Effect of Electrode Immersion Depth on the Electrical Resistance and Heat Generation in the Electroslag Remelting Proces
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https://doi.org/10.1007/s11837-020-04249-7 Ó 2020 The Minerals, Metals & Materials Society
ELECTROMETALLURGICAL PROCESSING
Effect of Electrode Immersion Depth on the Electrical Resistance and Heat Generation in the Electroslag Remelting Process YULONG CAO ,1,2,3 GUANGQIANG LI,1,2,5 ZHOUHUA JIANG,4 YANWU DONG,4 ZHENGRONG ZHAO,1,2,3 and CHENRUI NIU1,2,3 1.—The State Key Laboratory of Refractories and Metallurgy, Wuhan University of Science and Technology, Wuhan 430081, China. 2.—Key Laboratory for Ferrous Metallurgy and Resources Utilization of Ministry of Education, Wuhan University of Science and Technology, Wuhan 430081, China. 3.—Hubei Provincial Key Laboratory for New Processes of Ironmaking and Steel Making, Wuhan University of Science and Technology, Wuhan 430081, China. 4.—School of Metallurgy, Northeastern University, Shenyang 110819, China. 5.—e-mail: [email protected]
A numerical simulation based on the coupling of electromagnetic-fluid-thermal analysis was developed to investigate the effects of electrode immersion depth (EID) on the electrical resistance and heat generation in the electroslag remelting (ESR) process. The total electric current was obtained by integrating the current density at the slag/metal interface, and the electrical resistance is the ratio of potential to current. It indicates that the EID variation changes the shape, size, and current path of the slag pool, and, as a result, the current density, heat generation, and melting power are directly proportional to the EID, while the electrical resistance of the slag pool is inversely proportional to the EID. The distance between the electrode and the molten-metal pool and the contact areas between the electrode and the slag are the main factors affecting the distribution of voltage, current density, Joule heating, and temperature in the slag pool of the ESR process. A change in the current density affects the electrical resistance and heat generation, which has a direct effect on the ESR process.
INTRODUCTION At present, electroslag remelting (ESR) technology has taken an important role in the special steel smelting field and is being rigorously used to produce solid ingots of specified chemistry that are free of solidification defects and have a good surface quality and uniform grain structure.1 In the ESR process, the temperature distribution of the slag pool needs to be controlled primarily, which, in turn, closely affects the slag/metal reaction, inclusion removal, shape of the molten pool, and solidification quality of the ingots. As the significant operation parameters, the electrode immersion depth (EID),2–4 slag pool depth,5 and fill ratio6 have great impacts on the heat transfer, fluid flow, melt rate, and molten-metal pool depth in the ESR process. During ESR, the electrical parameters, such as the current, voltage, and electrical
resistance, are continuously recorded. The variation of the resistance, known as resistance swing, is often used to control the EID.1 An EID model7 has been developed in order to describe
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