Assessment of Porosity Defects in Ingot Using Machine Learning Methods during Electro Slag Remelting Process

Abstract

The porosity defects in the ingot, which are caused by moisture absorption in slag during the electroslag remelting process, deserve the researcher’s attention in the summer wet season. The prediction of slag weight gain caused by moisture absorption is critical for developing slag baking and scheduling strategies and can assist workshop managers in making informed decisions during industrial production of electro slag remelting. The moisture absorption in slag under the conditions of different air humidity, experimental time, slag particle size, and CaO content in the slag are investigated by slag weight gain experiments. The purpose of this study is to predict the rate of weight gain in slag using observed weight gain data and machine learning (ML) models. The observation dataset includes features and rate of weight growth, which serve as independent and dependent variables, respectively, for ML models. Four machine learning models: linear regression, support vector regression, random forest regression, and multi-layer perceptron, were employed in this study. Additionally, parameters for machine learning models were selected using 5-fold cross-validation. Support vector regression outperformed the other three machine learning models in terms of root-mean-square errors, mean squared errors, and coefficients of determination. Thus, the ML-based model is a viable and significant method for forecasting the slag weight gain rate, whereas support vector regression can produce results that are competitive and satisfying. The results of slag weight gain data and ML models show that the slag weight gain increases with the increase of air humidity, experimental time, slag particle size, and CaO content in the slag. The porosity defect in the ingot during the ESR process often appears when the moisture in the slag exceeds 0.02%. Considering saving electric energy, the complexity of on-site scheduling, and 4 h of scheduling time, the slag T3 (CaF2:CaO:Al2O3:MgO = 37:28:30:5) is selected to produce H13 steel ESR ingot in the winter, and slag T2 (CaF2:CaO:Al2O3:MgO = 48:17:30:5) is selected to produce H13 steel ESR ingot in the summer.