The Research On Distribution Of Multi-physics Field And Solidification Under The Vibrating Electrode In ESR Process

ESR(Electroslag Remelting)is a complex metallurgical process in which consumable electrodes are embedded into molten slag and then solidified into ingot in a water-cold crystallizer.The ESR process contains intricate physical and chemical process of electromagnetic,flow,heat transfer,solidification and so on.The refined ingot was conferred better mechanic property and chronic use-time,but it consume electric energy.This project comes up with a new idea—vibrating electrode,in order to increase the quality of ingot and decrease the energy consumption.It is reported that vibration electrode promote the relative movement between electrode and molten slag,and it could promote heat transfer.Therefore the vibrating electrode is the method which decrease energy consumption and increase solidification quality.Besides,the vibrating electrode method is easy to implement and has strong practicability.The main work of this paper is to investigate the effect of the consumable electrode of horizontal and vertical vibration on ESR process,and to analyze the changes of ESR process with vibration amplitude,frequency.The main contents are listed as follows:(1)The electromagnetic field,temperature field and velocity field and the solidification process in the coupling model is calculated by finite volume method.(2)Various physical fields and the size of droplets with vertical and horizontal vibrating electrodes are obtained and compared to those without vibrating electrode.(3)The influence of vibration amplitude and frequency and others parameters on ESR process are analyzed by calculating the changes of physical fields with different amplitude and frequency of vertical and horizontal vibration.The conclusions of this topic article:(1)Vibrating electrode can effectively increase the relative motion between the electrode and the molten slag fluid,and promote heat transfer capacity,increasing the melting rate.Both in vertical and horizontal vibration state,dropping process present periodical alteration.The droplets present reciprocating in horizontal direction keep with the electrode.While,if the electrode vibrate in vertical direction,the droplets switch from small to large and then smaller.The-vibrating electrode could make droplets smaller and more,it means increase interacting are between molten slag and metal,and increase refine efficiency(2)The increasing of frequency and amplitude promote the relative movement between electrode and molten slag.Therefore it make the droplets smaller,The average temperature of molten slag lower and molten pool more shadow.The molten slag temperature would become more uniform and it is to beneficial to solidification.(3)Compared with non-vibration,horizontal vibration makes the droplets smaller,temperature of molten slag lower and molten pool more shadow,However,the vertical vibration makes the droplets larger,temperature of molten slag higher and molten pool deeper.On the condition of vertical vibrating,droplets would become larger and concentrate mainly on center line of molten slag,and it makes current more centralized and it goes against to uniform of temperature.