Electromagnetic behavior for laboratory scale and industrial scale electroslag remelting process

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1 46 10 () Vol.46 No Journal of Central South University (Science and Technology) Oct DOI: /j.issn ( ) () TP391 A (2015) Electromagnetic behavior for laboratory scale and industrial scale electroslag remelting process LIU Fubin, LI Yongwang, JIANG Zhouhua, LI Huabing, GENG Xin, CHEN Xu (School of Materials and Metallurgy, Northeastern University, Shenyang , China) Abstract: The electromagnetic phenomena occurring in the electroslag remelting (ESR) have a significant influence on the performance and the quality of ingot product. The electromagnetic phenomena (current density, magnetic field intensity, electromagnetic force and Joule heating) of ESR system were described by numerical simulation. Moreover, the model was verified according to the magnetic field intensity measured results reported. There is a good agreement between the calculated results and the measured results in slag bath. The results show that the skin effect is remarkable in industrial scale ESR system. The current density at electrode surface increases with the increase of working current frequency. Furthermore, the characteristic of current density distribution, magnetic field intensity, electromagnetic force and Joule heating in the slag bath during laboratory scale and industrial scale ESR process were analyzed. Key words: electroslag remelting (ESR); electromagnetic field; Lorentz force; numerical simulation [1] (Foundation item)( )(863 )(2012AA03A502) (LT )(Project ( ) supported by the National Natural Science Foundation of China; Project (2012AA03A502) supported by the National High Technology Research and Development Program of China (863 Program); Project (LT ) supported by Innovative Research Team in University of Liaoning Province) liufb@smm.neu.edu.cn

2 [2 12] Dilwari [2 3] Maxwell [6] Jardy [7 8] Li [9] Maxwell ANSYS Maxwell [2] 1) 2) [7] 3) [7] 4) 1 Maxwell 1) Faraday B E (1) t 2) Ampere H J (2) B 0 (3) J 0 (4) E V/mB T H A/m J A/m 2 t, s F JB J H (5) Lorentz 0 J J QJoule (6) μ 0 H/mσ Ω m Maxwell 2 1 Hˆ Hˆ r j ˆ 2 0H r r r z Ĥ H θ ω j 1 (7)(2) J ˆ Jˆ r z Hˆ z 1 ( rhˆ ) r r J ˆr J ˆz J r J z (5) 2π / 1 * F ˆ ˆ r 0 Re( H Jz) 2 (9) 1 ˆ ˆ* Fz 0 Re( H Jr) 2 Re Jˆr * Jˆz * J ˆr J ˆz Q Joule * * 1 Jˆ ˆ ˆ ˆ Re rjr JzJ z 2 sl( T ) (7) (8) (10) (ANSYS solid97 ) () 0 V 1.2 ( 1) [13] 1(a) (b) [6] 50%CaF 2 30%Al 2 O 3 20%CaO M2

value of magnetic field intensity (a) (b)

/Hz 50 5, 25, 40, 50, 60 /(kω 1 m 1 ) 2.

3 3582 () 46 40%~60% CaF 2 10%~20% CaO20%~30% Al 2 O 3 10%, SiO 2 5% MgO() Cr5 1 2 (r=60 mm) Fig. 2 Comparison of predicted and measured value of magnetic field intensity (a) (b) 1 Fig. 1 Finite element model of electroslag remelting 1 Table 1 Parameters of model [6] /mm ()/ (mmmm) /mm /mm 5 20 /( ) 37 0 /ka /Hz 50 5, 25, 40, 50, 60 /(kω 1 m 1 ) /(kω 1 m 1 ) /(MH m 1 ) , (CT3 ) [6] f=50 Hz / 0 V 4 f=50 Hz ka 50 Hz (r=60 mm) 2 /(z=0) (a) (b) 3 Fig. 3 Distribution of electric potential in ESR

4 (a) (b) 4 Fig. 4 Distribution of current density of ESR 4(a) 1/ πf m 3 m ( 4(b)) Hz 60 Hz 60 ka/m ka/m f=50 Hz 6 (a) (z=1 m)(b) (z=0.5 m) /Hz Fig. 5 Current density distribution of industrial scale ESR (a) (b) 6 Fig. 6 Distribution of magnetic field intensity in ESR 7 f=50 Hz 7 (r=0.35 m) (r=0.475 m)

5 3584 () 46 9 / 9 / x / 1z=0.88 m()2z=0.88 m(/) 3z=0.84 m()4z=0.70 m(/) 5z=0.68 m() 7 Fig. 7 Distribution of magnetic field intensity along radius at different axial locations in industrial scale ESR process ka/m(7.37 ka/m) Patel [14] f=50 Hz 8 (a) (b) 8 Fig. 8 Distribution of Lorentz force in ESR /Hz / Fig. 9 Effect of frequency on Lorentz force distribution of slag-metal interface in industrial scale ESR 10 f=50 Hz 10 10(a) (b) 90.4 MW/m MW/m 3 () () ( 4) ( 10)

10 3585 (a) (b) 10 Fig. 10 Distribution of Joule heat generation in ESR 3 1) ANSYS 2) 3) 4) [1]. [M]. :, 2010: 13 14. LI Zhengbang. Theory and practice of electroslag remelting[m].

[3] Dilawari A H, Szekely J. Heat transfer and fluid flow phenomena in electroslag refining[j]. Metallurgical Transactions B, 1978, 9(1): 77 87. [4] Ballantyne A S, Mitchell A.

Modelling of fluid flow and heat transfer in industrial-scale ESR system[j]. Ironmaking and Steelmaking, 1981, 8(5): 225 231. [6],. [J]., 1995, 31(2): 51 60. WEI Jihe, REN Yongli.

Magnetohydrodynamic and thermal behavior of electroslag remelting slags[j]. Metallurgical Transactions B, 1991, 22(1): 111 120. [8] Kharicha A, Schütenhöer W, Ludwig A, et al.

6 (a) (b) 10 Fig. 10 Distribution of Joule heat generation in ESR 3 1) ANSYS 2) 3) 4) [1]. [M]. :, 2010: LI Zhengbang. Theory and practice of electroslag remelting[m]. Beijing: Metallurgical Industry Press, 2010: [2] Dilawari A H, Szekely J. A mathematical model of slag and metal flow in the ESR process[j]. Metallurgical Transactions B, 1977, 8(1): [3] Dilawari A H, Szekely J. Heat transfer and fluid flow phenomena in electroslag refining[j]. Metallurgical Transactions B, 1978, 9(1): [4] Ballantyne A S, Mitchell A. Modeling of ingot thermal fields in consumable electrode remelting processes[j]. Ironmaking and Steelmaking, 1977, 4(4): [5] Choudhary M, Szekely J. Modelling of fluid flow and heat transfer in industrial-scale ESR system[j]. Ironmaking and Steelmaking, 1981, 8(5): [6],. [J]., 1995, 31(2): WEI Jihe, REN Yongli. Mathematical simulation of magnetic field in ESR system[j]. Acta Metallurgica Sinca, 1995, 31(2): [7] Jardy A, Ablitzer D, Wadier J F. Magnetohydrodynamic and thermal behavior of electroslag remelting slags[j]. Metallurgical Transactions B, 1991, 22(1): [8] Kharicha A, Schütenhöer W, Ludwig A, et al. Multiphase modelling of the slag region in ESR Process[C]//Proceedings of the 2007 International Symposium on Liquid Metal Processing and Casting. Nancy, 2007: [9] Li B K, Wang F, Tsukihashi F. Current, magnetic field and joule heating in electroslag remelting processes[j]. ISIJ International, 2012, 52(7): [10] Choudly M, Szekely J, Medovar B I, et al. The velocity filed in the molten slag region of ESR systems[j]. Metallurgical Transactions B, 1982, 13(1): [11] Launder B E, Spading D B. The numerical computation of turbulent flows[j]. Comput Methods Appl Mech Eng, 1974, 3(2): [12] DONG Yanwu, ZHENG Lichun, JIANG Zhouhua. Mathematical modelling of producing hollow ingot by electroslag casting with liquid metal[j]. Ironmaking & Steelmaking, 2013, 40(2): [13] LI Wanzhou, WANG Weiyu, HU Yuechen, et al. The estimation and control of the electroslag remelting melt rate by mechanism-based modeling[j]. Metallurgical Transactions B, 2011, 42(2): [14] Patel A D. Electrode immersion depth effects in the ESR process[c]//proceedings of the 2011 International Symposium on Liquid Metal Processing and Casting. Nancy: SPIM, 2011: ( )

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