王资兴,李青,王磊.数值模拟电极缩孔对IN718合金电渣重熔过程的影响[J].稀有金属材料与工程,2018,47(12):3579~3589.[wangzixing,liqing,wanglei.Numerical simulation of the influence of electrode shrinkage cavity on the ESR process of IN718 alloy[J].Rare Metal Materials and Engineering,2018,47(12):3579~3589.]
数值模拟电极缩孔对IN718合金电渣重熔过程的影响
投稿时间:2018-04-06  修订日期:2018-06-10
中文关键词:  电渣重熔,数值模拟,电极缩孔
基金项目:国家自然科学基金项目(U1708253)
中文摘要:
      利用自主开发的ESR过程仿真软件,针对直径430 mm的IN718合金铸锭,通过设计不同形状尺寸的电极缩孔,进行电渣重熔过程的数值模拟计算和分析。结果表明,基于电磁场、流场和温度场等多物理场耦合计算自主开发的ESR数学模型及仿真软件,可以用于ESR冶炼全过程数值模拟,模型计算的熔池形状和深度、二次枝晶臂间距分布规律与实际剖锭分析结果接近。电极中存在缩孔改变了电极与渣池的接触面积,从而显著影响渣池的焦耳热和电磁力分布,而缩孔沿电极轴向尺寸的变化对二者分布的影响则很少。在恒熔速条件下,当缩孔半径小于0.025 m时,缩孔对熔炼过程几乎没有影响;当缩孔尺寸继续增大时,渣池温度场和流场发生明显改变,渣池温度逐步升高,中心向下流速相对减弱;电极缩孔尺寸变化对熔池温度场及两相区尺寸影响不明显。缩孔半径尺寸对电流和功率等熔炼参数的影响呈非线性关系,临界变化值约为0.05 m,当缩孔半径低于临界值时,对电流和功率等影响较小;高于临界值时,随着缩孔半径增加,电流和功率显著增加,并且增速不断加快。从工艺过程控制稳定性角度而言,该尺寸电极缩孔半径应控制在0.05 m以下。
Numerical simulation of the influence of electrode shrinkage cavity on the ESR process of IN718 alloy
英文关键词:Electroslag remelting, Numerical simulation, Electrode shrinkage cavity
英文摘要:
      Abstract: Numerical simulation and analysis of the influence of electrode shrinkage cavity on electroslag remelting (ESR) process of a 430mm diameter ingot of IN718 alloy were carried out using the self-developed ESR process model. Electromagnetic fields of ESR system were simulated with specially designed various shape and size of cavity in the electrode. The results show that the changed contacting area between the electrode and the slag, owing to the cavity, plays the predominant role on the distributions of the Joule heat and electromagnetic force in the slag, while the effect of axial dimension change of the shrinkage cavity is negligible. Constant melt rate ESR processes were simulated for the different radius cavity situations. It is shown that, at a constant melt rate, no effect of shrinkage cavity on the ESR process can be seen as its radius is less than 0.025 m, and only minute influence on the slag flow when the radius reaches 0.05 m. As the radius increases over 0.05 m, increasingly evident influence on the slag zone appears with the center downward flow weakened and temperature risen. Nevertheless, there is no obvious influence of the cavity on the ingot including the melt pool and mush zone. There are nonlinear relations between the shrinkage cavity radius and the ESR melting parameters including current and power, with a critical value about 0.05 m for the radius. Below the critical value, faint or even no change of the parameters appears, while, above the value, the parameters of power and current soon turn into high speed increase, approximately in a linear manner. From the standpoint of process control stability, the shrinkage cavity radius should be controlled less than 0.05 m.
作者单位E-mail
王资兴 宝钢股份研究院 wangzixing@baosteel.com 
李青 宝钢股份研究院  
王磊 东北大学 wanglei@mail.neu.edu.cn 
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