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<p>To reveal the influence of elemental interactions on macrosegregation in multicomponent alloys, this study established a transient multi-physics model for electroslag remelting K500 alloy. The model couples electromagnetic fields, two-phase flow, heat transfer with solidification, and multicomponent solute transport. Its accuracy was verified against industrial 1-ton ingot measurements. By comparing predictions from the no-solute, Al–Ti–Ni simplified-component, and Al–Ti–C–Si–Mn–Fe–Ni full-component models, we evaluated the feasibility of simplified models for segregation simulation and investigated how initial Al content affects macrosegregation. The results show that the no-solute and simplified-component models overestimate pool depth by 6.33 and 3.62 pct, respectively. These simplified models fail to accurately track the dynamic evolution of the solidus and liquidus temperatures, leading to overestimation of segregation levels for Al and Ti. In the full-component model, the segregation severity of the solutes Al, Si, Mn, C, Ti, and Fe increases progressively. All solutes exhibit positive segregation in the ingot center and negative segregation at the ingot bottom and ingot surface. As the initial Al content increases from 2.85 to 3.05 wt pct, the content ranges of all solutes expand by 6.04 to 13.44 pct. These results demonstrate that elevated Al content intensifies macrosegregation by enhancing solutal buoyancy, lowering the liquidus temperature, and prolonging the mushy zone duration. Appropriately reducing the initial Al content within the specification range can enhance ingot homogeneity and alleviate macrosegregation.</p>

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Modeling Macrosegregation in K500 Alloy During Electroslag Remelting: Multicomponent Interactions and Aluminum Content Effects

  • 期刊论文

  • 发表日期：

    2026年6月16日

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  • Ying Liu,
  • Xuechi Huang,
  • Kai Du,
  • Minxuan Zhu,
  • Guang Yang,
  • Zhongqiu Liu,
  • Baokuan Li

摘要

To reveal the influence of elemental interactions on macrosegregation in multicomponent alloys, this study established a transient multi-physics model for electroslag remelting K500 alloy. The model couples electromagnetic fields, two-phase flow, heat transfer with solidification, and multicomponent solute transport. Its accuracy was verified against industrial 1-ton ingot measurements. By comparing predictions from the no-solute, Al–Ti–Ni simplified-component, and Al–Ti–C–Si–Mn–Fe–Ni full-component models, we evaluated the feasibility of simplified models for segregation simulation and investigated how initial Al content affects macrosegregation. The results show that the no-solute and simplified-component models overestimate pool depth by 6.33 and 3.62 pct, respectively. These simplified models fail to accurately track the dynamic evolution of the solidus and liquidus temperatures, leading to overestimation of segregation levels for Al and Ti. In the full-component model, the segregation severity of the solutes Al, Si, Mn, C, Ti, and Fe increases progressively. All solutes exhibit positive segregation in the ingot center and negative segregation at the ingot bottom and ingot surface. As the initial Al content increases from 2.85 to 3.05 wt pct, the content ranges of all solutes expand by 6.04 to 13.44 pct. These results demonstrate that elevated Al content intensifies macrosegregation by enhancing solutal buoyancy, lowering the liquidus temperature, and prolonging the mushy zone duration. Appropriately reducing the initial Al content within the specification range can enhance ingot homogeneity and alleviate macrosegregation.