The effect of electric current on morphology and orientation selection of non-metallic inclusions in molten metal has been investigated using theoretical modelling and numerical calculation. Two geometric factors, namely the circularity () and alignment ratio () were introduced to describe the inclusions shape and configuration. Electric current free energy was calculated and the values were used to determine the thermodynamic preference between different microstructures. Electric current promotes the development of inclusion along the current direction by either expatiating directional growth or enhancing directional agglomeration. Reconfiguration of the inclusions to reduce the system electric resistance drives the phenomena. The morphology and orientation selection follows the routine to reduce electric free energy. The numerical results are in agreement with our experimental observations.
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