Numerical Simulation on Motion Behavior of Inclusions in the Lab-Scale Electroslag Remelting Process with a Vibrating Electrode

In order to meet the requirement of high-quality ingots, the vibrating electrode technique in the electroslag remelting (ESR) process has been proposed. Non-metallic inclusions in ingots may cause serious defects and deteriorate mechanical properties of final products. Moreover, the dimension, numbe...

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Autores principales:	Fang Wang, Boyang Sun, Zhongqiu Liu, Baokuan Li, Shuo Huang, Beijiang Zhang
Formato:	article
Lenguaje:	EN
Publicado:	MDPI AG 2021
Materias:	vibrating electrode electroslag remelting numerical simulation motion behavior of inclusions removal ratio Mining engineering. Metallurgy TN1-997
Acceso en línea:	https://doaj.org/article/726e2e8e521542dcb0105893a0affed2
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spelling	oai:doaj.org-article:726e2e8e521542dcb0105893a0affed22021-11-25T18:21:55ZNumerical Simulation on Motion Behavior of Inclusions in the Lab-Scale Electroslag Remelting Process with a Vibrating Electrode10.3390/met111117842075-4701https://doaj.org/article/726e2e8e521542dcb0105893a0affed22021-11-01T00:00:00Zhttps://www.mdpi.com/2075-4701/11/11/1784https://doaj.org/toc/2075-4701In order to meet the requirement of high-quality ingots, the vibrating electrode technique in the electroslag remelting (ESR) process has been proposed. Non-metallic inclusions in ingots may cause serious defects and deteriorate mechanical properties of final products. Moreover, the dimension, number and distribution of non-metallic inclusions should be strictly controlled during the ESR process in order to produce high-quality ingots. A transient 2-D coupled model is established to analyze the motion behavior of inclusions in the lab-scale ESR process with a vibrating electrode, especially under the influence of the vibration frequency, current, slag layer thickness, and filling ratio, as well as type and diameter of inclusions. Simulation model of inclusions motion behavior is established based on the Euler-Lagrange approach. The continuous phase including metal and slag, is calculated based on the volume of fluid (VOF) method, and the trajectory of inclusions is tracked with the discrete phase model (DPM). The vibrating electrode is simulated by the user-defined function and dynamic mesh. The results show that when the electrode vibration frequency is 0.25 Hz or 1 Hz, the inclusions will gather on one side of the slag layer. When it 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 current increases from 1200 A to 1800 A, the flow following property of inclusions in the slag layer becomes worse. The removal ratio of inclusions reaches the maximum value of 92% with the current of 1500 A. The thickness of slag layer mainly affects the position of inclusions entering the liquid-metal pool. As the slag layer thickens, the inclusions removal ratio increases gradually from 82.73% to 85.91%. As the filling ratio increases, the flow following property of inclusions in the slag layer is enhanced. The removal ratio of 10 μm inclusions increases from 94.82% to 97%. However, for inclusions with a diameter of 50 μm, the maximum removal ratio is 96.04% with a filling ratio of 0.46. The distribution of 50 μm inclusions is significantly different, while the distribution of 10 μm inclusions is almost similar. Because of the influence of a vibrating electrode, 10 μm <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><msub><mrow><mrow><mi>Al</mi></mrow></mrow><mn>2</mn></msub><msub><mi mathvariant="normal">O</mi><mn>3</mn></msub></mrow></semantics></math></inline-formula> and <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><mrow><mi>MnO</mi></mrow></mrow></semantics></math></inline-formula> have a similar removal ratios of 81.33% and 82.81%, respectively.Fang WangBoyang SunZhongqiu LiuBaokuan LiShuo HuangBeijiang ZhangMDPI AGarticlevibrating electrodeelectroslag remeltingnumerical simulationmotion behavior of inclusionsremoval ratioMining engineering. MetallurgyTN1-997ENMetals, Vol 11, Iss 1784, p 1784 (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	vibrating electrode electroslag remelting numerical simulation motion behavior of inclusions removal ratio Mining engineering. Metallurgy TN1-997
spellingShingle	vibrating electrode electroslag remelting numerical simulation motion behavior of inclusions removal ratio Mining engineering. Metallurgy TN1-997 Fang Wang Boyang Sun Zhongqiu Liu Baokuan Li Shuo Huang Beijiang Zhang Numerical Simulation on Motion Behavior of Inclusions in the Lab-Scale Electroslag Remelting Process with a Vibrating Electrode
description	In order to meet the requirement of high-quality ingots, the vibrating electrode technique in the electroslag remelting (ESR) process has been proposed. Non-metallic inclusions in ingots may cause serious defects and deteriorate mechanical properties of final products. Moreover, the dimension, number and distribution of non-metallic inclusions should be strictly controlled during the ESR process in order to produce high-quality ingots. A transient 2-D coupled model is established to analyze the motion behavior of inclusions in the lab-scale ESR process with a vibrating electrode, especially under the influence of the vibration frequency, current, slag layer thickness, and filling ratio, as well as type and diameter of inclusions. Simulation model of inclusions motion behavior is established based on the Euler-Lagrange approach. The continuous phase including metal and slag, is calculated based on the volume of fluid (VOF) method, and the trajectory of inclusions is tracked with the discrete phase model (DPM). The vibrating electrode is simulated by the user-defined function and dynamic mesh. The results show that when the electrode vibration frequency is 0.25 Hz or 1 Hz, the inclusions will gather on one side of the slag layer. When it 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 current increases from 1200 A to 1800 A, the flow following property of inclusions in the slag layer becomes worse. The removal ratio of inclusions reaches the maximum value of 92% with the current of 1500 A. The thickness of slag layer mainly affects the position of inclusions entering the liquid-metal pool. As the slag layer thickens, the inclusions removal ratio increases gradually from 82.73% to 85.91%. As the filling ratio increases, the flow following property of inclusions in the slag layer is enhanced. The removal ratio of 10 μm inclusions increases from 94.82% to 97%. However, for inclusions with a diameter of 50 μm, the maximum removal ratio is 96.04% with a filling ratio of 0.46. The distribution of 50 μm inclusions is significantly different, while the distribution of 10 μm inclusions is almost similar. Because of the influence of a vibrating electrode, 10 μm <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><msub><mrow><mrow><mi>Al</mi></mrow></mrow><mn>2</mn></msub><msub><mi mathvariant="normal">O</mi><mn>3</mn></msub></mrow></semantics></math></inline-formula> and <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><mrow><mi>MnO</mi></mrow></mrow></semantics></math></inline-formula> have a similar removal ratios of 81.33% and 82.81%, respectively.
format	article
author	Fang Wang Boyang Sun Zhongqiu Liu Baokuan Li Shuo Huang Beijiang Zhang
author_facet	Fang Wang Boyang Sun Zhongqiu Liu Baokuan Li Shuo Huang Beijiang Zhang
author_sort	Fang Wang
title	Numerical Simulation on Motion Behavior of Inclusions in the Lab-Scale Electroslag Remelting Process with a Vibrating Electrode
title_short	Numerical Simulation on Motion Behavior of Inclusions in the Lab-Scale Electroslag Remelting Process with a Vibrating Electrode
title_full	Numerical Simulation on Motion Behavior of Inclusions in the Lab-Scale Electroslag Remelting Process with a Vibrating Electrode
title_fullStr	Numerical Simulation on Motion Behavior of Inclusions in the Lab-Scale Electroslag Remelting Process with a Vibrating Electrode
title_full_unstemmed	Numerical Simulation on Motion Behavior of Inclusions in the Lab-Scale Electroslag Remelting Process with a Vibrating Electrode
title_sort	numerical simulation on motion behavior of inclusions in the lab-scale electroslag remelting process with a vibrating electrode
publisher	MDPI AG
publishDate	2021
url	https://doaj.org/article/726e2e8e521542dcb0105893a0affed2
work_keys_str_mv	AT fangwang numericalsimulationonmotionbehaviorofinclusionsinthelabscaleelectroslagremeltingprocesswithavibratingelectrode AT boyangsun numericalsimulationonmotionbehaviorofinclusionsinthelabscaleelectroslagremeltingprocesswithavibratingelectrode AT zhongqiuliu numericalsimulationonmotionbehaviorofinclusionsinthelabscaleelectroslagremeltingprocesswithavibratingelectrode AT baokuanli numericalsimulationonmotionbehaviorofinclusionsinthelabscaleelectroslagremeltingprocesswithavibratingelectrode AT shuohuang numericalsimulationonmotionbehaviorofinclusionsinthelabscaleelectroslagremeltingprocesswithavibratingelectrode AT beijiangzhang numericalsimulationonmotionbehaviorofinclusionsinthelabscaleelectroslagremeltingprocesswithavibratingelectrode
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Numerical Simulation on Motion Behavior of Inclusions in the Lab-Scale Electroslag Remelting Process with a Vibrating Electrode

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