Hot Test and Simulation of ESR Hollow Ingots Formation in Current Supplying Mould with Electrodes Change

A new electroslag remelting (ESR) technology for hollow ingot manufacture was recently commercialized due to the cooperation between Northeastern University of China and Elmet-Roll engineering company (Ukraine). The usage of T-shape current supplying mould (CSM) and ingot withdrawing system as well as the change of consumable multi electrode (electrodes) are the main features of performed process. Using the new process the 20t ESR hollow ingots (hollows) with perfect quality of surfaces and defect-free macrostructure were manufactured. Any visible defects in the external and internal surface of hollow ingot including all areas of electrodes changes were not found. It becomes to be possible due to non-stop supply of electric current via CSM from second transformer. Both the high cleanness and fine as-cast microstructure of hollow ingots were proved. Simulation of slag flow and heat transfer at ESR process was developed by using the ANSYS software. The model has been verified by measuring of geometry of liquid metal pool was revealed in macrostructure of 650/450mm hollow ingots.