers and ferro-alloys to react with oxygen dissolved in the molten steel at LRF.

(4) Liquid and fluid slag: slag should be liquid to enhance slag metal reaction, so Flux addition like fluorspar increases slag fluidity but increases refractories erosion.

(5) Stirring: Stirring of liquid steel by some gasses as Nitrogen or Argon increases metal-slag interface and reaction rate.

FORGING - Mechanism and Types

Metal forging is a manufacturing process in which metal is shaped and formed through the application of localized compressive forces. The process typically involves heating the metal to a high temperature, making it more malleable, and then using a tool or die to apply force to deform it into the desired shape.

Key characteristics and steps of metal forging include:

- Heating: The metal is heated to a temperature where it becomes more pliable and can be easily shaped. The exact forging temperature varies depending on the type of metal being used.

- Forging: There are various methods of forging, including:

➡️ Hammer Forging: In this method, a power hammer or a mechanical hammer is used to repeatedly strike the heated metal to shape it.

➡️Press Forging: Hydraulic or mechanical presses are employed to apply a steady, controlled force to the metal, shaping it into the desired form.

➡️Roll Forging: The metal is passed between two rollers that exert pressure on it, changing its shape.

➡️Die Design: Dies or molds are used to define the shape and dimensions of the final forged product. These molds can be simple or highly complex, depending on the part being produced.

- Cooling: After the forging process, the metal is often quenched or cooled to set its shape and strengthen its structure. This cooling process can be done using various methods, including air cooling, water quenching, or oil quenching.

- Trimming and Finishing: The forged part may require additional trimming, machining, or finishing operations to meet precise specifications and surface quality standards.

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Join our subscription-based telegram group for Metallurgy Quizzes for BARC 2024, GATE 2025, JET, GET, and Interviews.     
   
We have uploaded MCQs (1500+ questions) on physical metallurgy, materials characterization, General Materials science,   Mechanical metallurgy,  Mechanical properties,  metal forming process, thermodynamics, and extractive metallurgy.   
 
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