scholarly journals A Comprehensive Mathematical Model of Electroslag Remelting with Two Series-Connected Electrodes Based on Sequential Coupling Simulation Method

Metals ◽  
2020 ◽  
Vol 10 (5) ◽  
pp. 658
Author(s):  
Wenjie Tong ◽  
Wanming Li ◽  
Ximin Zang ◽  
Huabing Li ◽  
Zhouhua Jiang ◽  
...  
Keyword(s):  
Mathematical Model ◽  
Molten Metal ◽  
Skin Effect ◽  
Simulation Method ◽  
Melting Rate ◽  
Joule Heat ◽  
Electroslag Remelting ◽  
Metal Pool ◽  
Sequential Coupling ◽  
Molten Metal Pool

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.

Numerical Simulation of Electroslag Remelting Process for Producing GH4169 under Different Current Frequency

2012 ◽  
Vol 482-484 ◽  
pp. 1556-1565 ◽  
Author(s):  
Qiang Liang ◽  
Xi Chun Chen ◽  
Hao Ren ◽  
Cheng Bin Shi ◽  
Han Jie Guo
Keyword(s):  
Molten Metal ◽  
Simulation Software ◽  
Electroslag Remelting ◽  
Metal Pool ◽  
Current Frequency ◽  
Volumetric Heating ◽  
Physical Fields ◽  
Physical Phenomena ◽  
Insight Into ◽  
Molten Metal Pool

A comprehensive analysis of the physical processes that occur in Electroslag Remelting (ESR) process under steady state conditions and axisymmetric was performed using the simulation software MeltFlow. The detailed plots of current distribution, volumetric heating, flow, temperature and turbulent mixing provide insight into the various physical phenomena that occur in ESR process. The effect of current frequency on various physical fields was analyzed. It is shown that, the current in the slag tends to become more uniform due to the low electrical conductivity of the slag; after the current enters the ingot, the skin effect increases with the increase of the current frequency; the Joule heating and the Lorentz force are highest near the tip of the electrode in the slag, and increase with the increase of the current frequency; the velocities in the slag are slightly higher than those in the molten metal pool; with the increase of the current frequency, the liquidus temperature moves down, and the molten metal pool is deepened. Simulation results agree well with experimental results. Therefore, the generation and extent of defects could be predicted in different process.

Minimization of Thermal Stresses in Continuously-Cast Ingot with Restriction on its Molten-Metal Pool Volume

1999 ◽  
Vol 30 (4-6) ◽  
pp. 296-302
Author(s):  
F. V. Nedopekin ◽  
Victor K. Tolstykh ◽  
N. A. Volodin ◽  
V. V. Belousov ◽  
S. V. Gridin
Keyword(s):  
Molten Metal ◽  
Thermal Stresses ◽  
Metal Pool ◽  
Cast Ingot ◽  
Continuously Cast ◽  
Molten Metal Pool

scholarly journals Effect Of Technological Parameters On Sizes Of Molten Metal Pool In Plasma-arc Surfacing Of Copper Plates Of Mccb Moulds

2015 ◽  
Vol 2015 (1) ◽  
pp. 21-25 ◽  
Author(s):  
V.G. Kozhemyakin ◽  
◽  
V.A. Shapovalov ◽  
V.R. Burnashev ◽  
D.V. Botvinko ◽  
...  
Keyword(s):  
Molten Metal ◽  
Metal Pool ◽  
Plasma Arc ◽  
Technological Parameters ◽  
Molten Metal Pool

scholarly journals Research on the ingot shrinkage in the electroslag remelting withdrawal process for 9Cr3Mo roller

2019 ◽  
Vol 38 (2019) ◽  
pp. 672-682
Author(s):  
Wanming Li ◽  
Ximin Zang ◽  
Haiyang Qi ◽  
Dejun Li ◽  
Xin Deng
Keyword(s):  
Temperature Field ◽  
Yield Function ◽  
Joule Heat ◽  
Electroslag Remelting ◽  
Slag Bath ◽  
Magnetic Flux Density ◽  
Sequential Coupling ◽  
Field Velocity ◽  
Physical Fields ◽  
Good Agreement

AbstractIn order to reduce the air gap between ingot and mould in the electroslag remelting withdrawal (ESRW) process, the taper of the mould should be consistent with the ingot shrinkage.Athree-dimensional mathematical model was developed to describe the interaction of multiple-physical fields (Joule heat, electromagnetic field, velocity field, and temperature field) and ingot shrinkage during the ESRW process. The variations of material thermal and mechanical properties, as well as the yield function with temperature, were considered. The shrinkage behavior of 9Cr3Mo roller in the ESRW process was simulated using the sequential coupling method. A good agreement between the calculated value and the measured valuewas obtained in the temperature field and stress field. Numerical results showed that maximum values of current density, Joule heat, and electromagnetic forcewere at the electrode corner of the slag bath. The direction of the magnetic flux density was tangential to the slag bath and had a clockwise rotation. There were two pairs of vortices and two high temperature zones in the slag bath. The shrinkage displacement was obtained through thermal-stress analysis. As the distance from the mould outlet decreases, the shrinkage displacement of ingot increases. As for the electroslag remelting withdrawal process for 9Cr3Mo roller, the variation of the shrinkage displacement from the slag/metal interface to the mould outlet was 0.0028 m. The maximum shrinkage displacement is at the mould outlet, and the value was 0.0089 m.

scholarly journals Experimental research and numerical simulation of moving molten metal pool

2015 ◽  
Vol 1 (0) ◽  
pp. 15-00367-15-00367 ◽  
Author(s):  
Penghui CHAI ◽  
Nejdet ERKAN ◽  
Masahiro KONDO ◽  
Koji OKAMOTO ◽  
Hongyang WEI
Keyword(s):  
Numerical Simulation ◽  
Molten Metal ◽  
Experimental Research ◽  
Metal Pool ◽  
Molten Metal Pool

Modeling the Conditions for Microdroplets Formation and their Detachment from the Molten Metal on the Electrode

2021 ◽  
Vol 313 ◽  
pp. 1-7
Author(s):  
V.D. Sarychev ◽  
S.A. Solodsky ◽  
Sergey A. Nevskii ◽  
M.A. Kuznetsov ◽  
D.P. Ilyaschenko ◽  
...  
Keyword(s):  
Mathematical Model ◽  
Molten Metal ◽  
High Frequency ◽  
Plasma Discharge ◽  
Pulse Action ◽  
Materials Processing ◽  
Physical Processes ◽  
Micro Scale ◽  
Physical Mechanisms ◽  
Frequency Pulse

Formation of nanostructure states on the surface of materials exposed to concentrated flows of energy is one of the relevant problems of modern materials processing. In the paper the authors describe the mechanism of the micro-scale droplets formation based on the study and modeling of the physical processes and technological aspects of the interaction between the heterogenic plasma flows and the molten substance at the electrode tip. The authors show new physical mechanisms and criteria for micro-and nanoparticles origination, develop a physical-mathematical model of the interaction between the molten metal and the plasma discharge with imposed high-frequency pulse action.

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