Mathematical Simulation on the Influence of Melting Rate and Melting Current on Droplet Behavior During Electroslag Remelting Process

A comprehensive mathematical model of electroslag remelting with two series-connected electrodes (TSCE-ESR) was constructed based on sequential coupling method. The influence of droplet effect on electroslag remelting process (ESR) was considered in this model. Compared with one-electrode electroslag remelting (OE-ESR), the multi-physics field, droplet formation and dripping behavior, and molten metal pool structure of TSCE-ESR process were studied. The results show that during the process of TSCE-ESR, the proximity effect of the electrodes suppresses the skin effect, and Joule heat is concentrated in the area between the two electrodes of slag pool, making the temperature distribution of the slag pool more uniform. The heat used to melt the electrode in the process of TSCE-ESR accounts for about 34% of the total Joule heat, which is lower than the OE-ESR (17%). Therefore, it makes a higher melting rate and a smaller droplet size in the process of TSCE-ESR. Compared with OE-ESR, TSCE-ESR process can realize the unification of higher melting rate and shallow flat molten metal pool. Compared with the results without droplet effect, it is found that in the simulation results with droplet effect, the depth and the cylindrical section of molten metal pool increased, and the width of the mushy zone is significantly reduced, which is more consistent with the actual electroslag remelting process.

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Effect of melting rate on microsegregation and primary MC carbides in M2 high-speed steel during electroslag remelting

China Foundry ◽

10.1007/s41230-021-9009-1 ◽

2021 ◽

Vol 18 (3) ◽

pp. 163-169

Author(s):

Fu-xing Yin ◽

Ming Su ◽

Fa Ji ◽

Qing-chao Tian ◽

Ya-guan Bai ◽

...

Keyword(s):

High Speed ◽

High Speed Steel ◽

Melting Rate ◽

Electroslag Remelting ◽

M2 High Speed Steel

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Monitoring the melting rate of a consumable electrode in electroslag remelting

Metallurgist ◽

10.1007/bf00738503 ◽

1986 ◽

Vol 30 (6) ◽

pp. 214-216

Author(s):

S. I. Samoilenko ◽

M. A. Kutalov ◽

R. P. Samygin ◽

P. M. Platonov

Keyword(s):

Melting Rate ◽

Electroslag Remelting ◽

Consumable Electrode

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Droplet Formation and Dripping Behavior during the Electroslag Remelting Process with Two Series-Connected Electrodes

Metals ◽

10.3390/met10030386 ◽

2020 ◽

Vol 10 (3) ◽

pp. 386 ◽

Cited By ~ 1

Author(s):

Wenjie Tong ◽

Wanming Li ◽

Ximin Zang ◽

Huabing Li ◽

Zhouhua Jiang ◽

...

Keyword(s):

Proximity Effect ◽

Physical Simulation ◽

Fluid Model ◽

Metal Droplet ◽

Droplet Formation ◽

Input Power ◽

Electroslag Remelting ◽

Filling Rate ◽

Molten Layer ◽

Droplet Behavior

The formation and dripping behavior of droplets in the process of the electroslag remelting with two series-connected electrodes (TSCE-ESR) has an important influence on the optimization of power supply parameters and the purity of the electroslag ingot. In this article, through numerical simulation based on the VOF (volume of fluid) model, combined with the transparent experimental device for physical simulation, the mechanism of metal droplet formation and the effect of the filling rate on its droplet behavior were studied. The results showed that the proximity effect, instead of the skin effect, is a major factor influencing droplet formation in TSCE-ESR process. The proximity effect makes the region inside the two electrode tip melt first, and the molten steel converges at the electrode tips to form a droplet source. The process of droplet formation and dropping can be divided into three stages: formation of molten layer, droplet stretching and necking, and detachment. In the stage of droplet stretching and necking, the increase in the contact area between the droplet and the slag and the instantaneous increase of the current provide good thermodynamic and dynamic conditions for the removal of non-metallic inclusions. After the droplet drops into the slag pool, it promotes the flow of slag and improves the heat and mass transfer efficiency of the slag/metal interface. The relatively large filling rate can form smaller and dispersed droplets, which improves the refining effect. At the same time, the increase of the filling rate can improve the input power and the electrode remelting rate.

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Numerical analysis of role of melting rate on electroslag remelting continuous directional solidification of a die steel

Journal of Iron and Steel Research International ◽

10.1007/s42243-021-00720-0 ◽

2022 ◽

Author(s):

Jie Zhang ◽

Jing Li ◽

Cheng-bin Shi

Keyword(s):

Numerical Analysis ◽

Directional Solidification ◽

Melting Rate ◽

Electroslag Remelting ◽

Die Steel

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Numerical Simulation Study of Consumable Electrode Melting Process in Electro-Slag Remelting Ingots

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.189-193.3895 ◽

2011 ◽

Vol 189-193 ◽

pp. 3895-3898 ◽

Cited By ~ 2

Author(s):

Lei Rao ◽

Qi Yao Hu ◽

Xiao Long Li

Keyword(s):

Mathematical Model ◽

Droplet Diameter ◽

Melting Process ◽

Melting Rate ◽

Entire System ◽

Technological Parameters ◽

High Quality ◽

Diameter Droplet ◽

Melting Current

Electro-slag remelting (ESR) is a kind of special metallurgy techniques to produce high quality alloy materials. The interface of electrode and slag is the energy entrance of entire system in the remelting process. Mathematical model of consumable electrode’s melting process has been built in this paper. Some valuable variation rules of droplet diameter, droplet forming time, melting rate and purification coefficient following melting current and slag bath depth have been studied through a series of simulation work. Based on the mechanism studying of the consumable electrode’s melting, some meaningful experience to optimize the technological parameters and improve material quality of electro slag ingot has been gotten.

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Macroscale Modeling of Multi-Physics Fields during Vacuum Arc Remelting of Ti-6Al-4V

Materials Science Forum ◽

10.4028/www.scientific.net/msf.789.603 ◽

2014 ◽

Vol 789 ◽

pp. 603-607

Author(s):

Bin Zhu ◽

Xiang Yi Xue ◽

Hong Chao Kou ◽

Cong Xiao ◽

Jin Shan Li

Keyword(s):

Temperature Field ◽

Molten Pool ◽

Element Model ◽

Melting Rate ◽

Vacuum Arc ◽

Physical Interaction ◽

Water Cooling ◽

Vacuum Arc Remelting ◽

Cooling Conditions ◽

Melting Current

A 3-D finite element model has been established using ANSYS12.0 software to simulate multi-physical interaction behavior during the Vacuum Arc Remelting (VAR) of 740-mm-diameter ingots of Ti-6Al-4V. The models of temperature field, electromagnetic and flow field were combined by progressive method. The effect of thermal contraction was considered in the simulation of temperature field and electromagnetic by setting a thin layer with different nature parameters at the ingot-crucible interface. The model results demonstrate the distributions of temperature, Lorenz force and flow velocity, and the influence of water cooling conditions, melting current and other process parameters. The molten pool behavior is mostly dominated by buoyancy force under circumstances in this case. The increase of the melting current results in an increase of the pool depth and melting rate, and causes great change of the molten pool profile, while the influence of the water cooling conditions is ignored.

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