Numerical simulation and analysis for molten droplets evolution during electroslag remelting process
Excellent mechanical properties of electroslag ingot come from low segregation,dense microstructure,fine and uniformly distributed inclusions in the electroslag ingot.And electroslag products can meet the demands of the high-end equipment manufacturing industry for high-performance metal materials effectively.Among the factors af-fecting the quality of electroslag ingot,fluid flow in the slag domain is one of the key factors to affect the metallurgi-cal effect of electroslag remelting(ESR).In order to have a deep insight into the coupling phenomenon of multiple physical fields in ESR process accurately,the open source software OpenFOAM was applied to describe the transfer phenomena in ESR process by direct numerical simulation(DNS)method,standard k-ε model and renormalization Group(RNG)k-ε model.The results show that the formation and movement of metal droplets predicted by DNS are in good agreement with experimental results.The molten slag flow in electroslag remelting is not fully developed turbulence,the DNS is a better method to describe the molten slag flow in ESR than k-ε turbulence model.The in-terfacial energy between steel and slag has significant effects on the droplet evolution.The velocity of droplet is greater during the formation of the droplet.When the interfacial energy between steel and slag is 0.6 N/m,the droplet is like a small sphere.When the interfacial energy between steel and slag is 0.7 N/m and 0.8 N/m,the droplet is like a cone.When the interfacial energy between steel and slag is not less than 0.9 N/m,the droplet is like a spheroidicity.When the interface energy between steel and slag is less than 0.8 N/m,there is a satellite drop-let when the primary melt droplets break away from the thin neck.When the interfacial energy between steel and slag is not less than 0.9 N/m,there is no satellite droplet when the primary melt droplet is separated from the thin neck.The appearance of satellite droplet can improve the quality of ESR ingot.
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