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A Machine Vision-Enhanced Framework for Tracking Inclusion Evolution and Enabling Intelligent Cleanliness Control in
Yong Lyu1,2, Yunhai Jia2, Lixia Yang2
1School of Metallurgical and Ecological Engineering, University of Science and Technology Beijing, Beijing 100083, China.
Materials (Basel, Switzerland)
|January 10, 2026
Summary
A new system accurately analyzes non-metallic inclusions in High-Strength Low-Alloy (HSLA) steel across production stages. It reveals how electroslag remelting and forging refine inclusions, enabling better quality control.
Area of Science:
- Metallurgical Engineering
- Materials Science
- Analytical Chemistry
Background:
- Non-metallic inclusions in High-Strength Low-Alloy (HSLA) steel significantly impact performance.
- Conventional methods struggle with accurate inclusion characterization in large components.
- Understanding inclusion behavior throughout processing is crucial for quality control.
Purpose of the Study:
- To develop an integrated system for automated, full-process analysis of non-metallic inclusions in HSLA steel.
- To investigate the evolution and distribution of inclusions from electrode to forged billet.
- To provide insights for optimizing HSLA steel production processes.
Main Methods:
- Development of an integrated analysis system combining motion control, optical imaging, and laser spectral analysis.
- Systematic sampling and analysis across the industrial process chain: consumable electrode, electroslag remelting (ESR) ingot, and forged billet.
- Utilizing an intelligent analysis framework with a YOLOv11 detection model and spectral feedback.
Main Results:
- Electroslag remelting (ESR) effectively reduced Type D inclusions.
- Type C silicate inclusions showed significant enrichment in the ESR ingot tail due to solidification dynamics.
- Subsequent forging led to substantial refinement and dispersion, achieving high purity in the billet tail.
Conclusions:
- The developed system enables rapid, automated, and compositional analysis of inclusions in meter-scale HSLA steel samples.
- Key process insights were gained, highlighting the roles of ESR and forging in inclusion control.
- Enhanced process strategies and an intelligent analysis framework were proposed for achieving controllable defect levels in HSLA steel.
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