Effect of MgO Content in LF Refining Slag on Inclusion Removal and Cleanliness Improvement in GCr15 Bearing Steel

In this study, a laboratory-scale slag–steel reaction experiment was conducted to systematically evaluate the influence of the initial MgO content (3–7 wt.%) in LF refining slag on the cleanliness of GCr15 bearing steel. The assessment was performed from multiple perspectives by comparing the total oxygen content (T[O]) in molten steel, the inclusion area fraction, and the inclusion number density after 30 min of slag–steel interaction. To further elucidate the thermodynamic driving forces and kinetic mechanisms governing inclusion capture by slag, a predictive slag adsorption model was developed using an in-house computational code coupled with FactSage 8.1. Under conditions of slag basicity R (CaO/SiO2) ranging from 4.0 to 8.0, MgO content varying from 0 to 7 wt.%, and a constant Al2O3 content of 32 wt.%, the chemical driving force ΔC (the mass-fraction difference between slag components and inclusions), the slag viscosity η, and the combined parameter ΔC/η were calculated at 1600 °C for three representative inclusion types: Al2O3, MgO·Al2O3, and MgO. In addition, the model was employed to quantitatively characterize the adsorption capacity of slag toward Mg–Al binary inclusions under varying MgO levels. Both experimental observations and model calculations demonstrate that the slag–steel reaction markedly enhances inclusion removal, as evidenced by pronounced decreases in T[O], inclusion number density, and inclusion area fraction after reaction. With increasing MgO content in slag, T[O] and inclusion-related indices exhibit a consistent trend of first decreasing and then increasing, reaching minimum values at an MgO level of 5 wt.%. Further analysis reveals a positive correlation between the apparent inclusion-removal rate constant ko and ΔC/η corresponding to MgO·Al2O3 inclusions. Moreover, the slag’s adsorption capacity toward Mg–Al binary inclusions decreases overall as the MgO fraction in inclusions increases. Notably, when the MgO content in inclusions exceeds 29 wt.%, the adsorption capacity undergoes an abrupt drop, indicating a pronounced cliff-like attenuation behavior.