ARL iSpark Plus Optical Emission Spectrometer: Basic inclusion analysis

Significance of the Topic

Non-metallic inclusions critically influence steel performance and production efficiency.
These inclusions can cause defects such as nozzle clogging and mechanical property deviations, leading to substantial processing costs and customer complaints.
Real-time monitoring and control of inclusions are therefore essential for modern steel manufacturing.

Objectives and Study Overview

This application note presents the Basic Inclusion Analysis Spark-DAT option for the Thermo Scientific ARL iSpark Plus optical emission spectrometer.
The goal is to enable rapid, simultaneous elemental and non-metallic inclusion analysis in low alloy steels.
It reports counts of key inclusion types and size categories with minimal additional measurement time, supporting up to several hundred samples per day.

Methodology and Instrumentation

The Spark-DAT method integrates inclusion evaluation with standard OES elemental analysis in under one second per sample.
Key features:

• Simultaneous determination of elemental composition and inclusion counts.
• Detection of inclusions bearing Al, Ca, Mg, S and specific compounds: Al2O3, CaO·Al2O3, CaO, spinels (Al2O3·MgO), CaS and MnS.
• Classification of inclusions into small (S), medium (M) and large (L) size categories, yielding SML counts per mm3.

Instrumentation:

• Thermo Scientific ARL iSpark Plus optical emission spectrometer.
• Photomultiplier channels for Al, Ca, Mg, Mn and S.
• Low alloy steel calibration and OXSAS analytical software for data collection and reporting.

Main Results and Discussion

The analysis provides quantitative counts of multiple inclusion types and size distributions, enabling:

• Fast assessment of inclusion burden and critical size populations.
• Combined reporting of elemental concentrations and inclusion metrics.
• Export of results in PDF, Excel, SPC or LIMS formats for streamlined quality control.

This approach delivers high sensitivity without compromising sample throughput, facilitating near-real-time process monitoring.

Benefits and Practical Applications

• Ultra-fast evaluation of non-metallic inclusions alongside full elemental analysis.
• Enhanced control over steel properties by distinguishing critical inclusion sizes.
• Reduction in production issues such as nozzle blockages and quality defects.
• High throughput supports continuous quality feedback in steelmaking operations.

Future Trends and Potential Applications

Emerging developments include:

• Extension to advanced inclusion chemistries and high-alloy steels.
• Integration with machine learning for predictive quality control.
• Automation of sample handling to increase throughput further.
• Adoption within Industry 4.0 frameworks for digital steel mill workflows.

Conclusion

The Basic Inclusion Analysis Spark-DAT option on the ARL iSpark Plus delivers rapid, precise inclusion and elemental analysis in steel.
With minimal extra analysis time, it equips steel producers with critical data to optimize quality and process efficiency.

References

• Thermo Scientific Standard Inclusion Analysis application note (AN41219).
• Thermo Fisher Scientific Application Note AN41218, 01/24.