Numerical Simulation on Motion Behavior of Inclusions in the Lab-Scale Electroslag Remelting Process with a Vibrating Electrode
Abstract
:1. Introduction
2. Model Description
- The depth of consumable electrode immersed in the slag layer remains unchanged, and the tip of the electrode keeps flat;
- Only the removal of original inclusions is considered, but not the generation of new inclusions, as well as the chemical reaction and dissolution of inclusions;
- The solidification process of molten metal is not considered;
- The physical parameters of slag and metal are assumed to be constant.
3. Simulation Setup
4. Results
4.1. Temperature-Field Distribution
4.2. Flow Field and Streamlines Distribution
4.3. Effect of Electrode Vibration Frequency on Inclusions Motion Behavior
4.4. Effect of Current on Inclusion Motion Behavior
4.5. Effect of Slag-Layer Thickness on Inclusion Motion Behavior
4.6. Effect of Filling Ratio on Inclusion Motion Behavior
4.7. Effect of Type and Diameter of Inclusion on Its Motion Behavior
5. Discussion
6. Conclusions
- Compared with a conventional electrode, the temperature distribution in the liquid-metal pool is more uniform, and the average temperature is significantly higher than that with a conventional electrode at the same time. Besides, the streamlines in the slag layer and liquid-metal pool are symmetrical, showing a clear demarcation at the slag/metal interface with a vibrating electrode.
- Distribution of streamlines in the slag layer and liquid-metal pool is chaotic in the ESR process with conventional electrode. However, in the ESR process with a vibrating electrode, the streamlines in the slag layer and the liquid-metal pool are symmetrically distributed, and there is a clear demarcation at the slag/metal interface.
- When the electrode vibration frequency is 0.25 Hz or 1 Hz, inclusions will gather on one side of the slag layer. When the electrode vibration frequency increases from 0.25 Hz to 1 Hz, the removal ratio of 10 μm and 50 μm inclusions increases by 5% and 4.1%, respectively. When the electrode vibration frequency is 0.5 Hz, inclusions are distributed uniformly on both sides of the slag layer in the ESR process.
- When the current increases, the flow-following property of inclusions property in the slag layer becomes worse in the ESR process. When the current is 1200 A, it is obvious to see that inclusions flow with the vortex in the center of the slag layer. The removal ratio of inclusions reaches the maximum value, 92%, with a current of 1500 A.
- As the thickness of the slag layer increases, the inclusions removal ratio increases gradually. the number of inclusions entering the liquid-metal pool at a certain angleunder the influence of the vortex in the center of the slag layer gradually decreases, while the number of inclusions entering the liquid-metal pool near the left and right side walls gradually increases under the influence of the falling flow near the mold wall. The maximum is 85.91%.
- With the filling ratio increasing, the flow-following property of inclusions in the slag layer enhances. The maximum removal ratio of 10 μm inclusions is 97%. However, the maximum removal ratio of 50 μm inclusions is 96.04% when the electrode filling ratio is 0.46.
- Most of the 50 μm inclusions congregate at the electrode entrance and the top of the slag layer, while inclusions uniformly distributes in the slag layer. However, the distribution of inclusions and inclusions with a diameter of 10 μm in slag layer are similar. Due to the influence of the vibrating electrode, 10 μm inclusions and inclusions have a similar inclusions ratio of 81.33% and 82.81%, respectively.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
Appendix A
Appendix A.1. Electromagnetic Field
Appendix A.2. Fluid Flow and Heat Transfer
Appendix A.3. Inclusions Motion
Appendix A.4. Boundary Conditions
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Parameter | Value |
---|---|
Physical properties of liquid metal | |
Density | ) |
Viscosity | 0.006 (kg/m·s) |
Specific heat | 866 (J/kg·K) |
Thermal conductivity | 30.5 (W/m·K) |
Electric conductivity | (S/m) |
Liquidus/solidus temperature | 1798/1768 (K) |
Latent heat of fusion | 270 (kJ/kg) |
Physical properties of slag layer | |
Density | |
Viscosity | 0.03 kg/(m·s) |
Specific heat | 1255 J/(kg·K) |
Thermal conductivity | 10.5 W/(m·K) |
Electric conductivity | (S/m) |
Liquidus/solidus temperature | 1610/1590 (K) |
Dimension of geometry model | |
Length | 120 (mm) |
Height | 90 (mm) |
Electrode filling ratio | 0.46/0.38/0.54 |
slag layer thickness | 60/50/70 (mm) |
Electrode immersing depth | 5.0 (mm) |
Operating condition | |
Electrode vibration frequency | 0.50/0.25/1 (Hz) |
Current | 1500/1200/1800 (A) |
Inclusions density | ) |
Inclusions diameter | 10/30/50 (μm) |
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Wang, F.; Sun, B.; Liu, Z.; Li, B.; Huang, S.; Zhang, B. Numerical Simulation on Motion Behavior of Inclusions in the Lab-Scale Electroslag Remelting Process with a Vibrating Electrode. Metals 2021, 11, 1784. https://doi.org/10.3390/met11111784
Wang F, Sun B, Liu Z, Li B, Huang S, Zhang B. Numerical Simulation on Motion Behavior of Inclusions in the Lab-Scale Electroslag Remelting Process with a Vibrating Electrode. Metals. 2021; 11(11):1784. https://doi.org/10.3390/met11111784
Chicago/Turabian StyleWang, Fang, Boyang Sun, Zhongqiu Liu, Baokuan Li, Shuo Huang, and Beijiang Zhang. 2021. "Numerical Simulation on Motion Behavior of Inclusions in the Lab-Scale Electroslag Remelting Process with a Vibrating Electrode" Metals 11, no. 11: 1784. https://doi.org/10.3390/met11111784