| Summary: | Macrosegregation is the key issue in the solidification field. Oxygen and its inclusions play the important role in driving the melt flow and the resulting macrosegregation in steel. Here, to reveal the inducing mechanism and quantitative model of oxygen content in real industrial steel ingots, we demonstrate for the first time that there exists the critical oxygen content in triggering the formation of channel-type segregation, the most undesirable macrosegregation type in steel. Our multiscale simulations from density functional theory calculations to multiphase/multicomponent macromodel, clarify the quantitative conditions initializing channel-type segregation and reveal two typical growth modes via oxide flotation. The oxygen content model and criterion to induce the channel onset is built accordingly, which are validated by the numerous full ingot dissections and experimental characterizations including the in situ electrolysis of inclusions, X-ray microtomography, scanning electron microscope, large-scale measurement system of inclusions and chemical analysis. With oxygen controlled below this critical value of 0.0008 wt%, channel disappears. This study quantitatively uncovers the novel role of oxygen in steel, changes the traditional sole concept of cleanliness, and highlights an innovative and controlling-effective route to fabricate homogenized steel.
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