Advances in Electroslag Remelting and Continuous Casting Technology

A Special Issue of Metals (ISSN 2075-4701) belonging to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: 31 March 2027 | Viewed by 682

Editors


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Guest Editor
School of Metallurgy, Northeastern University, Shenyang 110819, China
Interests: electroslag remelting; CFD; inclusions; solidification
School of Metallurgy, Northeastern University, Shenyang 110819, China
Interests: numerical modelling; non-metallic inclusion; remelting electroslag; physical modelling; solidification
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Special Issue Information

Dear Colleagues,

Electroslag remelting (ESR) and continuous casting (CC) are pivotal technologies for manufacturing high-performance alloys with controlled solidification structures, minimized defects, and superior mechanical properties. This Special Issue seeks cutting-edge technologies addressing core challenges in clean steel production, including segregation control, the removal of inclusions, slag–metal interactions, and microstructure homogeneity. We invite contributions leveraging advanced methodologies such as computational fluid dynamics (CFD) and machine learning to drive innovations in process efficiency and product quality.

The scope covers the following topics: fundamental mechanisms, including solidification behavior in ESR/CC systems, thermodynamics of slag systems and inclusion evolution, and macrosegregation mitigation strategies for ultra-clean steel production; process innovations, such as novel electromagnetic devices, slag compositions for enhanced metal purification, and development in combined external field control; and digital transformation, involving the CFD modeling of molten metal flow, heat transfer, thermal stress, machine learning-based defect prediction, and real-time process optimization. We welcome original research, reviews, and industrial case studies that demonstrate transformative impacts on metallurgical process reliability and product integrity.

Dr. Xuechi Huang
Dr. Fang Wang
Guest Editors

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Keywords

  • electroslag remelting
  • continuous casting
  • solidification
  • segregation
  • clean steel
  • inclusions
  • slag
  • CFD
  • machine learning
  • optimization

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Published Papers (1 paper)

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Research

24 pages, 20203 KB  
Article
Multiphysics Simulation of Slag-Skin Evolution and Process Parameter Effects During Electroslag Remelting of X2CrNiMo18.12 (Nitrogen-Controlled) Steel
by Zhengping Lu, Yinxi Ding, Nachuan Ju, Jianneng Zheng, Lianlong Li, Bin Qiu, Jie Zeng, Tao Liu and Haomin Wu
Metals 2026, 16(9), 964; https://doi.org/10.3390/met16090964 - 1 Sep 2026
Viewed by 180
Abstract
X2CrNiMo18.12 (nitrogen-controlled) stainless steel is prone to slag-shell erosion during electroslag remelting (ESR), which may lead to steel breakout and mold leakage. To investigate the evolution behavior of the slag shell and molten pool, a transient multiphysics model coupling electromagnetic, flow, and thermal [...] Read more.
X2CrNiMo18.12 (nitrogen-controlled) stainless steel is prone to slag-shell erosion during electroslag remelting (ESR), which may lead to steel breakout and mold leakage. To investigate the evolution behavior of the slag shell and molten pool, a transient multiphysics model coupling electromagnetic, flow, and thermal fields was developed based on the volume of fluid (VOF) method and dynamic mesh technique. The distributions of the coupled physical fields and the effects of electrical parameters and cooling intensity on slag-shell stability and molten-pool morphology were systematically analyzed. The results show that a pronounced edge effect exists at the lower electrode corner, resulting in concentrated current density, Joule heating, and Lorentz force. Under the combined effects of electromagnetic force and thermal buoyancy, a dominant circulation vortex is formed in the slag pool, which governs heat transfer and slag-shell evolution. The slag-shell thickness is determined by the competition among vortex-induced erosion near the mold wall, erosion by molten steel at the slag–metal interface, and mold cooling. Among these factors, erosion by molten steel is the primary cause of steel breakout and mold leakage. Increasing the current from 2.5 to 3.5 kA significantly increases the melt superheat, transforms the molten pool from a shallow U-shape to a deep V-shape, and reduces the slag-shell thickness to approximately 0.95 mm, leading to leakage failure. In contrast, a moderate current of 2.5–3.0 kA combined with a cooling intensity above 2400 W·m−2·K−1 maintains the slag-shell thickness at approximately 2 mm and effectively suppresses steel breakout and mold leakage. These findings provide guidance for process optimization and operational safety in the ESR of X2CrNiMo18.12 steel. Full article
(This article belongs to the Special Issue Advances in Electroslag Remelting and Continuous Casting Technology)
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