Supersized ESR—Strategies for a Further Optimization and Size Increase of the Process

Knabl, Matthias; Eynatten, Klaus von; Kubin, Michael; Scheriau, Alexander; Holzgruber, H.

doi:10.1007/s00501-018-0763-3

Cited by 5 publications

(1 citation statement)

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“…Most turbine manufacturers employ the electroslag remelting (ESR) process to produce the rotor ingot. ESR is a secondary refining technique that is used for the production of some varieties of high-grade specialty steels and alloys due to its extraordinary advantages [4,5]. During the molten steel droplet formation and dropping through the molten slag pool process, the good contact between the molten slag and steel makes the steel refined by removing the harmful elements and nonmetallic inclusions or reacting with the molten slag to adjust the compositions of the steel.…”

Section: Introductionmentioning

confidence: 99%

Effect of B2O3 on the Crystallization Behavior of CaF2-Based Slag for Electroslag Remelting 9CrMoCoB Steel

Peng

Geng

Liu

et al. 2019

Metals

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The non-isothermal crystallization characteristics of the electroslag remelting (ESR)-type slag with varied B2O3 contents were investigated by non-isothermal differential scanning calorimetry (DSC), field emission scanning electron microscopy (SEM-EDS), and X-ray diffraction (XRD). The crystallization mechanism of the B2O3-bearing slag was also identified based on kinetics analysis. The results showed that the primary crystalline phase was CaF2, there was no change in the type of the primary crystal as B2O3 content increased, and the morphology of the CaF2 crystal was mainly dendritic. The sequence of crystal precipitation during the cooling process was CaF2 to Ca12Al14O32F2 and MgO/MgAl2O4, followed by Ca3B2O6. The activation energy of CaF2 crystallization increased firstly, then decreased and reached stability, while the activation energy of Ca3B2O6 crystallization increased continuously with the increasing B2O3 content. The crystallization behavior of CaF2 was three-dimensional growth with a constant nucleation rate. The proper B2O3 content added into the CaF2-based ESR slag should be around 1.0% to limit the precipitation of the CaF2 crystal to attain good surface ingot quality and stable ESR operation.

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Section: Introductionmentioning

confidence: 99%

Effect of B2O3 on the Crystallization Behavior of CaF2-Based Slag for Electroslag Remelting 9CrMoCoB Steel

Peng

Geng

Liu

et al. 2019

Metals

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Evolution and Formation of Non-metallic Inclusions During Electroslag Remelting of a Heat-Resistant Steel for Ultra-supercritical Power Plants

Wang

Shi

Liang

et al. 2022

Metall Mater Trans B

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Solidification Principle in Large Vertical Steel Casting Under the EMS Effect

Zhang

et al. 2023

Metall Mater Trans B

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The surging demand for large high-quality rotor shafts or similar steel components in heavy industries (energy sector) poses new challenges to steelmakers. Based on the experience of conventional ingot and continuous casting, several new process concepts have been proposed, e.g., vertical continuous casting (VCC), semi-continuous casting (SCC), and segment casting (SC), but none of them are optimally put in operation. The main problems include the control of the as-cast structure and macrosegregation. Electromagnetic stirring (EMS) is necessary to obtain the center equiaxed zone, but EMS-induced multiphase flow can cause severe macrosegregation and uneven distribution of the as-cast structure between equiaxed and columnar. In this study, an advanced mixed columnar-equiaxed solidification model was used to investigate the formation of the as-cast structure and macrosegregation in an example of SCC with a large format (diameter 1 m). The main role of EMS is to create crystal fragments by fragmentation, which is regarded in this work as the only origin of equiaxed grains. The created equiaxed grains are brought by the EMS-induced (primary and secondary) flow and gravity-induced sedimentation to the central/lower part of the casting. The main goal of this study was to understand the solidification principle of SCC. In addition, a numerical parameter study by varying the EMS parameters was also performed to demonstrate the model capability towards the process optimization of SCC.

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Supersized ESR—Strategies for a Further Optimization and Size Increase of the Process

Cited by 5 publications

References 0 publications

Effect of B2O3 on the Crystallization Behavior of CaF2-Based Slag for Electroslag Remelting 9CrMoCoB Steel

Effect of B2O3 on the Crystallization Behavior of CaF2-Based Slag for Electroslag Remelting 9CrMoCoB Steel

Evolution and Formation of Non-metallic Inclusions During Electroslag Remelting of a Heat-Resistant Steel for Ultra-supercritical Power Plants

Solidification Principle in Large Vertical Steel Casting Under the EMS Effect

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