Simulation numérique du procédé de refusion sous laitier électroconducteur

Abstract : Electro Slag Remelting (ESR) is widely used for the production of high-value-added alloys such as special steels or nickel-based superalloys. Because of high trial costs and complexity of the process, trial-and-error based approaches are not well suitable for fundamental studies and optimization of the process.Consequently, a transient-state numerical model which accounts for electromagnetic phenomena and coupled heat and momentum transfers in an axisymmetrical geometry has been developed. The model simulates the continuous growth of the electroslag remelted ingot through a mesh-splitting method. In addition, solidification of the metal and slag is modelled by an enthalpy-based technique. A turbulence model is implemented to compute the motion of liquid phases (slag and metal), while the mushy zone is described as a porous medium whose permeability varies with the liquid fraction, thus enabling an accurate calculation of solid/liquid interaction. The coupled partial differential equations are solved using a finite-volume technique.Computed results are compared to experimental observation of 4 industrial remelted ingots fully dedicated to the model validation step. Pool depth and shape are particularly investigated in order to validate the model. Comparison shows that the model can be used as a predictive tool to analyse the process behavior. Nevertheless, it is necessary to pay a particular attention to the estimation of the thermophysical properties of metal and especially slag.These results provide valuable information about the process performance and influence of operating parameters. In this way, we present some examples of model use as a support to analyse the influence of operating parameters. We have studied the variation of electrode immersion depth, fill ratio and water pressure in the cooling circuit.
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Valentine Weber. Simulation numérique du procédé de refusion sous laitier électroconducteur. Autre. Institut National Polytechnique de Lorraine, 2008. Français. ⟨NNT : 2008INPL010N⟩. ⟨tel-01749536⟩

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