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A failed disc that was forged from S355J2 round bar was investigated in order to determine the failure route cause. The purpose of this paper is to determine the defects and route cause analysis regarding their origin.

Macroscopic evaluation, microstructure observation using light optical metallography and scanning electron microscopy with EDX analysis were the techniques used to analyse and characterize the defected areas.

Macro-inclusions (up to 850 µm) that correspond to high melting aluminium rich calcium-aluminate particles were detected. Their formation, possibly due to improper calcium treatment during ladle furnace steel refining process might be associated with clogging problems at casting. SEM-EDX analysis revealed whitish spots containing Zr that could be related to submerged entry nozzle (SEN) erosion/breakage. Characteristic is the large size and unusual shape of the traced particles, as well as the presence of low Si, Na, K. The findings indicated that nozzle clogging and/or breakage at casting was most possibly the root cause of the product’s quality degradation.

After extended root cause analysis, specific countermeasures are proposed to avoid clogging phenomena. The suggestions are based on the findings taking into account restrains of the steel-making process. Emphasis was laid in detecting the weaknesses that lead to product quality degradation and consequently in optimizing the steel-making process. Such incidents are often found during steelmaking a useful suggestion to steelmakers is to mark and remove cast parts after SEN problems are encountered. In this way quality issues in intermediate and/or final products will be avoided.