On Validity of Axisymmetric Assumption for Modeling an Industrial Scale Electroslag Remelting Process

A full 3D simulation of an industrial scale electroslag remelting (ESR) process (phi 750mm ingot) is performed, and results are verified by experiment. A typical non-axis symmetry flow pattern and temperature field in the slag region is demonstrated. A statistical analysis of the turbulent flow in the slag and melt pool is performed to quantitatively characterize the transient behavior of the flow. By comparing the 3D calculation with a 2D axis-symmetrical calculation, we find that the predicted shape of melt pool (profile of the solidifying mushy zone of the ingot) are quite similar, leading to the conclusion that a 2D calculation is sufficient to solve the melt pool profile of the ingot.