Abstract:
For the stringent requirements for high-quality clean steel in modern manufacturing to be satisfied, the precise control and efficient removal of nonmetallic inclusions have become key tasks in metallurgical production. This paper systematically reviews the latest research progress worldwide on the electric-field regulation of nonmetallic inclusions in molten steel. We aim to offer a solid theoretical foundation and engineering guidance for advancing and applying this novel metallurgical technology. First, three fundamental mechanisms underlying electric-field regulation are elaborated. The interfacial electric double layer theory demonstrates that most oxide inclusions, such as Al
2O
3, acquire positive charges at the molten steel interface, enabling directional migration toward the cathode under an external electric field. The electromagnetic repulsion mechanism relies on the considerable conductivity difference between inclusions and molten steel, generating an electromagnetic force that drives inclusions to move opposite to the direction of molten steel flow. The electric-free energy driving mechanism indicates that current distortion around inclusions creates a current density gradient, pushing inclusions from high-current-density regions to low-current-density regions. Notably, these mechanisms differ in migration directions: the electric double layer mechanism supports parallel migration relative to the electric current, whereas the other two mechanisms favor vertical migration. However, they all validate the feasibility of electric-field-driven inclusion separation. Second, multidimensional regulatory effects of electric fields on typical inclusions (Al
2O
3, MnS, TiN, etc.) are analyzed from five aspects: quantity, size, morphology, distribution, and interfacial properties. Optimized electric-field parameters can significantly reduce inclusion number density; for instance, pulsed electric fields reduce the density of Al
2O
3 inclusions by over 20% in ultra-low-carbon steel. Electric fields effectively refine inclusions, decreasing the proportion of large inclusions (>5 μm) and increasing fine inclusions (≤5 μm). In terms of morphology, electric fields transform dendritic, irregular Al
2O
3 and rod-like MnS into spherical or ellipsoidal particles, mitigating stress concentration in steel substrates. Regarding distribution, electric fields induce an ordered arrangement of inclusions along current lines, thus improving structural homogeneity. Additionally, external electric fields adjust interfacial tension and wetting angle between molten steel and refractories, suppressing interfacial reactions and reducing inclusion adhesion. Third, industrial applications confirm the remarkable performance of electric-field regulation. In continuous casting of aluminum-killed and rare-earth steel, pulsed electric fields dramatically reduce submerged entry nozzle (SEN) clogging, smooth inner nozzle surfaces, increase continuous casting heats, and lower slab defect rates. For example, in industrial trials, SEN clogging thickness decreases by approximately 30%, and steel surface defects decrease from 1.21% to 0.75%. Through the optimization of inclusion characteristics, electric fields also enhance the tensile strength, ductility, fatigue life, and corrosion resistance of steel, thereby satisfying the demands of high-end steel products. Nevertheless, critical research gaps remain. Quantitative matching models linking steel grades, inclusion types, and electric-field parameters are absent, and current equipment lacks real-time adaptive adjustment for dynamic casting conditions. Future research should establish quantitative prediction models, develop machine-learning-based intelligent optimization systems, explore high-temperature in situ observation techniques, investigate composite inclusion responses, and integrate electric fields with bubble flotation for synergistic purification. In summary, electric-field regulation represents an efficient, adaptable approach for controlling molten steel inclusions, and it has substantial potential to upgrade clean steel manufacturing. This review supports the technical innovation and scaled industrial application of electric-field regulation in high-quality steel production.