A Computational Model of the Electroslag Remelting (ESR) Process and Its Application to an Industrial Process for a Large Diameter Superalloy Ingot

This paper presents a comprehensive computational model for the prediction of the transient Electroslag Remelting (ESR) process for cylindrical ingots based on a two-dimensional axisymmetric analysis. The model analyzes the behavior of the slag and growing ingot during the entire ESR process involving a hot-slag start with an initial transient, near-steady melting, hot-topping and subsequent solidification of the slag and ingot after melting ends. The results of model application to an industrial ESR process for a 1.12 m diameter nickel-iron-chromium superalloy and its validation are presented. They demonstrate the comprehensive capabilities of the model in predicting the behavior of the ingot and slag during the entire process and properties of the final ingot produced. Such analysis provides significant benefits for the optimization of existing process schedules and design of new processes for different alloys and ingot sizes.