Three-Dimensional Mathematical Model of Oxygen Transport Behavior in Electroslag Remelting Process
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LECTROSLAG remelting (ESR) is wildly employed for producing high performance steels and nickel-based alloys due to its unique advantages, such as the effective control of steel chemistry, excellent solidification structure and surface quality of final ingots, and powerful removal of non-metallic inclusions.[1,2] During this process, a direct or alternating current (DC/AC) is applied in the system, and the Joule heating in the slag is sufficient to melt the electrode. The molten metal feeds a liquid metal pool, which solidified directionally in the watercooled mold. It is generally known that oxygen in steel, which will cause unwanted pores and generation of oxide inclusions during solidification, influences the steel quality.[3,4] Its removal has been a tough task for many metallurgists for a long time. The initial oxygen in the electrode, the oxygen in the atmosphere, the oxide scale formed on the electrode, and the slag composition affect the oxygen transport behavior as well as the oxygen
XUECHI HUANG, BAOKUAN LI, and ZHONGQIU LIU are with the School of metallurgy, Northeastern University, Shenyang 110819, People’s Republic of China. Contact e-mail: [email protected]. edu.cn Manuscript submitted July 19, 2017.
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content in ESR ingot. Besides, the mass transfer process and species distribution are influenced by the multi-physical fields, especially the temperature distribution and the flow field. Therefore, it is essential to have a further and comprehensive understanding of oxygen transport behavior in ESR process. Lots of experimental investigations on the oxygen transfer have been done in the past decades.[3,5–8] Researchers confirmed that the ferrous oxide (FeO) content at the slag/metal interface, which represents the oxygen potential of slag, affects the oxygen transport behavior dramatically. However, the information provided by experiments was limited. The interaction among the multi-physical fields, especially the effect of temperature distribution and flow field on the mass transfer process was difficult to analyze. In this case, numerical simulation is widely adopted to perform fundamental studies owing to its low cost, simple implementation, and visualization. Weber et al.[9] developed a transient model to account for electromagnetic phenomena as well as heat and momentum transfer in an axisymmetrical geometry. The melt pool profile was predicted accurately. Kharicha et al.[10] numerically investigated the interaction between the electrodynamics and the phase distribution in ESR process. The interface tension and current frequency significantly affected the droplet formation. But their work ignored the mass transfer in ESR process. Recently, Wang et al.[11,12] first
established a comprehensive model to numerically describe the desulfurization and oxygen transfer during the direct current (DC) ESR process. The electrochemical reaction, which plays a major role in DC system, was carefully considered. However, the interaction among the slag and metal compositions were not taken into account
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