Predicting Melting Behavior of an Industrial Electroslag Remelting Ingot

Yanke, Jeff; Fezi, Kyle; Fahrmann, Mike; Krane, Matthew John M.

doi:10.1007/978-3-319-48102-9_7

Cited by 3 publications

(4 citation statements)

References 6 publications

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“…The electrode melt rate depends on the heat flux provided to the electrode and can be calculated according to the heat balance across the electrode tip. The heat transferred to the electrode can be divided into two parts: the heat flux diffused into the electrode ( q Sensible ) and the latent heat ( q Latent ).

q_{slag} = q_{Latent} + q_{Sensible}

…”

Section: Mathematical Modelingmentioning

confidence: 99%

“…Weber et al developed a comprehensive model to investigate the solidification of molten slag and metal with the enthalpy method. Yanke et al explored the effects of current level and mold diameter on slag skin using the volume of fluid (VOF) model and neglected the difference between molten slag and slag skin in electrical conductivity. Hugo et al and Jardy et al demonstrated the effects of mold current on slag skin at the same current level and found that the slag skin thickness increased with the existence of mold current.…”

Section: Introductionmentioning

confidence: 99%

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Numerical Simulation of the Dynamic Formation of Slag Skin and Heat Flow Distribution during the Electroslag Remelting Process

Liu

Kang

et al. 2018

steel research int.

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A 2D axisymmetric model is established to investigate the dynamic formation of slag skin and heat flow distribution during the electroslag remelting process. The growth of ingots is addressed with the dynamic mesh technique, and the volume of fluid model is employed to trace the slag/metal interface. The results indicate that the slag skin thickness at the slag/mold interface increases with the distance from the free slag surface, with a maximum thickness of 4 mm at the slag/pool interface. With the growth of ingot, the slag skin at the slag/pool interface is partially remelted by the hotter metal and finally solidifies around the solidified ingot with a thickness of 1 mm. The calculated percentage of heat flow is in reasonable agreement with the measurement. The loss of heat flow to the mold accounts for 67% of the power input, and approximately 28% of that power is absorbed by droplets in a laboratory scale ESR unit. The heat loss to slag/mold interface first increases with increasing slag temperature and then slowly decreases with decreasing slag bath height. The heat of the ingot primarily escapes from the baseplate at the initial stage. However, as the ingot grows, the heat loss in the radial gradually becomes dominant.

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q_{slag} = q_{Latent} + q_{Sensible}

…”

Section: Mathematical Modelingmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Numerical Simulation of the Dynamic Formation of Slag Skin and Heat Flow Distribution during the Electroslag Remelting Process

Liu

Kang

et al. 2018

steel research int.

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“…Here, an extensive reviews of mathematical models of fluid flow, electromagnetism, heat transfer, and solidification in the ESR are given . Because of their principle importance, only equations of the electromagnetic fields are discussed in details.…”

Section: Mathematical Modeling Of Transport Phenomenamentioning

confidence: 99%

“…Assuming a constant thickness of the liquid metal film which forms at the tip of the electrode (≈8 mm), Yanke et al used heat transfer coefficients at the slag‐electrode interface to predict the melt rate of the electrode for alloys Inconel 718™ and Waspaloy™. Furthermore, they studied effects of system size, applied current, and thickness of the slag skin layer on the melt rate and the pool depth .…”

Section: Mathematical Modeling Of Transport Phenomenamentioning

confidence: 99%

Review on Modeling and Simulation of Electroslag Remelting

Kharicha

Karimi-Sibaki

et al. 2017

steel research int.

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The Electroslag Remelting (ESR) is an advanced technology for the production of high quality materials, for example, hot work tool steels or nickel base alloys. In the past years, several models are developed aiming to predict the way in which the operational parameters affect the structure and chemical composition of the final ESR ingot. Proper modeling of this process depends on the ability of the model to predict the Multiphysics resulting from the complex coupling between many physical phenomena. This review includes the main findings starting from the 1970's, with a special focus on the results obtained in the period of 1999-2017. The difficulties related to the poorly known physical properties of ESR slags are discussed. Then, the main achievements in the field of electromagnetism, fluid flow, heat transfer, and solidification are also summarized. The review finishes by presenting the special topics representing the actual scientific frontiers, such as the physics of mold current, the importance of multiphase phenomena, and the difficulties in predicting the electrode melting rate.

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A 2D Multiphase Model of Drop Behavior during Electroslag Remelting

Chaulet

Kharicha

Charmond³

et al. 2020

Metals

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Electroslag remelting is a process extensively used to produce metallic ingots with high quality standards. During the remelting operation, liquid metal droplets fall from the electrode through the liquid slag before entering the liquid pool of the secondary ingot. To better understand the process and help to optimize the operating condition choice, a 2D axisymmetric multiphase model of the slag domain has been developed using a two fluid Eulerian approach. During their fall, droplets hydrodynamic interactions are calculated thanks to an appropriate drag law. Influence of droplets on the electromagnetic field and on the slag hydrodynamics is discussed, as well as their heat exchange with the slag. Even with a small volume fraction, the droplets influence is noticeable. The present investigation shows that small droplets have a large influence on the slag hydrodynamics, due to a great momentum exchange. However heat transfer is more influenced by large drops, which are found to be relatively far from the thermal equilibrium with the slag phase.

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Predicting Melting Behavior of an Industrial Electroslag Remelting Ingot

Cited by 3 publications

References 6 publications

Numerical Simulation of the Dynamic Formation of Slag Skin and Heat Flow Distribution during the Electroslag Remelting Process

Numerical Simulation of the Dynamic Formation of Slag Skin and Heat Flow Distribution during the Electroslag Remelting Process

Review on Modeling and Simulation of Electroslag Remelting

A 2D Multiphase Model of Drop Behavior during Electroslag Remelting

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