Pdf electroslag remelting of high technological steels hossam. Investigation of fluoride evaporation from caf 2 caoal 2 o. The evolution of inclusions during the electroslag remelting esr process, especially the inclusions in droplets is investigated by an industrial trial which remelts a plain carbon steel billet in. Cleanliness improvement and microstructure refinement of. Electroslag remelting esr is a secondary metallurgical process aiming at further puri. Overview of 50 years of development in electroslag remelting in. Features of slag metal interaction at electroslag remelting. Evaluation of the electroslag remelting process in medical. Electroslag remelting interim technical report by d. Rbf neural network softsensor model of electroslag remelting.
Jan 18, 2021 electroslag remelting esr gives a combination of liquid metal refining and solidification structure control. High pressure electroslag remelting a new technology of steel refining high pressure electroslag remelting a new technology of steel refining stein, g. As the drops of melting metal fall through the molten electroflux, impurities and mineral inclusions migrate from the drops into the. If the inline pdf is not rendering correctly, you can download the pdf file here. Electroslag remelting esr and vacuum arc remelting var are two forms of vertical continuous casting used for nonferrous metals, superalloys, and specialty alloy sections up to 1. The key to topquality steel electroslag remelting process and superalloys the electrode is a cast ingot that dips into, and melts in, a resistanceheated molten bath of electroflux. Plasma arc melting technology electroslag remelting. The liquid metal pool volumes in esr ingots are predicted from.
Analysis of the unsteady process of electroslag remelting 1 has shown that it need only be taken into account with application to. Electroslag remelting esr is commonly used to produce the highest levels of quality in plate steels, particularly in thick plates. This recent spike in activity is in part due to the need for such a tool in the specialty metal processing industry for new process development and optimization of existing melting parameters. Report of the committee on electroslag remelting and plasma arc melting, national materials advisory board, commission on sociotechnical systems, national research council. The advantages of both esr and var are combined in one process. The electromagnetic field and the droplet profile in electroslag remelting esr process play a pivotal role in the quality of final steel products. Electroslag remelting esr, also known as electroflux remelting, is a process of remelting and refining steel and other alloys for missioncritical applications in aircraft, thermal power stations, nuclear power plants, military technology, etc the electroslag remelting esr process is used to remelt and refine steels and various superalloys, resulting in highquality ingots.
An apparatus and method for electroslag remelting of metals and in particular steel. Due to the extremely short dwell time of the metal droplets in the liquid phase during remelting, the nitrogen pickup via the gas phase is insufficient. Recovery of alumina from electroslag remelting of tibearing. Dissolved gases such as hydrogen and nitrogen are removed, and the remelted metal is protected from oxidation. Effect of layerbylayer formation of ingot during electroslag remelting on.
Flemings massachusetts institute of technology cam bridge, massachusetts 029 interim technical report, contract number daag4674c0120 approved for. Effect of layerbylayer formation of ingot during electroslag. The macrostructure and the composition of the freckles in a lowalloy structure steel esr ingot were investigated to clarify the freckle formation mechanism. The electroslag remelting process esr is an important process for the production of very clean hightech materials for applications used for example in the aviation or energysector. The electroslag remelting esr process is an advanced smelting method to make purified steels based on rudiment steel in order to reduce impurity and get the highquality steel which is defined by. During electroslag remelting, casting imperfections, such as shrinkage cavities and macrostructure. Conclusions the possibility of prediction of the chemical composition of the electroslag metal. Electroslag remelting of titanium ginatta tecnologie. Review on desulfurization in electroslag remelting. The increasing demands for more excellent performance of steel urge metallurgists to further improve the steel cleanliness.
The competitive position of the steel in the market can be. In the centrifugal electroslag casting the mass transfer coefficients and convection constants are increased respectively from 5. On melting of electrodes during electroslag remelting. Computational modeling of the electroslag remelting. Insight into droplet formation in electroslag remelting. Krane1 1school of materials engineering, purdue center for metal casting research, purdue university, west lafayette, in, usa 2carpenter technology corporation, reading, pa, usa. A mathematical model of electroslag remelting esr process is established based on its technical features and dynamic characteristics. Electroslag remelting its status, mechanism and refining. There is renewed interest in modeling the electroslag remelting esr process as evidenced by the surge in publication in the past few years 19. T s g obtained after these treatments was called albearing slag. Novel application of electroslag remelting refining in the. One of the typical aspects of liquid metal refining during esr for the advanced steel and alloy production is desulfurization.
It uses a reactive, fluid slag as the protective refining. Eaf and refining by means of the electroslag remelting process esr. For predicting the key technology index of electroslag remelting esr process the melting rate and cone purification coefficient of the consumable electrode, a radial basis function rbf neural. Electroslag remelting an overview sciencedirect topics. Zang2 electroslag remelting esr hollow ingot process with tshape current supplying mould is a new metallurgical technology. Dec 28, 2015 the bureau of mines, in cooperation with the united states atomic energy commission, electroslag remelted two groups of type 316 stainless steel ingots for ultimate conversion to tubing for tests associated with the liquid metal fastbreeder reactor.
Electro slag remelting under vacuum vesr remelting is carried out under vacuum as in var, however, using a slag. The first, employed for a14%cu, is a small scale esr unit which consists of a. Influencing the electroslag remelting process by varying. New insights into the electroslag remelting process using. Pdf electroslag remelting of high technological steels. The electroslag remelting process esr is a consumable electrode remelting process for producing high quality ingots used in aerospace and energy applications. Download the electroslag melting process book for free in pdf, epub. Vacesr electroslag remelting under vacuum is a variation of the esr that provides vacuum degassing of the melt. Along with the esr process for ingot production is the commercial plasma arc remelt process for specialty steels, particularly where high nitrogen.
The electroslag melting process download books pdfepub and. However, the oxygen content of ingot processed by conventional esr may increase due to the surface oxidation of electrode 6. Also disclosed is a device for realizing the above method, which device is made as a mould having receptacles disposed at. Mathematical modelling of electroslag remelting p91 hollow ingots process with multielectrodes f. Freckle defects were found in electroslag remelting esr ingots, which severely limit the development of the largerdiameter ingots. As the drops of melting metal fall through the molten electroflux, impurities and. These include the esr electroslag re melting process, the esc electroslag casting process, skull remelting based on electronbeam processes, plasma arc processes, and electric arc processes. We cannot guarantee that every book is in the library. Evolution of nonmetallic inclusions during the electroslag. The bottom albearing slag was crushed and the alsiti droplets were taken out by magnetic separation for weighing. Although the process itself is well known for decades, there is still potential for improvements. Electroslag remelting furnaces background consarc esr technology breakthroughs in the 1960s consarcs engineers conceived a new approach to elctroslag remelting, quite different from others in use at the time.
Us3767831a process and apparatus for electroslag remelting. Electroslag remelting of type 316 stainless steel springerlink. The experimental results show that high recovery of alloying elements during electroslag remelting of such steels especially high nitrogen tool steel. In order to promote public education and public safety, equal justice for all, a better informed citizenry, the rule of law, world trade and world peace, this legal document is hereby made available on a noncommercial basis, as it is the right of all humans to know and speak the laws that govern them. Vesr features o combined process var and esr o avoid hydrogen and nitrogen pick up o no moisture from slag o no oxidation of the melt o danger of white spots reduced. The general metallurgy department of southural state university has already had many years of experience in developing and studying an esr process that takes place in a centrifugal force field 28. Evaluating tendency of freckle formation for electroslag. Download pdf 1277k download meta ris compatible with endnote, reference manager, procite, refworks bib tex. Investigation of fluoride evaporation from caf 2 caoal 2. The increasing demands for more excellent performance of steel urge. The electroslag remelting esr is an advanced technology for the production of high quality materials, for example, hot work tool steels or nickel base alloys. The reduction in imperfections achieved suggests electroslag remelting as a promising alternative to vacuum arc or vacuum induction melting. The electric current flowing through the to be molten electrode changes periodically.
Rbf neural network softsensor model of electroslag. In the past years, several models are developed aiming to predict the way in which the operational parameters affect the structure and chemical composition of the final esr ingot. A new multivariable selftuning proportionalintegralderivative pid controller tuned optimally by an improved particle swarm optimization ipso algorithm is proposed to control the twoinputtwooutput tito esr process. Multivariable pid decoupling control method of electroslag. The process is suitable for the remelting of superalloys and titanium alloys. Experimental investigation on the evolution of hydrogen in. Review on modeling and simulation of electroslag remelting. Metallurgical plant and technology international germany, 22, 3638. Electroslag remelting, hydrogen content, slagmetal interface. Esr process has been widely used as a secondary refining step for structural constructional steels, stainless steels and various other. Remelting using a volumeoffluid method simulation of slag. Mar 01, 2020 electroslag remelting esr has the absolute advantages in the removal of largesize inclusions, thus, which is widely applied in the production of highend alloy steels. The electroslag remelting esr process is used for the production of defectfree.
In the past few years, electroslag re melting has gained tremendous populari ty as a valuable processing technique for superalloys, tool steels and other high performance matisrials. Review on desulfurization in electroslag remelting springerlink. Ludwig all with leybold durferrit gmbh, erlenseegermany introduction the titanium metal as an engineering material came into use in the 1950s in the usa in response to the critical demands far low density, high strength material for aircrafts and emerging space technologies. Change in electrical and process characteristics during electroslag remelting. Electroslag remelting esr, also known as electroflux remelting, is a process of remelting and. Flemings massachusetts institute of technology cambridge, massachusetts 029 interim technical report, contract number daag4674c0120 da project approved for public release. Jul 23, 2020 the slags in electroslag remelting esr process serve as a heat source, a barrier to the atmosphere, and a medium for liquid metals refining 1,2,3,4,5. Figure 1 shows a schematic diagram of the esr process that uses a stationary watercooled crucible containing the slag and ingot. As for the electroslag remelting withdrawal process for 9cr3mo roller, the. Computational modeling of electroslag remelting esr process.
The electroslag remelting process is commonly used for refining of high grade steels or nickel, iron and cobaltbased superalloys. Originally established for achieving ultralow sulphur contents remelting esr process, especially the inclusions in droplets is investigated by an industrial trial which remelts a plain carbon steel billet in. Method of tests for electroslag remelting furnaces. S, o and h and nonmetallic inclusions, which account for reduction of corrosion resistance. In electroslag remelting using a volumeoffluid method jeffrey yanke1,2, kyle fezi1, rodney w. Applicated for several decades, this process can produce materials with a narrow chemical composition in. Electroslag remelting casting handbooks asm international. It is shown that to keep a constant melting rate, the heat supplied to the electrode must be continuously changed. Heat is supplied from an electrode above the melt and the top surface is protected with a thick slag layer esr or a. The nitrogen must, therefore, be supplied continuously during remelting in the form of solid nitrogenbearing additives. Deoxidation of liquid steel and alloy during electroslag remelting esr is always an ongoing concern for producing advanced clean steel and alloy. The electroslag melting process download books pdfepub. Mathematical modelling of electroslag remelting p91 hollow. A method of electroslag remelting of titanium or its alloys in a mould having a protective atmosphere from inactive gases supplied to the surface of the slag bath and the electrode, as well as into the melt and onto the ingot at the point where it comes out of the mould.
Remelting using a volumeoffluid method simulation of. Computational modeling of electroslag remelting esr. Introduction electroslag remelting process esr is on the stage of renaissance. Krane1 1school of materials engineering, purdue center for metal casting research, purdue university, west. Electroslag equipment technology electroslag remelting and. Electroslag remelting esr, refining, inoculation, quality steels.
The current which is being fed to the apparatus may be either an ordinary alternating current or a threephase alternating current and is converted into a substantially different current having a base frequency f which. Pdf the electroslag remelting process esr is important because it provides better control of the solidification microstructure and chemical. These processes contribute to reduction of impurity elements i. The thermal characteristics of the electroslag remelting process have been investigated on a. Rendering of electroslag remelting apparatus and crosssections electroslag remelting esr, also known as electroflux remelting, is a process of remelting and refining steel and other alloys for missioncritical applications in aircraft, thermal power stations, nuclear power plants, military technology, etc. Plasma arc melting technology electroslag remelting and. Electroslag refining starter general electric company. Thesis, faculty of engineering, cairo university, cairo. Electroslag refining esr is a process used to melt and refine a wide range of alloys for removing various impurities therefrom. Us3989091a method for electroslag remelting of titanium. Predicting melting behavior of an industrial electroslag remelting ingot.
Investigation of fluoride evaporation from caf 2 caoal 2 o 3. Recovery of alumina from electroslag remelting of ti. Us3989091a method for electroslag remelting of titanium or. Electrochemical reactions always occur at the electrodeslag and slagmetal melt interfaces during the electroslag remelting esr process. The paper deals with the development work in the field of electroslag remelting esr, which has been executed in austria since 1964 by. This article provides an overview of the esr and discusses the major components and operations of the esr furnaces. Zang2 electroslag remelting esr hollow ingot process with tshape current supplying mould is a new. Electroslag remelting december 1976 interim technical report by d. Effect of sio2 on the crystallization behaviors and inmold. Among these, ebr and var use vacuum as the protective and refining medium while esr is the most widely used remelting process today. Research on the ingot shrinkage in the electroslag remelting. The main purpose of the esr process is to purify metal and get the ingot with uniform density crystallization. Originally established for achieving ultralow sulphur contents remelting, rotating electrode, solidification structure, electrical behavior of rotating electrodes 1 introduction the electroslag remelting process esr is a refining process for metals used for special applications. Read as many books as you like personal use and join over 150.
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