Simulation of the Electric Signal During the Formation and Departure of Droplets in the Electroslag Remelting Process

Abstract

In the ESR process, it is very difficult to make experimental observations of the phenomena occurring within the molten slag. At present, the state of the process is solely evaluated from the variation of the measured electric variables. The present paper proposes the use of 3D numerical model to explore the complex coupling existing between the electrodynamics and the phase distribution during the process. The droplet formation during melting of an electrode under the action of a strong DC current is simulated with a multiphase-magnetohydrodynamic approach. A volume-of-fluid approach is used for the interface tracking, and the potential formulation is used to determine the electric and magnetic fields. The Lorentz force and the Joule heating are recalculated at each time step as a function of the phase distribution. The evolution of the electric resistance of the system during the droplet formation and departure is reported. The results are compared with the measurements made in experimental and industrial-scale ESR processes. Two values of metal/slag interfacial tension of 1 and 0.1 N m � 1 are explored. The effects of the control system as well as the presence of a horizontal magnetic field are also investigated. These results open the possibility to link online the voltage signal variation with real physical phenomena happening during the process.