A novel model for the removal and capture of inclusions in electroslag remelting process

Abstract

The cleanliness of steel is a critical factor influencing its corrosion resistance and mechanical properties. Electroslag remelting (ESR) technology has demonstrated excellent performance in removing inclusions from electroslag ingots. Typically, four primary pathways exist to remove and capture inherited inclusions from the electrode in the ESR process. Current numerical simulation research typically focuses on modeling two or three of these pathways. This study, presents a highly accurate model that integrates the electromagnetic field with the flow field and heat transfer throughout the entire process of inclusion movement, removal and capture processes in ESR. To validate the model's accuracy, a 2 t industrial-scale ESR furnace was utilized to prepare hot work tool steel H13. The model's ability to predict the distribution of inherited inclusions from the electrode was confirmed by comparing the metal droplet size in the residual electrode and the distribution of inclusions in the electroslag ingot as measured in industrial production. The results reveal that the proportion of inclusions exuded from the liquid metal film decreased as the size of inclusions increased from 5 to 20 μm. The proportion of inclusions that escape from the droplets and float up from the metal pool exhibited a significant increase. Notably, the escape of inclusions from metal droplets accounts for a substantial proportion (exceeding ten percent), and this stage is a crucial factor that must be considered in industrial-scale models.