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.

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.

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 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

scholarly journals A Sequential Approach to Numerical Simulations of Solidification with Domain and Time Decomposition

2019 ◽  
Vol 9 (10) ◽  
pp. 1972 ◽  
Author(s):  
Elzbieta Gawronska
Keyword(s):  
Parallel Computing ◽  
Computational Cost ◽  
Fixed Time ◽  
Simulation Software ◽  
Computational Method ◽  
Computational Time ◽  
Time Step ◽  
Sequential Approach ◽  
Time Partitioning ◽  
Physical Phenomena

Progress in computational methods has been stimulated by the widespread availability of cheap computational power leading to the improved precision and efficiency of simulation software. Simulation tools become indispensable tools for engineers who are interested in attacking increasingly larger problems or are interested in searching larger phase space of process and system variables to find the optimal design. In this paper, we show and introduce a new approach to a computational method that involves mixed time stepping scheme and allows to decrease computational cost. Implementation of our algorithm does not require a parallel computing environment. Our strategy splits domains of a dynamically changing physical phenomena and allows to adjust the numerical model to various sub-domains. We are the first (to our best knowledge) to show that it is possible to use a mixed time partitioning method with various combination of schemes during binary alloys solidification. In particular, we use a fixed time step in one domain, and look for much larger time steps in other domains, while maintaining high accuracy. Our method is independent of a number of domains considered, comparing to traditional methods where only two domains were considered. Mixed time partitioning methods are of high importance here, because of natural separation of domain types. Typically all important physical phenomena occur in the casting and are of high computational cost, while in the mold domains less dynamic processes are observed and consequently larger time step can be chosen. Finally, we performed series of numerical experiments and demonstrate that our approach allows reducing computational time by more than three times without losing the significant precision of results and without parallel computing.

Exploratory Studies on the Control of High-Speed Flows With Magnetogasdynamics

2002 ◽  
Author(s):  
Datta V. Gaitonde
Keyword(s):  
Flow Control ◽  
High Speed ◽  
Three Dimensional ◽  
Experimental Investigations ◽  
Control Mechanisms ◽  
Ground Testing ◽  
Simulation Efficiency ◽  
The Status ◽  
Physical Phenomena ◽  
Insight Into

Magnetogasdynamics (MGD) has the potential to lift many of the constraints presently inhibiting sustained hypersonic flight and affordable access to space. Given the difficulty of ground-testing under the expected harsh conditions, numerical methods can provide insight into the physical phenomena, and thus complement experimental investigations in the development of future concepts. This paper describes the status of an effort to develop a high-fidelity, fully three-dimensional method to explore MGD flow control in complex configurations. The theoretical model includes several non-ideal effects and takes recourse to a blend of first principles and phenomenological approaches to enhance simulation efficiency. Boundary conditions are summarized and sample verification exercises are presented. Exploratory calculations on a reentry vehicle and flow-through scramjet flowpath with MGD-bypass demonstrate the versatility of the approach and yield insight into dominant flow control mechanisms.

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