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The phenomenon, channel segregates (CS) as a result of gravity-driven flowdue to density contrast occurred in the solid-liquid mushy zones1duringsolidification, often causes the severe destruction of homogeneity and evensome fatal damages. Investigation on its mechanism sheds light on theunderstanding and controlling of the formation of solidifying metals,earth'score, igneous rock and sea ice. Until now, it still remains controversial whatcomposes the density contrasts and, to what extent, how it affects channelsegregates. Here, we show that in experimental 500kg and 100 ton commercialcast steel ingots CS originates from oxide Al2O3/MnS impurity clusters (OICs)initially nucleated from the oxide (Al2O3) particles, which induce an extraflow due to sharp density contrast between clusters and melt. The resultsuncover that, as OICs enrich and grow, their driven flow becomes stronger thanthe traditionally recognized inter-dendritic thermo-solutal convection,dominating the subsequent opening of the channels. This study extends theclassical macrosegregation theory, highlights a significant technologicalbreakthrough to control CS, and could quickly yield practical benefits to theworldwide manufacture of over 50 million tons of ingots, super-thick slab andheavy castings annually, as well as has general implications for theelaboration of other related natural phenomena.

How Channel Segregates Originates: The Flow of Accumulated Impurity Clusters in Solidifying Steels