3D Mathematics Model of Formation and Motion of Metal Droplets During Electro-Slag Remelting Process

Based on the mathematical model, this study investigated the process of electro-slag remelting. Maxwell equations are firstly solved to calculate the magnetic field and the distribution of joule heating. Then these two terms are implemented in momentum and energy equations via “User Defined Functions” in FLUENT. The Volume of Fluid method and the enthalpy-porosity approach are applied to capture the multiphase flow and the melting process. The magnetic field, the resulting Lorentz forces and the joule heating are modeled assuming they are independent of the flow. The results show that the molten steel film can generate at the tip of consumable electrode and converge into droplets which fall down through the slag bath and into the liquid metal pool. In addition, an intense non-axisymmetric flow occurs that cannot be realized by conventional two-dimensional model.