MeltFlow-New Insights into the Electro-Slag Remelting Process using Mathematical Modeling

New Insights into the Electro-Slag Remelting Process using Mathematical Modeling

Abstract

A mathematical model was developed to simulate the ESR process for cylindrical ingots. Typical results from this model which include current and joule heat distribution, temperature and flow field in the process are presented here. The model also predicts metallurgical parameters of interest like solidification time, cooling rate and the Rayleigh number. Inputs to the model include geometrical parameters like electrode and ingot diameter, slag height, and melting parameters like current, melt rate, power. Other inputs include slag & alloy properties and heat transfer coefficients. The effect of melting power and electrode & ingot diameter on the predicted flow and temperature within the process is examined. Model predictions are compared against experimentally measured pool shape from a 0.432 m diameter ESR ingot. Simulations were also conducted for different alloys using the identical melting parameters.