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<p>Electroslag fusion welding (ESFW) is a critical secondary manufacturing technology for joining large-section alloy components, where weld cleanliness, governed by the distribution of non-metallic inclusions, is a paramount quality indicator. This study presents a transient multiphysics model, integrating computational electromagnetics, numerical heat transfer, and computational fluid dynamics, to investigate the dynamics of inclusion removal and capture during the ESFW process. Using an Eulerian-Lagrangian framework, the model tracks the trajectories of inclusions with varying diameters (1 to 10&#xa0;<i>μ</i>m) and densities (2000 to 6000 kg/m<sup>3</sup>) under different geometric configurations of assembly clearance (10 to 20 mm) and plate electrode width (5 to 20 mm). The model's accuracy is validated against experimental measurements of the removal rate for large inclusions (&gt;&#xa0;10&#xa0;<i>μ</i>m) in supermartensitic stainless steel 04Cr13Ni5Mo. The results reveal that while inclusion removal efficiency is influenced by geometry—increasing with particle diameter and peaking at an intermediate density—the differences in the overall removal rate across the configurations studied are marginal. Crucially, the geometric configuration profoundly affects the spatial distribution of the inclusions that are ultimately captured. Smaller, lower-density inclusions tend to be captured near the central axis, while larger, higher-density particles are captured more peripherally. A comprehensive evaluation indicates that the 15 mm assembly clearance and 20 mm plate electrode width (15 mm:20 mm) configuration yields the best spatial uniformity in inclusion capture locations. This finding shifts the design criterion from solely maximizing removal to optimizing distribution, providing a more nuanced theoretical and practical basis for enhancing the overall quality and performance consistency of large-scale high-purity stainless steel components joined by ESFW.</p>

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Numerical Simulation of Inclusion Dynamics, Removal, and Capture in Large-Section Electroslag Fusion Welding: Geometric Design Criteria for Enhanced Weld Cleanliness

  • 期刊论文

  • 发表日期：

    2026年5月18日

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  • Haoran Xu,
  • Paixian Fu,
  • Hongwei Liu,
  • Xiuhong Kang,
  • Hanghang Liu,
  • Kaiyan Song,
  • Xuechi Huang,
  • Zhongqiu Liu,
  • Baokuan Li,
  • Dianzhong Li

摘要

Electroslag fusion welding (ESFW) is a critical secondary manufacturing technology for joining large-section alloy components, where weld cleanliness, governed by the distribution of non-metallic inclusions, is a paramount quality indicator. This study presents a transient multiphysics model, integrating computational electromagnetics, numerical heat transfer, and computational fluid dynamics, to investigate the dynamics of inclusion removal and capture during the ESFW process. Using an Eulerian-Lagrangian framework, the model tracks the trajectories of inclusions with varying diameters (1 to 10 μm) and densities (2000 to 6000 kg/m3) under different geometric configurations of assembly clearance (10 to 20 mm) and plate electrode width (5 to 20 mm). The model's accuracy is validated against experimental measurements of the removal rate for large inclusions (> 10 μm) in supermartensitic stainless steel 04Cr13Ni5Mo. The results reveal that while inclusion removal efficiency is influenced by geometry—increasing with particle diameter and peaking at an intermediate density—the differences in the overall removal rate across the configurations studied are marginal. Crucially, the geometric configuration profoundly affects the spatial distribution of the inclusions that are ultimately captured. Smaller, lower-density inclusions tend to be captured near the central axis, while larger, higher-density particles are captured more peripherally. A comprehensive evaluation indicates that the 15 mm assembly clearance and 20 mm plate electrode width (15 mm:20 mm) configuration yields the best spatial uniformity in inclusion capture locations. This finding shifts the design criterion from solely maximizing removal to optimizing distribution, providing a more nuanced theoretical and practical basis for enhancing the overall quality and performance consistency of large-scale high-purity stainless steel components joined by ESFW.