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How can oxide and sulfide inclusions cause metal parts to fail during forming?

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Diagram of a zinc-lead blast furnace system showing ore and coke entering through charge hoppers, with labeled furnace, air preheater, blower, taphole for slag and lead bullion, and a connected lead-splash condenser using rotors to separate and cool lead and zinc, with pathways for molten metals and off-gas. — metallurgy A zinc-lead blast furnace and lead-splash condenser. This technology is utilized mainly for producing zinc while managing both lead and zinc from raw materials, a technique that was highly influential in 20th-century smelting.

In the context of metallurgy and materials science, nonmetallic inclusions such as oxides and sulfides act as internal flaws within a metal workpiece. These impurities are typically trapped in the metal during the refining process.12

When a metal undergoes forming operations—processes that change the shape of the material—these inclusions can compromise the structural integrity of the part. Because they represent discontinuities or weak points within the metal matrix, they can serve as initiation sites for fracture when the material is subjected to stress. Essentially, these inclusions prevent the metal from deforming uniformly, leading to premature failure during manufacturing. To ensure the reliability of metal components, it is essential to minimize these inclusions through proper manufacturing and refining procedures.12