Simulation of Multi-electrode ESR Process for Manufacturing Large Ingot

Abstract

Electroslag remelting process will be an important method for manufacturing heavy casing and forging due to its ability to improve the cleanness, macrostructure, microstructure, the distribution and size of non-metallic inclusions. In this paper, a finite element coupling model has been developed based on four electrodes configuration mode for manufacturing large ingot. Maxwell equation, Faraday's law, Navier-Stokes equation, heat transfer equation has been adopted in the model to analyze the current density, Joule-heat density, magnetic induction intensity and electromagnetic force and fluid flow distribution. The impact of slag depth, electrodes immersion depth and filling ratio on the molten pool depth has been analyzed. Results indicated that four electrodes with two sets of bifilar configuration are better than single phase with one electrode type. The molten pool is shallower for four electrodes than conventional single electrode mode, which is in favor of improving large ingot quality. The larger slag pool depth is the shallower the molten pool is. The depth of molten steel pool increases with the increasing of electrode immersion depth under the same slag depth condition. In addition, increasing filling ratio can reduce the depth of molten steel pool, but the filling ratio should be less than 0.6 according to area for general materials. Comparing to the single electrode mode four electrodes configuration mode is in favor of manufacturing large ingot.