Investigation of effect of electrode polarity on electrochemistry and magnetohydrodynamics using tertiary current distribution in electroslag remelting process

Transport phenomena including the electromagnetic, concentration of ions, flow, and thermal fields in the electroslag remelting (ESR) process made of slag, electrode, air, mold, and melt pool are computed considering tertiary current distribution. Nernst–Planck equations are solved in the bulk of slag, and faradaic reactions are regarded at the metal–slag interface. Aiming at exploring electrochemical effects on the behavior of the ESR process, the calculated field structures are compared with those obtained using the classical ohmic approach, namely, primary current distribution whereby variations in concentrations of ions and faradaic reactions are ignored. Also, the influence of the earth magnetic field on magnetohydrodynamics in the melt pool and slag is considered. The impact of the polarity of electrode, whether positive, also known as direct current reverse polarity (DCRP), or negative, as known as direct current straight polarity (DCSP), on the transport of oxygen to the ingot of ESR is investigated. The obtained modeling results enabled us to explain the experimental observation of higher oxygen content in DCSP than that of DCRP operated ESR process.