Mathematical Modeling of ESR Process for Hollow Ingot with Current Supplying Mould

With increasing demand for large cylindrical forgings, a new technology–electroslag remelting (ESR) for direct manufacture of hollow ingots rather than solid ingots has been developed. The main features of the process include a T-shaped current supplying mould (CSM), double power supply, an ingot withdrawing system, a metal level automatic control system based on a level sensor using the electromagnetic eddy current method, and the exchange of a consumable multi-electrode. ANSYS software was used to calculate the fluid flow and heat transfer in the slag bath and metal pool of this ESR hollow ingot process with its T-shaped CSM. The mathematical model was verified by measuring the geometry of the liquid metal pool as observed in the macrostructure of ϕ650 mm (external diameter)/ϕ450 mm (internal diameter) hollow ingots by sulphur print method: the observed shape and depth of the slag bath were consistent with the simulated results. Simulation of the ESR process can improve understanding of the process and allow better operating parameters to be selected.