Numerical Simulations of the Molten Metal Droplet Formation in the Electroslag Remelting Process with a Rotating Electrode

Electroslag remelting (ESR) is a well-known process widely used in the production chain of high-quality alloys. Herein, numerical investigations of the implementation of a rotating-electrode (low rotation speed) modification to the flow behavior inside the slag area of a lab-sized ESR process are shown. Therefore, a coupled simulation approach between a commercial CFD (FVM) and electromagnetics (FEM) software is used. Comparative results for the simulated droplet formation between a stationary and a rotating electrode are shown. The results show a strong effect on the local shaping of the liquid metal film below the electrode and consequently a radial shift of the droplet incidence into the metal pool under electrode rotation. There are no observable positive effects on mean metal film thickness, droplet trajectory, or droplet size, which are suspected as possible explanations for observed material improvements in small-scale rotating electrode ESR processes. In addition, an overview of current bottlenecks, restrictions, and possible strategies for improved ESR process simulations is given.