The Electroslag Remelting (ESR) is an advanced technology for the production of high quality materials, example, hot work tool steels or nickel base alloys. In past years, several models are developed aiming to predict way in which operational parameters affect structure and chemical composition final ESR ingot. Proper modeling this process depends on ability model Multiphysics resulting from complex coupling between many physical phenomena. This review includes main findings starting...

Abstract Main modeling challenges for vacuum arc remelting (VAR) are briefly highlighted concerning various involving phenomena during the process such as formation and movement of cathode spots on surface electrode, plasma, side-arcing, thermal radiation in region, magnetohydrodynamics (MHD) molten pool, melting solidification ingot. A numerical model is proposed to investigate influence several decisive parameters mode (diffusive or constricted), amount gas cooling shrinkage gap at...

Abstract The numerical methods based on the unsteady Reynolds-averaged Navier–Stokes (URANS) equations are robust tools to model turbulent flow for industrial processes. They allow an acceptable grid resolution along with reasonable calculation time. Herein, URANS approach is validated against a water experiment special single port submerged entry nozzle (SEN) design used in thin slab casting (TSC) process. A 1-to-2 under-scaled was constructed, including SEN, mold, and strand Plexiglas...

In the present work, a new heat exchanger is introduced for conventional liquid cooling of cylindrical type lithium-ion cells which are contained in battery packs/modules electric vehicles. The coolant channels made polymeric hollow fibers (ø1 mm) embedded durable polydicyclopentadiene housing. Unlike commercially available metallic counterparts, proposed design lightweight, electrically non-conductive, and low cost materials. prototype stacked with 18650-type cycled 1 C range...

Abstract A comprehensive numerical model is proposed to study the influence of an axial magnetic field (AMF) on solidification behavior a Titanium-based (Ti–6Al–4V) vacuum arc remelting (VAR) ingot. Both static and time-varying AMF are examined. The 2D axisymmetric swirl includes calculating electromagnetic thermal fields in entire system composed electrode, plasma, ingot, mold. combination vector potential formulation induction equation accurately. Calculations flow melt pool ingot also...

A numerical model coupling electromagnetic field and plasma arc impact with multiphase transport phenomena such as flow, heat transfer solidification for the vacuum remelting (VAR) process is proposed. 3D simulations of VAR refining a Titanium-based (Ti–6Al–4V) alloy are made. Different distributions (diffusive, constricted centric, eccentric, rotating arcs) under an axial magnetic (AMF) studied, focusing on their flow patterns resulting melt pool as-solidifying ingot. Simulation results...

A full 3D simulation of an industrial scale electroslag remelting (ESR) process ( ϕ 750 mm ingot) is performed, and results are verified by experiment. typical non‐axis symmetry flow pattern temperature field in the slag region demonstrated. statistical analysis turbulent melt pool performed to quantitatively characterize transient behavior flow. By comparing calculation with a 2D axis‐symmetrical calculation, we find that predicted shape (profile solidifying mushy zone quite similar,...

Abstract During centrifugal casting, the thermal resistance at cast-mold interface represents a main blockage mechanism for heat transfer. In addition to refractory coating, an air gap begins form due shrinkage of casting and mold expansion, under continuous influence strong forces. Here, transfer coefficient h has been determined from calculations thickness d based on plane stress model taking into account thermoelastic stresses, forces, plastic deformations, temperature-dependent Young’s...

Continuous casting (CC) is one of the most important processes steel production; it features a high production rate and close to net shape. The quality improvement final CC products an goal scientific research. One defining issues this stability process. clogging submerged entry nozzles (SENs) typically results in asymmetric mold flow, uneven solidification, meniscus fluctuations, possible slag entrapment. Analyses retained SENs have evidenced solidification entrapped melt inside clog...

Three different approaches, known as primary, secondary, and tertiary current distributions, are employed to calculate the electric distribution throughout an electrochemical system. Ohm's law is used for primary whereas Nernst-Planck equations tertiary. The electromagnetic field calculated in entire system (CaF2-based electrolyte, air, electrode, graphite crucible), while electro-vortex flow concentration fields of ions solved only electrolyte. model accounts faradaic reaction formation...

In order to simulate the mold filling and solidification of outer shell large work rolls being cast by horizontal centrifugal casting, shallow water equations were adopted solve 2D average flow dynamics melt spreading inside cylindrical mold. The model accounts for force, Coriolis shear gravity convective diffusive energy transport. front was tracked fulfilling Stefan condition. Radiative heat losses included from both, free surface wall By introducing a stochastic factor account irregular...

Abstract In the present study, we investigate arc plasma expansion in an industrial vacuum remelting (VAR) process using experimental and numerical tools. Stainless steel is alloy of interest for electrode (cathode) ingot (anode). During operation VAR process, behaviors cathode spots were captured high-speed camera (Phantom v2512). We found that prefer to onset remain within partially melted surface at center tip. Existing outside melting zone accelerate toward edge extinguish. observed a...

Complex multi-phase phenomena, including turbulent flow, solidification, and magnetohydrodynamics (MHD) forces, occur during the continuous casting (CC) under applied electromagnetic brake (EMBr). The results of small-scale experiment liquid metal model for (mini-LIMMCAST) at Helmholtz-Zentrum Dresden-Rossendorf (HZDR), investigating MHD flow with a deep immersion depth 100 mm, are supplemented by newly presented numerical studies shallow position submerged entry nozzle (SEN) 50 mm below...

Two mathematical approaches have been compared for modeling the electrical behavior (e.g., electric/current density field) of an electrolyte. The first approach uses traditional Ohmic method (Laplace equation) based on assumption a uniform concentration ions in second utilizes ionic transport that takes into account effect electrochemical transport/reaction assuming quasi-electro neutral bulk For latter, Poisson–Nernst–Planck (PNP) equations are employed to include impacts non-uniformity...

The solution of the inverse heat conduction problem (IHCP) is commonly found with sequential algorithm known as function specification method explicit updating formulas and sensitivity coefficients flux. This paper presents a different approach namely direct mathematical optimization minimizing least squares norm between experimental data simulation. A CFD open-source code OpenFOAM used together NLOPT DLIB libraries. To guarantee credibility simulation tool developed herein, real from spray...

Abstract The thin slab casting (TSC) is a breakthrough near-net-shape technique for flat products accompanied by rapid and solidification rates. TSC quality hinges on the turbulence, super-heat flow growth of solidified shell. electromagnetic brake (EMBr) commonly applied to control fresh melt after feeding through submerged entry nozzle (SEN). Numerical modelling perfect tool investigate multiphase phenomena in continuous (CC). presented study considers heat transfer solid shell...

A three-phase Eulerian model is proposed to investigate the induced flow due generation of gas bubbles between two parallel plates without forced convection with application alkaline water electrolysis (AWE). Earlier models, assuming a laminar regime, accurately predicted multiphase near electrodes but struggled calculate bulk liquid electrolyte away from them. Herein, we study influences electric current density distribution, turbulence effects, and interaction magnetic field known as...