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Non-metallic inclusions are formed from a variety of sources such as deoxidations, chemical interactions between the steel and slag, slag entrapment, breakdown of refractory materials and reoxidation by air. In particular, hard alumina inclusions are known to be detrimental to the mechanical properties of steel welds as well as to the steel materials themselves.1–6) Since alumina inclusions also affect the formation of internal stress, the control of morphology and size of alumina inclusions in aluminum killed (AK) steels has been an important focus in the steel industry.7) Okohira et al.8) found that dendritic alumina was enhanced at relatively high Al concentrations, i.e., 0.04–0.06 mass%, in low carbon aluminum killed (LCAK) steel. The critical supersaturation for alumina nucleation in AK steel was measured by Li and Suito9) and was thermodynamically computed based on the Gibbs free energy change for nucleation by Wasai and Mukai.10) Dekkers et al.16–18) found that at high supersaturation, the initial stage of aluminum deoxidation was unstable during sampling, fast cooling and solidification, but subsequent isometric growth leads to the formation of spherical alumina due to a morphological instability of their surfaces. These spherical alumina particles grow into dendrites and form clusters. However, at low supersaturation, small faceted particles of less than 5 μm were formed. And they11–13) proposed that the morphology of alumina inclusions was dependent on its atomic structure, supersaturation degree, impurities and agglomeration followed by sintering. As discussed by Dekkers et al.,12,13) the formation of metastable secondary particles during sampling could not be avoided irrespective of the sampler used. This is the most ambiguous factor affecting the analysis of the morphology and size of inclusions in steel. In the current work, a novel experimental methodology was employed to clarify the effects of supersaturation degree, reaction time and surface roughness of the substrate on the morphology and size distribution of alumina inclusions formed at the iron/refractory interface. 2. Theoretical Background

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Morphologies of Alumina Nano- and Microparticles at the Fe/Al2O3 Interface and the Effects of Reaction Time and Substrate Roughness on Size Distribution