It describes the principles of ingot solidification and various defects. In summary, for effective electroslag remelting of superalloys to take place, the slag should have in general the following characteristics. It should form a smooth layer upon solidification on the mold wall to provide a good ingot surface. We have studied the effect of electroslag remelting on the content and composition of nonmetallic inclusions. The resulting improvements in the efficiency and performance of the process established consarc as the leading manufacturer of esr systems worldwide. On melting of electrodes during electroslag remelting. Electroslag remelting esr is a consumable electode remelting process in which liquid metal droplets are refined with contact of a molten slag providing a cleaner, more uniform alloy with minimum segregation. Influencing the electroslag remelting process by varying. 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. Electro slag remelt process patriot special metals. Friedrich1 1 ime process metallurgy and metals recycling, rwthaachen university, intzestr. Flip book maker for converting pdf to flip book ebook for digital.
A comprehensive analysis of the physical processes that occur in electroslag remelting esr process under steady state conditions and axisymmetric was performed using the simulation software meltflow. It should be essentially non reactive with the alloy. An analysis on formation of anf6 electroslag fluxes skin. Finer, more dispersed inclusions improved transverse ductility improved uniformity reduction of segregation. A selfconsistent model for electrode temperature gradients in the electroslag. Make sure your android phone or tablet is connected to wifi.
Consarc electrode eschange esr furnaces utilize multiple electrodes, one at a time in series, to form a single larger ingot. New insights into the electroslag remelting process using. The mro brand of electrolytic manganese that is used for these alloys requires additional refining due to its high content of sulfur and dissolved gases. The method is used for remelting nitride hardened steels alloyed by nitrogen. The books are easily downloadable and you can take them home and read. Mathematical modeling of melting and freezing processes taylor. If you would like to participate, please visit the project page, where you can join the discussion and see a list of open tasks. Inspire a love of reading with prime book box for kids discover delightful childrens books with prime book box, a subscription that delivers new books every 1, 2, or 3 months new customers receive 15% off your first box. 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. Electroslag remelting how is electroslag remelting abbreviated. Pdf electroslag remelting of high technological steels. How to download pdf ebooks from libgenlibrary genesis. Electroslag remelting furnace,smelting equipment manufacturer. In the remelted ingot defects can arise despite directionally solidification, such as tree ring patterns, freckles and white spots.
Instead of a vacuum atmosphere, a layer of slag floats on top of the molten steel, protecting it from oxygen and other atmospheric gases during melting. Electroslag remelting of titanium ginatta tecnologie. Patel carpenter technology, corp, 101 w bern st, reading pa 19601, usa. During electroslag remelting, the temperature of the slag, which consists of various components caf 2, cao, sio 2, al 2 o 3, and others, exceeds 2500c. Many properties of esr steels are dramatically superior to those of conventionally produced steels. This article is within the scope of wikiproject metalworking, a collaborative effort to improve the coverage of metalworking on wikipedia. Among these, ebr and var use vacuum as the protective and refining medium while esr is the most widely used remelting process today. Electroslag remelting furnace is a special kind of smelting equipment used to melt consumable electrodes in the slag pool by using the heat generated by the remelting current. Fluorides and chlorides of alkaline and alkalineearth metals are used as additions, which enable improvement of various technological and metallurgical properties of the flux table 1, whereby one of the main requirements to fluxes for electroslag welding esw and electroslag remelting esr of titanium is complete absence of oxides, because presence in flux even in small amounts of such. Geometry a quasi steady state, where the fluxes are in equilibrium is used for the numerical simulation. An overview of of energy efficiency and future needs for.
Effects of electrode immersion depth and remelting rate on. Remelting variations under vacuum apart from the remelting of a consumable electrode in a watercooled copper crucible, there is a recent development of the vacuum arc remelting process, namely vacuum arc double electrode remelting vader. Electrode exchange furnaces always utilize two esr furnace heads, and can be designed to exchange into either a static melt station or a withdrawal melt station that is. Electroslag remelting its status, mechanism and refining. Fig ure 5 shows the basic design of the vader process with a static crucible. It uses a reactive, fluid slag as the protective refining. Usage of worked out metallurgical slag in electroslag. The laboratoryscale remelting experiments had been. An electroslag remelting process esr starts when the lower tip of a consumable electrode is immersed into a pool of molten slag. Effects of electrode immersion depth and remelting rate on electroslag remelting process song jinchun, wang changzhou and li song northeastern university, shenyang 110819, china abstract.
Majority of inclusions are eliminated during esr depending on slag composition, temperature and melt rate. The premelted slag possessing electrical conductivity is located on the watercooled mold base connected to a power supply. A thesis submitted to the faculty of graduate studies in partial. The method, which significantly increases the quality of the metals and alloys produced, was. The commercial code fluent is used for the numerical simulation of the electroslag remelting process. Influencing the electroslag remelting process by varying fluorine content of the utilized slag proceedings of emc 2015 5 longitudinal discs from the ingot center were used to visualize the macro structure and to obtain information about the depth and shape of. Introduction this process was developed originally in the erstwhile ussr in 1930. This stage can be qualified as steady melting state. In the electroslag remelting process, the electrode molten state is a critical factor determining. A wide variety of electroslag remelting furnace options are available to you, there are 22 suppliers who sells electroslag remelting furnace on, mainly located in asia. Background consarc esr technology breakthroughs in the 1960s consarcs engineers conceived a new approach to electroslag remelting, quite different from others in use at the time. New insights into the electroslag remelting process using mathematical modeling ashish d.
Most of the research should be done in recycling and remelting areas develop and design aluminum remelting furnace for the future that minimizes melt loss, increase cost effectiveness, increase safety, improve fuelenergy efficiency, improve melt rates and reduce emissions. Electroslag remelting has been established as a new measure for the production of quality steels. In this mould, the resultant remolten ingot grows to the extent the electrode melts. Develop and design aluminum remelting furnace for the future that minimizes melt loss, increase cost effectiveness, increase safety, improve fuelenergy efficiency, improve melt rates and reduce emissions develop a low cost process for metal purification of primary alloys from. In the 1960s consarcs engineers conceived a new approach to electroslag remelting, quite different from others in use at the time. Numerical simulation of electroslag remelting process for. Poirier author see all formats and editions hide other formats and editions. So, the correlation of reacted phases of system in the beginning of process and in the steady phase of remelting differs, because at the beginning the whole. Multiple electrode electroslag remelting furnaces consarc. The slag and a part of the steel phase are simulated. This reference book presents mathematical models of melting and solidification processes that are the key to the. Pdf hydrogen pickup during electroslag remelting process. Use of electroslag refining for novel insitu alloying. Electroslag remelting an electrometallurgical process in which a metal in the form of a consumable electrode is remelted in a bath of an electrically conducting synthetic slag by the action of heat released upon the passage of electric current through the slag.
Thermal characteristics of the electroslag remelting. Along with the esr process for ingot production is the commercial plasma arc remelt process for specialty steels, particularly where high nitrogen contents may be desired, as in austenitic stainless steels. Based on more than forty years of experience with both processes, deutsche edelstahlwerke have excellent knowhow and process engineering in place, which is optimally adapted to. This article provides an overview of the esr and discusses the major components and operations of the esr furnaces. During esr process such steels are continuously alloyed by nitrogen containing compounds. Electroslag remelting of the metal wastes of nickel alloys. The metal droplet is then crystallized into esr ingot in the watercooled crystallizer after being cleansed with the slag liquid. The electroslag remelting process is a remelting process with a consumable electrode. Typical reactions for chain assembling are polyaddition continuous or step wise and condensation polymer ization polycondensation 1 figure 1. This work aims at the suitability of electroslag process on production of high technological steels such as maraging steel, modified high speed tool steel niobium, high nitrogen, and free.
Esr and var electroslag remelting electroslag remelting. Melting in vacuum has a long history of over 100 years, beginning in the 1920s after induction furnaces were introduced. Electrodes for remelting can be used in the ascast condition. Oct 10, 2012 the electroslag remelting of the metal wastes of nickel alloys is studied, and the obtained results demonstrate that the chemical composition and the physicomechanical and service properties of the ingots meet the requirements of the specifications for these alloys. Usually, after esr, the metal does not contain sany inclusion larger than 1012 mm. The new generation flux of low basetoacid ratio based on workedout metallurgical slag was developed. Based on more than forty years of experience with both processes, deutsche edelstahlwerke have excellent knowhow and process engineering in place, which is optimally adapted to meet their customers requirements. An analysis on formation of anf6 electroslag fluxes skin of. 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. Create, share and embed online magazines, transforming your pdfs into online flipping books. Esr technology esr is the continuous remelting of a consumable electrode by means. Download free ebooks for students and read business.
The esr process can include a computerized melt control system that fully automates the melting process. The lower part of the remelting unit consists of a watercooled copper mould, which ensures uniform heat dissipation and even solidification. Great selection of modern and classic books waiting to be discovered. Page 2 of 9 the consumable electrods are as cast or forged cylindrical parts made of an alloy to be remelt. Review on modeling and simulation of electroslag remelting abdellahkharicha, ebrahimkarimisibaki,menghuaiwu,andreasludwig,andjanbohacek the electroslag remelting esr is an advanced technology for the production of high. Pdf supported by ebook readers, ios and android devices.
In this process, there is a slowly melting consumable electrode and a watercooled mold for solidification, as in vacuum arc remelting, but the melting is conducted under normal atmosphere and is accomplished by a thick, superheated layer of slag on top of. This is why esr is recognized as the preferred production method for highperformance superalloys that are used today in industries such as aerospace and nuclear engineering as well as for heavy forgings. Just like with var vacuum furnace, in the esr process an air melted ingot is suspended over a vessel into which the ingot is melted by electrical current, to reform drip by drip as a new ingot. The voltage gradients in the slag bed are predicted using a resistance network analogue and tested against experimental results. Introduction to stainless steels asm international. It allows you to access to paid content or books that are not digitized anywhere. The pickup of hydrogen during electroslag remelting process for several slags consisting of caf2al2o3caosio2mgo had been investigated. Discover delightful childrens books with prime book box, a subscription that delivers new books every 1, 2, or 3. The electroslag remelting ingots are then used as a charge for remelting in a vacuum induction furnace according to a standard. Electroslag remelting esr is commonly used to produce the highest levels of quality in plate steels, particularly in thick plates. The heat generation and distribution in the slag bed is discussed. Review on modeling and simulation of electroslag remelting.
Pdf effect of electroslag remelting on the nonmetallic. Electroslag remelting article about electroslag remelting. This interim report describes research conducted at the massachusetts institute of technology on macrosegregation in ingots produced by the electroslag remelting esr process. The top countries of supplier is china, from which the percentage of electroslag remelting furnace supply is 100% respectively. Thermal characteristics of the electroslag remelting process. 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. Flipbuilder provides flash and html5 flip book maker software to build wonderful page flipping effect ebooks from pdf, images and office files. Stub this article has been rated as stubclass on the projects quality scale. Increased pressure prevents removal of dissolved nitrogen from the liquid steel to. Electroslag remelting how is electroslag remelting.
Effect of electroslag remelting on the nonmetallic. Based on the results and a thermodynamic assessment of the formation of the nonmetallic inclusions, a mechanism for inclusion behavior during electroslag remelting has been proposed. Increased pressure prevents removal of dissolved nitrogen from the liquid steel to the atmosphere. These kinds of processes produce large ingots of higher quality then that of the original material, by controlled solidification and chemical refinement. After this initial regime, the required heat flux decreases smoothly during the 80 to 90 % of the remelting time. Open library is an open, editable library catalog, building towards a web page for every book ever published. Influencing the electroslag remelting process by varying fluorine content of the utilized slag proceedings of emc 2015 5 longitudinal discs from the ingot center were used to visualize the macro structure and to obtain information about the depth and shape of the liquid metal pool see figure 3, left. Remelting primary objective is to obtain a favorable structure while maintaining of low hydrogen content and increasing the technical and economic evidence of the remelting process itself. The detailed plots of current distribution, volumetric heating, flow, temperature and turbulent mixing provide insight into the various physical phenomena that occur in esr process. Freckles and white spots affect the material properties much more significantly. The electroslag remelting of the metal wastes of nickel alloys is studied, and the obtained results demonstrate that the chemical composition and the physicomechanical and service properties of the ingots meet the requirements of the specifications for these alloys. Rendering of electroslag remelting apparatus and crosssections.
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