Review of mathematical models of fluid flow, heat transfer, and mass transfer in electroslag remelting process

Abstract

The electroslag remelting (ESR) process has been used effectively to produce large ingots of high quality based on the controlled solidification and chemical refining that can be achieved. Despite the widespread application of industrial facilities, there are still issues that prevent an effective control of the process. This is particularly critical considering the large ingots produced industrially which makes the traditional trial and error approach prohibitively expensive. Thus, mathematical models of the process are a good alternative as a process control tool. To predict the relationship between operating parameters such as power input and type, fill ratio, depth of electrode immersion, and slag chemistry and the casting rate, microstructural features, and ingot chemical composition, it is then necessary to develop mathematical models based on differential equations describing the fluid flow, heat transfer, and mass transfer phenomena that take place during the process. In the present paper, mathematical models of the transport phenomena occurring during ESR are reviewed. Although the models have evolved to a point where several features of the process can be predicted and the dominant transport mechanisms have been elucidated, more effort is required before the models can be applied to define actual operating conditions.