Herein, two‐dimensional (2D) single‐action die compaction process of copper (Cu) powder was simulated by the multiparticle finite element method (MPFEM) at particulate scale. The initial packing structure, generated by the discrete element method (DEM), was used as an input for the FEM model, where the mesh division of each particle was discretized. The evolution of macro‐ and microscopic properties, such as relative density, stress distribution, particle deformation, void filling behavior, and force transmission, during compaction and pressure release processes have been systematically studied. The results revealed that the force is mainly concentrated on largely deformed regions of the particles during compaction and formed a contact force network, which hindered the densification process. In the compact, the shorter side of the large void edges rendered higher stress than the longer side. On the other hand, the stress distribution of small void edges remained uniform. After pressure release, large residual stress was observed at the contact area of the adjacent particles and the maximum stress was observed at the particles’ edges. Moreover, the residual stress did not proceed to the interior of the particles. Meanwhile, the stress of large void edges has been completely released but exhibited a nonuniform distribution. The smaller fraction of void filling resulted in a larger reduction of the released stress after pressure removal. Also, the particles closer to the upper die exhibited higher average equivalent von Mises stress inside the particles during compaction and pressure release processes.

There are two problems to be solved in the numerical simulation of the top blown oxygen vacuum refining process. (1) The two-equation turbulence models underpredict the turbulence mixing shear process for high-temperature gradient jet flows. (2) The high compressibility of the jet in a low vacuum environment. In this study, the SST k-ω turbulence model is modified by the composite function of the compressibility factor and the total temperature gradient. Based on the experimental model of the Kotani vacuum jet, the modified turbulence model was used to simulate the supersonic jet behavior of oxygen lance at different ambient temperatures. The reliability of the model is verified by the semi-empirical formula of Ito and Muchi. The simulation results show that the entrainment rate is an important inducing factor. The potential core length and the supersonic core length at the temperature of 1800 K are 2.5 times and 2.0 times that at the temperature of 285 K, respectively. Besides, based on the ejection model established by Ricou and Spalding, the calculation formula of turbulence entrainment rate at different ambient temperatures is obtained. This research work will benefit greatly to the supersonic jet behavior in Vacuum Refining.

A computation fluid‐coupled discrete phase model (CFD‐DPM) was used to predict the motion characteristics of gas, particle, and liquid phases in the hot metal ladle. The influence of different voltage loading modes, voltage values, and powder injection speeds on the particle motion trail was investigated, while the effects on the particle concentration maximum difference in the stagnation region were discussed. The optimal injection and voltage parameters were proposed. The results are shown as follows: the loading voltage before injection is beneficial to the diffusion of particles in the molten pool. With the increase of voltage and injection speed, the distribution of particles in the upper part of the molten iron tends to be uniform. The bottom of the ladle is the stagnation region. Optimum voltage and injection speed were determined. Under the optimum conditions, particles are evenly dispersed and the particle concentration difference in the stagnation region is small. This research work will benefit greatly to the hot metal ladle desulfurization technology.

In this paper, factors influencing the inclusion removal in high‐manganese and high‐aluminum steel in RH refining process were studied by numerical simulations, production practice, and metallographic experiments. A mathematical model for inclusion removal was established, and the phenomenon of inclusions mixing in RH up‐leg region was verified due to fluid circulation. Removal efficiency of RH circulation time 120 s is much better than 600 s, and it was the lowest efficiency after 600 s. After 600 s circulation time, it shall not apply in production practice. The mass concentration of inclusions in practical steel was 11.64% probability error than values obtained by numerical simulation, because the numerical simulation did not consider the problem of inclusions adsorbing to the walls of refractory materials and corrosion of refractories. This work lays the foundation for the optimization and upgrading of process technology and establishes big data for full automation of RH out of furnace refining.

In the process of top-blown converter steelmaking, the jet characteristics of the oxygen lance nozzle have a direct impact on the slag melting rate within the molten pool and the stirring effect of the molten steel, which influence steelmaking efficiency and product quality. In this research, a five-hole oxygen lance nozzle model suitable for 100-ton converters was established. Through numerical simulation, the effect of oxygen preheating temperature (300–900 K) on velocity decay, impact characteristics, and stirring performance of the five-hole oxygen lance jet under high-temperature conditions (1873 K) was analyzed. Results indicate that at high temperatures, increasing the oxygen preheating temperature significantly extends the length of the high-velocity jet region (jet velocity ≥500 m/s). However, this intensifies jet deflection and velocity decay, while also substantially shortening the length of the supersonic region. The optimal operating gun positions are 2.9 m for slag treatment and 2.5 m for conventional melting operations, corresponding to oxygen preheating temperatures of 800 and 600 K, respectively. Compared to the preheating temperature of 300 K, the 800 K oxygen jet increases the slag treatment area by 62.23% and reduces molten steel splashing by 76.44%. At a preheat temperature of 600 K, the effective impact area of the oxygen jet increases by 5.38%, the molten steel splatter rate decreases by 77.09%, and the mixing time increases by 68.18%. Notably, selecting an appropriate preheating temperature can effectively reduce splatter and enhance slag melting rate while also slightly improving smelting efficiency. Although mixing time significantly increases during this process, it can be shortened by adjusting the torch position and oxygen flow rate.