Study of Single-Power, Two-Circuit ESR Process with Current-Carrying Mold: Development of the Technique and Its Physical
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ELECTROSLAG remelting (ESR) has been widely used for manufacturing high-quality steel and alloys because of ingot unique characteristics of including homogeneous composition, sound structure, tiny and even-distributed nonmetallic inclusions, and good mechanical properties. Refining and solidification are conducted in a water-cooled copper mold, which is not a refractory in the process. Many factors including power parameters, slag, filling ratio, amount and temperature of cooling water, and so on affect the ingot quality. Nevertheless, the influence extent of these factors cannot be achieved immediately due to the high-temperature system of the process. Many efforts have been made to improve the ingot quality. Some physical and mathematical simulations have been applied to investigate the relationship among various parameters. Some physical experimental models similar to the electroslag remelting process have been established for investigating the droplets formation. Low-melting-temperature metals have been adopted as electrodes, and the solution of LiCl-KCl, NaOH, or NaCl has been employed as slag. An oscilloscope is used to detect the occurrence of a droplet departure in conventional nontransparent slag by monitoring the curve of voltage, and then the dripping frequency can be obtained during the process.[1–3]
YANWU DONG, Associate Professor, ZHOUHUA JIANG, Professor, HAIBO CAO and ZHIWEN HOU, Ph.D. Candidates, and KEAN YAO, Master Candidate, are with the School of Metallurgy, Northeastern University, Shenyang, 110819, Liaoning, P.R. China. Contact e-mail: [email protected] Manuscript submitted June 25, 2016. METALLURGICAL AND MATERIALS TRANSACTIONS B
Holzgruber et al.[4] conducted an experiment using a double power two-circuit ESR system with current carrying mold, and the principle is shown in Figure 1 (right). A shallower molten steel pool and ingot with low-element segregation are achieved in their works. Yet, there was some interference to the current of the two circuits using double power found in our experiments. Therefore, a novel single-power, two-circuit ESR process with current-carrying mold is put forward in this article as shown in Figure 1 (left). There are two circuits for current to pass in the system but with only a single power supply. On the one hand, the current path is as follows: transformer fi consumable electrode fi slag pool fi ingot fi base plate fi transformer, and on the other hand, electric current flows from transformer fi current conductive part of mold (conductor) fi slag pool fi ingot fi base plate fi transformer. The both current circuits are in parallel. Although there has been some study of the application of current-carrying mold,[4–7] related data are still scarce, especially about single-power, two-circuit ESR with current-carrying mold (ESR-STCCM). Therefore, a physical simulation apparatus has been established to investigate the current distribution ratio of two circuits with only one power in this work. In addition, corresponding work on the conventional ESR process (CESR) has bee
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