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In the framework of the European RFCS project named ISA-PESR, an integrative software simulation tool focusing on numerical modelling of the protective gas electro-slag remelting (PESR) process has been built up. To achieve this goal several tasks were organised. First the collection of data concerning the physical properties of the materials involved during the process was performed. This concerns the selected slag, the steel and the copper mould. In the second task, several experimental remeltings were performed within both small- and industrial-scale devices. After remelting, the pool profiles and the electrode shapes were obtained. The third task consisted of investigating numerically some phenomena that are not well understood at the present time. In particular, the interaction between the falling steel droplets and the slag flow was carried out with a multiphase model of the Fluent CFD software. In addition to that, the prediction of the exact shape of the metal-slag interface was successfully undertaken. The last task was to develop and implement a module into Calcosoft-2D, a commercially available software package of the ESI Group, originally dedicated to continuous casting process simulation. The mathematical, numerical and validation development are presented in details. This software package is able to predict all important steps of the PESR operation such as the melting of the electrode, the influence of Lorentz forces on buoyancy, and the melt convection during solidification. By simulating the PESR process it is now possible to improve the process control during remelting and optimise the feed rate of additives and alloying elements during remelting.

Additional information

Authors: KHARICHA A, University of Leoben, Leoben (AT);LUDWIG A, University of Leoben, Leoben (AT);WU M, University of Leoben, Leoben (AT);SCHOLZ H, ALD Vacuum Technologies, Hanau (DE);SCHÜTZENHÖFER W, Böhler Edelstahl, Deuchendorf (AT);REITER G, Böhler Edelstahl, Deuchendorf (AT);TANZER R, Böhler Edelstahl, Deuchendorf (AT);MACKENBROCK A, ESI Group, Paris (FR);KÖSER O, ESI Group, Paris (FR);CAROSI A, Centro Sviluppo Materiali (CSM), Roma (IT);SORCI R, Centro Sviluppo Materiali (CSM), Roma (IT);ARCOBELLO-VARLESE F, Centro Sviluppo Materiali (CSM), Roma (IT)
Bibliographic Reference: EUR 23917 EN (2009), 150 pp. Euro: 20
Availability: Katalogue Number: KI-NA-23917-EN-S The paper version can be ordered online and the PDF version downloaded at:
ISBN: ISBN: 978-92-79-12479-2
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