Numerical Investigation on the Electroslag Remelting of High Carbon Martensitic Stainless Steels
Abstract
:1. Introduction
2. Numerical Simulation
2.1. Assumptions
2.2. Electromagnetic Phenomena
2.3. Flow Field
2.4. Energy Conservation and Solidification
2.5. Macrosegregation
2.6. Modelling Parameters
3. Results and Discussions
3.1. Temperature and Flow Field
3.1.1. Effect of Melting Rate on Temperature and Flow Field
3.1.2. Effect of Filling Ratio on Temperature and Flow Field
3.1.3. Effect of Slag Thickness on Temperature and Flow Field
3.2. Solidification Structure
3.2.1. Effect of Melting Rate on Solidification Structure
3.2.2. Effect of Filling Ratio on Solidification Structure
3.2.3. Effect of Slag Thickness on Solidification Structure
3.3. Macrosegregation
3.3.1. Effect of Melting Rate on Macrosegration
3.3.2. Effect of Filling Ratio on Macrosegration
3.3.3. Effect of Slag Thickness on Macrosegration
4. Conclusions
- 1.
- As the increase of melting rate, the molten metal pool depth increases, the temperature gradient and highest slag temperature decrease, the anticlockwise vortex in the slag and the clockwise vortex in the metal pool enlarge. LST, PDAS and SDAS increase greatly, meanwhile the segregation of C and Cr deteriorates with increasing melting rate.
- 2.
- Increase of filling ratio reduces the metal pool depth within a small range but increases the mushy zone width, maximum slag temperature and metal temperature at slag/metal interface. A mild increase of LST and SDAS is observed but the change of PDAS is little with rise of filling ratio. In the same time, centerline segregation of C and Cr increases marginally with increasing filling ratio.
- 3.
- The metal pool depth increases firstly and then decrease slightly with rising slag thickness. The flow intensity in the vortex center weakens and the highest slag temperature decreases as rise of slag thickness. LST, PDAS, SDAS, segregation of C and Cr present similar change tendency with metal pool depth as the increase of slag thickness.
- 4.
- Through a comprehensive consideration on temperature and flow field, metal pool profile, solidification structure and element segregation, a low melting rate less than 120 kg/h, a filling ratio of about 0.23–0.33 and a slag thickness of 0.08–0.10 m are suggested for ESR process of high carbon stainless steels in this study.
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
List of Symbols
Vector operator nabla (1/m) | |
Electrical conductivity (1/(Ω·m)) | |
Complex amplitude of magnetic field intensity (A/m) | |
Vacuum permeability (T·m/A) | |
In electrical equations | |
Angular frequency (Hz) | |
Dynamic viscosity (Pa·s) | |
Complex amplitude of current density (A/m2) | |
Lorentz force (N/m3) | |
Conjugate () | Complex conjugate of magnetic flux density (T) |
Conjugate () | Complex conjugate of current density (A/m2) |
Joule heating (W) | |
Axial direction | |
Amplitude of the total current entering the slag (A) | |
radius (m) | |
Radius of ESR ingot (m) | |
Density(kg/m3) | |
Velocity (m/s) | |
Gravitational acceleration (m/s2) | |
Pressure (Pa) | |
Effective viscosity (Pa·s) | |
Sensible enthalpy (J/kg) | |
Enthalpy change (J/kg) | |
Effective thermal conductivity (W/(m·K)) | |
Reference sensible enthalpy (J/kg) | |
Reference temperature (K) | |
Specific heat capacity (J/(kg·K)) | |
L | Latent heat (J/kg) |
, | Liquidus and solidus temperature (K) |
, | Primary and secondary dendrite arm spacing (μm) |
Temperature gradient (K/m) | |
Solidification rate (m/s) | |
melting rate (kg/h) | |
Ambient temperature (K) | |
Emissivity | |
Stefan-Boltzmann constant | |
Turbulence dissipation (m2/s3) | |
Thermal conductivity (W/(m·K)) | |
Turbulent viscosity (Pa·s) | |
Generation of turbulence kinetic energy due to the mean velocity gradients (Pa s) | |
Concentration of an alloying element | |
Turbulent thermal conductivity (W/(m·K)) | |
Turbulent Prandtl number | |
Source term due to mass flux of alloying element (kg/(m3·s)) | |
Schmidt number |
Appendix A
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Element | C | Cr | Mo | V | Si | Mn | Co | Ni | Fe |
---|---|---|---|---|---|---|---|---|---|
Content, wt% | 1.0 | 14.37 | 1.09 | 0.23 | 0.36 | 0.33 | 1.47 | 0.18 | Balance |
Parameter | Value |
---|---|
Mold diameter, m | 0.228 |
Electrode diameter, m | 0.09, 0.11, 0.13, 0.15 |
Ingot height, m | 1.2 |
Slag height, m | 0.08, 0.10, 0.12, 0.14 |
Melting rate, kg/h | 90, 120, 150, 180 |
Current, kA | 3.75 |
Frequency, Hz | 50 |
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Liu, X.; Zhou, G.; Shen, Y.; Yan, W.; Li, J. Numerical Investigation on the Electroslag Remelting of High Carbon Martensitic Stainless Steels. Metals 2023, 13, 482. https://doi.org/10.3390/met13030482
Liu X, Zhou G, Shen Y, Yan W, Li J. Numerical Investigation on the Electroslag Remelting of High Carbon Martensitic Stainless Steels. Metals. 2023; 13(3):482. https://doi.org/10.3390/met13030482
Chicago/Turabian StyleLiu, Xingyu, Guotao Zhou, Yangyang Shen, Wei Yan, and Jing Li. 2023. "Numerical Investigation on the Electroslag Remelting of High Carbon Martensitic Stainless Steels" Metals 13, no. 3: 482. https://doi.org/10.3390/met13030482