Abstract
The real-time computational simulation of arc melting process with considering complex interactions and solid–liquid mushy zone in molten anode has been successfully conducted to provide the fundamental data for highly economical performance of arc melting process. The configuration of molten anode predicted by realistic numerical model shows the quantitative agreement with the experimental data. The effects of sulfur content concentration in molten metal, arc current and cathode vertex angle on the welding structure is discussed in detail. Finally, the heat exchange efficiency and molten cross-sectional area are evaluated under different arc currents and cathode vertex angles for optimum welding process with high efficiency.
