Computational Modeling of Electroslag Remelting (ESR) Process Used for the Production of High-Performance Alloys

This paper presents a comprehensive computational model for the prediction of the transient Electroslag Remelting (ESR) process for cylindrical ingots based on axisymmetric two-dimensional 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 for an illustrative ESR process for Alloy 718 and its validation using results from an industrial trial 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 can benefit the optimization of existing process schedules and design of new processes for different alloys and different ingot sizes.