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<p>The Electroslag Casting is a near-net-shape forming technology that has been challenging to apply to no common cavity condition. To address this challenge, Electroslag Overflow Forming (ESOF) technique was developed, based on ESRC. To validate its feasibility and guide the design of the ESOF process, a study combining numerical simulation and experimental research was conducted. A Volume of Fluid (VOF) multiphase flow model was established to simulate the two-phase flow in ESOF process. The results indicated that when the current was 75 V and the simulated input current was below 4000 A, isolated liquid-phase regions of metal appeared in the overflow channel, while in actual experiments, forming defects were observed. When the current reached 8000 A, the liquid metal could completely fill the 250 mm × 50 mm overflow region. It was concluded that forming defects were due to the premature solidification of the liquid slag and metal under low-power conditions, resulting in uneven cooling conditions. For the ESOF process, the relationship between input current and filling rate adhered to an empirical formula. Finally, the ESOF experiments under no common cavity confirm that the ESOF technique can be applied to a broader range of applications.</p>

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Numerical Simulation Study of the Effect of Input Current on Filling Rate and Forming Defects in Electroslag Overflow Forming Process

  • 期刊论文

  • 发表日期：

    2025年1月7日

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  • Heng Cao,
  • Yu Wang,
  • Yanchun Lou,
  • Zengrui Wang,
  • Yunbao Gao,
  • Lei Cao

摘要

The Electroslag Casting is a near-net-shape forming technology that has been challenging to apply to no common cavity condition. To address this challenge, Electroslag Overflow Forming (ESOF) technique was developed, based on ESRC. To validate its feasibility and guide the design of the ESOF process, a study combining numerical simulation and experimental research was conducted. A Volume of Fluid (VOF) multiphase flow model was established to simulate the two-phase flow in ESOF process. The results indicated that when the current was 75 V and the simulated input current was below 4000 A, isolated liquid-phase regions of metal appeared in the overflow channel, while in actual experiments, forming defects were observed. When the current reached 8000 A, the liquid metal could completely fill the 250 mm × 50 mm overflow region. It was concluded that forming defects were due to the premature solidification of the liquid slag and metal under low-power conditions, resulting in uneven cooling conditions. For the ESOF process, the relationship between input current and filling rate adhered to an empirical formula. Finally, the ESOF experiments under no common cavity confirm that the ESOF technique can be applied to a broader range of applications.