Numerical And Physical Simulation Of Producing Nickel-base Alloy By ESR With Current Conductive Mould

Nickel based alloys are widely used in the fields of marine,environmental protection,energy,chemical and food because of its good oxidation resistance,corrosion resistance and so on.With the development of economy and society,electricity,petroleum,chemical,and shipbuilding industries continue to large-scale development,the nickel-based alloy components which applied proposed large-scale needs.Because the temperature range of the nickel based alloy is high,so the composition is easy to segregation.Single power double circuit current conductive mould ESR has two current loops,it can adjust the flow distribution of slag pool;improve the temperature distribution,which is helpful to get a shallow metal pool.In this paper,physical and numerical simulation was calculated for ESR with current conductive mould.The different filling ratio and electrode insert depth were studied through physical simulation.The results show that the current ratio almost remained at around 1.13 when the filling ratio is 0.6,electrode insert depth are 14 mm,17 mm,20 mm.when the electrode insert depth is 20 mm,the current ratio increase from 1.683 to 1.741,then to 2.227,with the filling ratio increase from 0.5 to 0.6,and then increase to 0.7.The mathematical models were established for compared electromagnetic force,flow field,temperature distribution in the slag pool of ESR with current conductive mould and traditional ESR.And the influence of different process parameters,such as electrode inserts depth,slag pool depth,conductor insert depth,electrode diameter were also analyzed.By comparison,the potential gradient,current density,joule heat and electromagnetic force are larger at the bottom of conductor in ESR with current conductive mould.The maximum current density is 1.05×106 A·m-2,the maximum joule heat is 2.40×109 J·m-3,the maximum magnetic induction intensity is electromagnetic force is 5960 N·m-3,and the direction is upward.There are three distinct swirls in slag pool,the swirl which under the conductor is rotated counterclockwise,the swirl under the consumable electrode and next to consumable electrode are rotated clockwise,and the maximum velocity of slag pool is 0.0432 m·s-1.High temperatre region in slag pool is at the center of the slag-metal interface.And the highest temperature is 2300 K.The maximum molten metal pool depth is 66 mm,and the maximum mushy zone is 17 mm.The angle between the tangent and horizontal is 32°,which draw from quarter of slag-metal interface and metal pool.The results of different parameters shows that the maximum velocity of the slag pool decrease and the highest temperature and metal pool increase with electrode insert depth increase.The maximum velocity of the slag pool,the highest temperature and metal pool decrease with slag pool depth increased.The metal pool is increase with voltage increase.The maximum velocity of the slag pool decrease and the metal pool become shallower with filling ratio increased.