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1
Tong, Wenjie, Wanming Li, Ximin Zang, Huabing Li, Zhouhua Jiang, and Dejun Li. "A Comprehensive Mathematical Model of Electroslag Remelting with Two Series-Connected Electrodes Based on Sequential Coupling Simulation Method." Metals 10, no. 5 (May 19, 2020): 658. http://dx.doi.org/10.3390/met10050658.
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A comprehensive mathematical model of electroslag remelting with two series-connected electrodes (TSCE-ESR) was constructed based on sequential coupling method. The influence of droplet effect on electroslag remelting process (ESR) was considered in this model. Compared with one-electrode electroslag remelting (OE-ESR), the multi-physics field, droplet formation and dripping behavior, and molten metal pool structure of TSCE-ESR process were studied. The results show that during the process of TSCE-ESR, the proximity effect of the electrodes suppresses the skin effect, and Joule heat is concentrated in the area between the two electrodes of slag pool, making the temperature distribution of the slag pool more uniform. The heat used to melt the electrode in the process of TSCE-ESR accounts for about 34% of the total Joule heat, which is lower than the OE-ESR (17%). Therefore, it makes a higher melting rate and a smaller droplet size in the process of TSCE-ESR. Compared with OE-ESR, TSCE-ESR process can realize the unification of higher melting rate and shallow flat molten metal pool. Compared with the results without droplet effect, it is found that in the simulation results with droplet effect, the depth and the cylindrical section of molten metal pool increased, and the width of the mushy zone is significantly reduced, which is more consistent with the actual electroslag remelting process.
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Chumanov, I. V., A. N. Anikeev, and D. V. Sergeev. "Studying Influence of Rotation an Electrode on the Number Nonmetallic Inclusions in Received Eletroslag Metal." Materials Science Forum 934 (October 2018): 154–58. http://dx.doi.org/10.4028/www.scientific.net/msf.934.154.
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Quality improvement metal, in particular decrease content nonmetallic inclusions, is very important tasks as mechanical, thermal and anticorrosive characteristics metal depend on it. Electroslag remelting well influences quality on metal: content harmful impurity decreases, metal density increases, nonmetallic inclusions are removed. A method quality improvement metal by means of removal of nonmetallic inclusions at classical electroslag remelting and remelting with rotation electrode it is offered in this article. Also metallographic surveys experimental materials received are given in article which showed that ESR with rotation electrode deletes nonmetallic inclusions for 55-56 % more effectively, than classical remelting.
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Jiang, Zhou Hua, Jia Yu, Fu Bin Liu, Xu Chen, and Xin Geng. "Application of Mathematical Models for Different Electroslag Remelting Processes." High Temperature Materials and Processes 36, no. 4 (April 1, 2017): 411–26. http://dx.doi.org/10.1515/htmp-2016-0146.
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AbstractThe electroslag remelting (ESR) process has been effectively applied to produce high grade special steels and super alloys based on the controllable solidification and chemical refining process. Due to the difficulties of precise measurements in a high temperature environment and the excessive expenses, mathematical models have been more and more attractive in terms of investigating the transport phenomena in ESR process. In this paper, the numerical models for different ESR processes made by our lab in last decade have been introduced. The first topic deals with traditional ESR process predicting the relationship between operating parameters and metallurgical parameters of interest. The second topic is concerning the new ESR technology process including ESR with current-conductive mould (CCM), ESR hollow ingot technology, electroslag casting with liquid metal(ESC LM), and so on. Finally, the numerical simulation of solidification microstructure with multi-scale model is presented, which reveals the formation mechanism of microstructure.
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Shi, Chengbin. "Deoxidation of Electroslag Remelting (ESR) – A Review." ISIJ International 60, no. 6 (June 15, 2020): 1083–96. http://dx.doi.org/10.2355/isijinternational.isijint-2019-661.
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K.M Kelkar, J. Mok, S. V. Patankar, and A. Mitchell. "Computational modeling of electroslag remelting processes." Journal de Physique IV 120 (December 2004): 421–28. http://dx.doi.org/10.1051/jp4:2004120048.
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Alloys used for the production of rotating components in aeroengines and land-based turbines are subject to stringent requirements to ensure absence of melt-related defects such as inclusions and segregation. Accordingly, the production of the superalloys alloys used in these applications involves multiple remelting stages, each of which plays a distinct role in ensuring that the final ingot is defect-free. Because of the complexity of these processes, high-temperature environments, and high initial and operating costs, trial-and-error based approaches for process design are inadequate. Computational modeling provides fundamental understanding of the physical phenomena and quantitative information about the effects of process parameters. Therefore, such models are very useful for design of new processes and optimization of existing processes. The paper describes a generalized framework for the modeling of the Electro-Slag Remelting (ESR) process. The model accounts for electromagnetic, fluid flow and heat transfer phenomena in a coupled manner for axisymmetric, steady-state conditions. A control-volume based computational method is used for the solution of the governing equations. The model incorporates a number of physically motivated computational features for efficient and accurate analysis of the transport processes. These include use of the effective viscosity approach for handling the liquid, mushy, and solid regions, implicit treatment of the interaction at the slag-metal interface, and contact heat transfer at the ingot-mold interface. Further, the computational method has been enhanced to address the AC electromagnetics in the ESR process. Thus, the model is able to predict the Joule heating within the slag, the distribution of the Lorentz force, the pool shape, and the motion in the slag and metal pools that arises due to buoyancy and Lorentz forces. The model is being validated using available experimental measurements for pool shape in full- scale ESR furnaces. Results of the model predictions for the flow, temperature, and electromagnetic fields are presented along with a comparison of the predicted and measured pool shapes.
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Shi, Zhiyue, Wenquan Cao, Chengjia Shang, and Xiaodan Zhang. "Effect of inclusion type on the rotating bending fatigue properties of a high carbon chromium bearing steel." IOP Conference Series: Materials Science and Engineering 1249, no. 1 (July 1, 2022): 012032. http://dx.doi.org/10.1088/1757-899x/1249/1/012032.
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Abstract The use of the double vacuum melting route (conventional second refining + vacuum arc refining, CSR+VAR) and the electroslag remelting route (vacuum induction melting + electroslag remelting, VIM+ESR)) has been investigated for the SAE52100 (100Cr6) bearing steel. The tensile properties, impact toughness, hardness and RCF life of the CSR+VAR steel and the steel prepared using the VIM+ESR route are similar. The number and size of TiN inclusions in the VIM+ESR steel are higher and larger than those in the CSR+VAR steel, providing an explanation for the observation of better fatigue properties for the CSR+VAR steel. Two major types of inclusions, magnesium aluminates/Al2O3-CaO-CaS and TiN, are located in different areas in a map of stress intensity factor versus rotatory bending fatigue cycles (NRBF ). The negative impact of TiN inclusions on fatigue properties are greater than those of magnesium aluminates/Al2O3-CaO-CaS inclusions.
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Jiang, Zhou Hua, and Xin Geng. "Research on the Surface Quality of ESR Large Slab Ingots." Advanced Materials Research 146-147 (October 2010): 670–73. http://dx.doi.org/10.4028/www.scientific.net/amr.146-147.670.
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A special bifilar 40t electroslag remelting(ESR) furnace for slab products has been fabricated to produce heavy plates for special application. The ESR slabs with the maximum thickness of the world in size of 980 mm thickness, 2000 mm wideness and 2800 mm length have been produced successfully. However, the ingots surface quality is a serious problemn in ESR process for large slab ingots, for ingot and mold with a relatively mobile, larger ingot contraction and thicker slag skin. Using CaF2-CaO-Al2O3-SiO2-MgO slag, suited remelting rate, lower filling ration, smooth movement of mold and adjusting taper of the mold and are necessary for improving surface quality of the ESR large slab ingots.
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Stovpchenko, G. P., A. V. Sybir, G. O. Polishko, L. B. Medovar, and Ya V. Gusiev. "Mass Transfer in Electroslag Processes with Consumable Electrode and Liquid Metal." Uspehi Fiziki Metallov 21, no. 4 (December 2020): 481–98. http://dx.doi.org/10.15407/ufm.21.04.481.
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Experimental and numerical comparisons of mass transfer processes during the electroslag remelting with consumable electrode (ESR) and electroslag refining with liquid metal (ESR LM) showed their identical refining capacity, despite the smaller both the slag–metal contact surface (twice) and metal overheat (by 70–95 K) in the latter case. As revealed, due to effect of metal movement inside the liquid metal drop, it moves in liquid slag faster than a solid particle of the same diameter. Under comparable conditions, it is experimentally confirmed that desulphurization at the ESR takes place mainly on the contact surface between the slag and metal baths, but not in the liquid metal film at the tip of a consumable electrode.
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Qi, Yongfeng, Jing Li, Chengbin Shi, Hao Wang, and Dingli Zheng. "Precipitation and growth of MnS inclusion in an austenitic hot-work die steel during ESR solidification process." Metallurgical Research & Technology 116, no. 3 (2019): 322. http://dx.doi.org/10.1051/metal/2018114.
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This study follows a previous presentation of metallurgical results and operating parameters about the comparison between conventional ESR and continuous unidirectional solidification of electroslag remelting (ESR-CDS) and more precisely the effect of cooling rate on the precipitation and growth of inclusions in an austenitic hot-work die steel [Y.F. Qi, J. Li, C.B. Shi, R.M. Geng, J. Zhang, Effect of directional solidification in electroslag remelting on the microstructure and cleanliness of an austenitic hot-work die steel, ISIJ Int. 58, 1275–1284 (2018)]. A thermodynamic study, a classical solidification model and a growth model for MnS inclusions were used orderly to interpret the metallurgical results. Optical microscopy (OM) and scanning electron microscopy (SEM) were used to characterize microstructure and inclusions (i.e. number, size, morphology and distribution) in the as-cast ingots. The results showed that the as-cast microstructure was refined and the dendritic arm spacings were reduced through ESR-CDS process. The characteristics of inclusions showed that the number density and the size of inclusions in ingot were much more reduced through ESR-CDS process in comparison with ESR process. The starting time for the precipitation of MnS inclusion is retarded, which is due to the segregation of elements Mn and S lowered by higher cooling rate in ESR-CDS in comparison with that in ESR. The starting time for the precipitation of MnS inclusion in ESR was fs = 0.92, while that in ESR-CDS was fs = 0.95.
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Wang, Chang Zhou, and Jin Chun Song. "Electrode Feeding Speed Control and Experiment Research of ESR Furnace Based on S Style Control Curve." Advanced Materials Research 619 (December 2012): 480–84. http://dx.doi.org/10.4028/www.scientific.net/amr.619.480.
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The electrode feeding mechanism and the feeding speed control system of the electroslag remelting furnace are studied. The electrode feeding mechanism is designed based on the electro-hydraulic proportional control technique, and the mechanism’s three-dimensional model is established. The electrode feeding mechanism’s electro-hydraulic proportional control system is simulated. The basic feeding speed model and the error-correction feeding speed model are established; and the S style speed control curve of the electrode feeding system is designed. Experiments were carried out; the system control curves and the experimental production dissection results were obtained. It was found that, the electrode feeding system and the feeding speed control system studied in this paper met the craft procedure and technique requirements of large electroslag remelting furnace, and the method’s validity was verified.
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Wang, Chang Zhou, Xi Liang Liu, Jin Chun Song, and Zhi Wei Zhang. "Dynamic Research of the Split-Pillar Rotation Process for Electroslag Remelting Furnace." Applied Mechanics and Materials 52-54 (March 2011): 959–63. http://dx.doi.org/10.4028/www.scientific.net/amm.52-54.959.
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Electroslag Remelting (ESR) technology is a main method of special metallurgy; and split pillar is one of the most important mechanical units of ESR. The split pillar works not only as the mother body of ESR cross arm, but also as the rotation driving device of the cross arm. Since the tremendous mass of the cross arm and electrodes, serious inertia torque generates when the split pillar rotates, which leads to motion instability and problems of angle location and even safety threatens. In this paper, based on virtual machine technology, dynamic research of the rotation process of the electroslag-remelting-furnace split pillar was proceeded; influences of driving torque applied on the split pillar was researched, as the driving torque being constant, anti-step and with brake torque. 3D solid model of the split pillar and clamping device were established; main technical parameters were accomplished; and simulation research of the dynamic process was proceeded. It was found that, appropriate brake torque was important to better motion stability of the split pillar. The best brake torque was acquired, and the action time of the brake torque was obtained.
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Campbell, John. "A Future for Vacuum Arc Remelting and Electroslag Remelting—A Critical Perspective." Metals 13, no. 10 (September 23, 2023): 1634. http://dx.doi.org/10.3390/met13101634.
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In the secondary metals refining processes, vacuum arc remelting (VAR) and electroslag remelting (ESR), the consumable electrode is commonly produced by vacuum induction melting (VIM) which employs the regrettably primitive casting technique of simply pouring into the open top of the mold. Despite the vacuum, the resulting oxidizing conditions and the immensely powerful turbulence accompanying the top-pouring of the electrode is now known to create a substantial density of serious cracks. The cracks in the cast electrode are bifilms (double oxide films), which in turn are proposed to be responsible for the major faults of the VAR ingot, including undetectable, horizontal macroscopic cracks, white spots (clean and dirty varieties) and in-fallen crown. The remedial action to solve all these issues at a stroke is the provision of a counter-gravity cast electrode, cast in air or vacuum, or provision of any similar electrode substantially free from bifilm defects. The ESR process is also described, explaining the reasons for its significantly reduced sensitivity to the top-poured VIM electrode, but indicating that with an improved electrode, this already nearly reliable process has the potential for perfect reliability. The target of this critical overview is an assessment of the potential of these secondary refining processes to produce, for the first time, effectively defect-free metals, metals we can trust.
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Ju, Jiantao, Zhihong Zhu, Yue Gu, Kangshuai Yang, and Qiming Zhang. "Evolution of Inclusions in Incoloy825 during Electroslag Remelting." Metals 12, no. 2 (January 22, 2022): 208. http://dx.doi.org/10.3390/met12020208.
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Fifty kilogram-scale electroslag remelting (ESR) experiments using slag with different TiO2 contents in an electroslag furnace were performed to investigate the size, amount and types of inclusions in an electrode and remelted ingots. The results show that the contents of aluminum and titanium increased and decreased, respectively, compared to those in a consumable electrode. The inclusions in the consumable electrode were TiS, TiN and Al2O3 surrounded by a TiN layer, and the inclusions in the remelted ingots were TiN, MgO-Al2O3 and MgO-Al2O3 surrounded by a TiN layer. With the increase in the height of the ingots, the average size of inclusions increased from 2.5 to 4.4 μm. Increasing the TiO2 content in the slag promoted the formation of MgO-Al2O3 and made the inclusions larger in the remelted ingots. To make the size of inclusions in remelted ingots of Incoloy825 smaller, the TiO2 in the slag should be decreased. The TiS in the electrode was removed during ESR. Part of the TiN dissociated during the reaction between the liquid metal and slag by molten slag, and most of the TiN inclusions originated from the consumable electrode. The Al2O3 inclusions surrounded by a TiN layer in the consumable electrode were finally transformed to MgO-Al2O3 and MgO-Al2O3 surrounded by a TiN layer in the remelted ingots.
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Gao, Xiaoyong, Lin Zhang, Xuanhui Qu, Yifeng Luan, and Xiaowei Chen. "Effect of CeO2 addition in the slag on inclusions of FGH96 superalloy during electroslag remelting." Metallurgical Research & Technology 117, no. 5 (2020): 501. http://dx.doi.org/10.1051/metal/2020041.
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The FGH96 superalloy was electroslag remelted by utilizing CeO2 containing slag. CeO2/Al2O3 ratio and atmosphere are found to be the main factors that control the oxide inclusion contents during electroslag remelting (ESR). The reaction between CeO2 in the molten slag and Al in the molten alloy leads to the increased dissolved Ce in the molten alloy, which is effective to remove oxide inclusions. Dissolved Ce reacts with MgO in the inclusions, leading to the transformation of Al2O3–MgO inclusion in the electrode to Al2O3–MgO–Ce2O3 and Al2O3–Ce2O3 inclusions in the ESR ingot. In case of low CeO2/Al2O3 ratio of 0.263, oxygen content decreases to as low as 8 ppm after ESR under vacuum, and the number density of oxide inclusion decreased by an order of magnitude in comparison to the electrode. In case of high CeO2/Al2O3 ratio of 5.0, oxygen content decreases further to 6 ppm no matter what the condition is.
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L, Medovar, Polishko G, Petrenko V, and Stovpchenko G. "Modern electroslag technologies of electrode remelting and processing of liquid metal (review)." 2,2020 (125) 2,2020, no. 2,2020 (125) (March 2020): 17–25. http://dx.doi.org/10.34185/tpm.2.2020.03.
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Objective. The results of the analysis of advanced technologies of electroslag remelting are presented. Results It is shown that ESR today is the main and most challenging in obtaining of high quality metal. Protection of the melting chamber and the electrode from the atmosphere by inert gas (IESR) or melting under pressure (PESR) prevents oxidation, which is especially important during remelting of the steels and alloys with high content of easily oxidizable elements. Refusal to use a consumable electrode in the classical ESR in favor of liquid metal, provided by the use of current-suppling mold, is an effective solution to the problem of its manufacture (manufacturing price reaches 40-60% of the cost of ingot production, and in some cases impossible) and reduce energy costs. Scientific novelty. During ESR LM, there is a decrease in temperature of slag and overheating of metal in comparison with classical ESR , the volume of liquid metal bath decreases that followed by improving conditions of ingot formation, at the expense of decrease in development of segregation processes and gives the chance to receive metal of homogeneous composition and structure. Practical significance. The advantages of the new ESR processes are a wide variation of the metal feed rate, less metal overheating and a flat bath, which provides molding with a homogeneous and defect-free internal structure and a smooth surface.
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Karimi-Sibaki, Ebrahim, Abdellah Kharicha, Menghuai Wu, Andreas Ludwig, and Jan Bohacek. "Toward Modeling of Electrochemical Reactions during Electroslag Remelting (ESR) Process." steel research international 88, no. 5 (March 17, 2017): 1700011. http://dx.doi.org/10.1002/srin.201700011.
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Alekseev, I. A., I. V. Chumanov, and D. V. Sergeev. "Development of technology for ingots production using electroslag remelting at direct current with consumable electrode rotation." Izvestiya. Ferrous Metallurgy 66, no. 5 (November 11, 2023): 623–30. http://dx.doi.org/10.17073/0368-0797-2023-5-623-630.
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The paper describes the problem of increasing the productivity of electroslag remelting (ESR) furnaces. The remelting technology on direct current is proposed as the most effective method. The description of the technology touches upon positive and negative effects affecting the specific productivity of smelting, energy consumption, and quality of the obtained ingots in terms of their physical and mechanical properties and chemical purity. The authors proposed the electroslag remelting method with rotation of the consumable electrode as a new technology, and realized a brief comparison with the external magnetic field application technology. The schemes that clearly demonstrate the principle of controlling the crystallization front shape and the thermal center localization in the slag bath are considered. A stationary numerical model for the slag bath of the operating semi-industrial furnace ESR A-550 on direct current with polarity reversing ability was developed. The mathematical apparatus consisting of electrothermal, hydrodynamic and convective parts was constructed. The authors designed the mesh domain for a slag bath located between the consumable electrode and the water-cooled crystallizer with diameters of 60 and 90 mm, respectively. The height of the sub-electrode zone is 10 mm. The current limit is 800 A and the voltage is 46 V. Numerical fields of current density and temperature distribution in the slag bath volume are obtained. The range of temperature values is located in the range from 1400 to 2200 °C at the peripheral and subelectrode zones of the slag bath, respectively. The scheme of the ESR furnace modernization is given in terms of mechanical part automation and transferring to direct current.
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Vlasov, Anatolii F., Nataliia A. Makarenko, Hanna M. Kushchii, and Denys M. Holub. "The Sectors Workpieces and Drum Reel’s Die Cubes Electroslag Casting with Exothermic Electrical Conductive Fluxes." Solid State Phenomena 313 (January 2021): 118–26. http://dx.doi.org/10.4028/www.scientific.net/ssp.313.118.
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It has been established that the developed method of manufacturing workpieces for the sectors of the drums of X20CrMoWV3 steel reel’s and die cubes from X5CrNiMo steel using a solid start and exothermic flux significantly reduces the complexity of their manufacture. The cast reel’s drum sectors workpieces and die cubes, obtained by the electroslag remelting (ESR) method, had a smooth surface without corrugations, sinkers, and slag inclusions. Heat treatment provides the required mechanical properties and the absence of flocs in the cast electroslag metal. An effective way to increase the performance of electroslag processes is using the exothermic flux, which contain scale, ferroalloys, aluminum powder and standard flux (welding flux ISO 14174 – S F AF3, etc.) in quantities sufficient for the exothermic reactions to occur, which ensures the generation of additional heat in the starting period of electroslag processes and contributes to the accelerated induction of the slag bath of the required volume at the “solid” start both monofilar and bifilar schemes of conducting the process instead of the “liquid” start. Electroslag processes using an exothermic alloyed flux on a “hard” start allow to obtain (compared to existing methods of slag bath formation) an increasing in the output of a suitable metal 2...10 %; saving on melting 1 kg of standard flux 1.2...1.4 kW h; reducing of the starting time of the ESR process to 25 %.
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Vlasov, Anatolii F., Nataliia A. Makarenko, Hanna M. Kushchii, and Denys M. Holub. "The Sectors Workpieces and Drum Reel’s Die Cubes Electroslag Casting with Exothermic Electrical Conductive Fluxes." Solid State Phenomena 313 (January 2021): 118–26. http://dx.doi.org/10.4028/www.scientific.net/ssp.313.118.
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It has been established that the developed method of manufacturing workpieces for the sectors of the drums of X20CrMoWV3 steel reel’s and die cubes from X5CrNiMo steel using a solid start and exothermic flux significantly reduces the complexity of their manufacture. The cast reel’s drum sectors workpieces and die cubes, obtained by the electroslag remelting (ESR) method, had a smooth surface without corrugations, sinkers, and slag inclusions. Heat treatment provides the required mechanical properties and the absence of flocs in the cast electroslag metal. An effective way to increase the performance of electroslag processes is using the exothermic flux, which contain scale, ferroalloys, aluminum powder and standard flux (welding flux ISO 14174 – S F AF3, etc.) in quantities sufficient for the exothermic reactions to occur, which ensures the generation of additional heat in the starting period of electroslag processes and contributes to the accelerated induction of the slag bath of the required volume at the “solid” start both monofilar and bifilar schemes of conducting the process instead of the “liquid” start. Electroslag processes using an exothermic alloyed flux on a “hard” start allow to obtain (compared to existing methods of slag bath formation) an increasing in the output of a suitable metal 2...10 %; saving on melting 1 kg of standard flux 1.2...1.4 kW h; reducing of the starting time of the ESR process to 25 %.
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Peng, Leizhen, Zhouhua Jiang, and Xin Geng. "Design of ESR Slag for Remelting 9CrMoCoB Steel under Simple Protective Ar Gas." Metals 9, no. 12 (December 2, 2019): 1300. http://dx.doi.org/10.3390/met9121300.
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Thermodynamic calculations by using Factsage 7.3 and simple protective gas electroslag remelting (ESR) experiments were conducted to design the appropriate ESR slag for remelting the qualified 9CrMoCoB ingot. First, the proper basic slag was determined based on the phase diagram of CaF2–CaO–Al2O3–x%MgO calculated using Factsage 7.3. Second, equilibrium reactions between 9CrMoCoB and the basic slag containing varied SiO2, and B2O3 contents were calculated to study the effects of B2O3 and SiO2 on B, Si, and Al contents in steel. Then, equilibrium reaction experiments were conducted to validate the calculated results. Finally, the appropriate slags were attained and the simple protective Ar gas ESR experiments were conducted to make a verification. Results showed that the liquid phase region of the slag of CaF2–CaO–Al2O3–x%MgO at 1300–1400 °C increased first, then decreased with the MgO addition. With the B2O3 content increasing, the boron content increased, while the Si, Al contents decreased, and at a given B2O3 addition, the B and Al contents decreased with the SiO2 content increasing, whereas the Si content increased. The appropriate slags for simple protective gas ESR remelting 9CrMoCoB were 55%CaF2–20%CaO–3%MgO–22%Al2O3–2%SiO2–1.3%B2O3 and 55%CaF2–20%CaO–3%MgO–22%Al2O3–3%SiO2–1.7%B2O3.
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Geng, Xin, Zhou-Hua Jiang, and Fu-Bin Liu. "Numerical Investigation on Solidification Behavior of Slab Ingot during Electroslag Remelting Process." Processes 11, no. 7 (July 13, 2023): 2085. http://dx.doi.org/10.3390/pr11072085.
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In the process of electroslag remelting (ESR) for large-sized slab ingots, controlling the surface quality of the slab ingot is challenging due to its relatively high width-to-thickness ratio. In this study, a three-dimensional dynamic mathematical model for single-electrode ESR slab ingots was developed using dynamic mesh technology, with the aid of the commercial software FLUENT. The model is based on the electromagnetic field equation, flow field equation, and energy equation. A detailed analysis of various physical fields and the distribution law of the metal pool shape was conducted. According to the calculation results, the maximum flow velocity of the molten slag was found below the consumable electrode, with the range of maximum velocity at different time points varying between 4.35 × 10−2 and 4.88 × 10−2 m/s. The range of the maximum temperature for the slag bath at different time points was between 2118 and 2122 K. As the remelting continued, the impact of the forced cooling of the bottom plate on the temperature of the metal pool weakened. Consequently, the temperature gradient of the electroslag ingot gradually decreased, the depth of the metal pool increased, and the height of the metal liquid head in the metal pool rose. The effects of different voltages, filling ratios, and mold chamfers on the shape of the metal pool were investigated using the established mathematical model. Based on the research findings from the mathematical model, the technical processes for ESR J80 large-sized slab ingots were improved, providing solutions to improve the surface quality of the ESR large-sized slab ingots.
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Ali, M., D. Porter, J. Kömi, E. P. Heikkinen, M. Eissa, Faramawy El, and T. Mattar. "The effect of electroslag remelting on the cleanliness of CrNiMoWMnV ultrahigh-strength steels." Journal of Mining and Metallurgy, Section B: Metallurgy 55, no. 3 (2019): 381–95. http://dx.doi.org/10.2298/jmmb190211042a.
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The cleanliness of ultrahigh-strength steels (UHSSs) without and with electroslag remelting (ESR) using a slag with the composition of 70% CaF2, 15% Al2O3, and 15% CaO was studied. Three experimental heats of UHSSs with different chemical compositions were designed, melted in an induction furnace, and refined using ESR. Cast ingots were forged at temperatures between 1100 and 950?C, air cooled, and their non-metallic inclusions (NMIs) were characterized using field emission scanning electron microscopy and laser scanning confocal microscopy. Thermodynamic calculations for the expected NMIs formed in the investigated steels with and without ESR were performed using FactSage 7.2 software while HSC Chemistry version 9.6.1 was used to calculate the standard Gibbs free energies (?G?). As a result of ESR the total impurity levels (TIL% = O% + N% + S%) and NMI contents decreased by as much as 46 % and 62 %, respectively. The NMIs were classified into four major classes: oxides, sulphides, nitrides, and complex multiphase inclusions. ESR brings about large changes in the area percentages, number densities, maximum equivalent circle diameters, and the chemical composition of the various NMIs. Most MnS inclusions were removed although some were re-precipitated on oxide or nitride inclusions leading to multiphase inclusions with an oxide or nitride core surrounded by sulphide, e.g. (MnS.Al2O3) and (MnS. TiN). Also, some sulphides are modified by Ca forming (CaMn)S and CaS.Al2O3. Some nitrides like TiN and (TiV)N are nucleated and precipitated during the solidification phase. Al2O3 inclusions were formed as a result of the addition of Al as a deoxidant to the ESR slag to prevent penetration of oxygen to the molten steel.
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Ju, Jiantao, Qidi Li, Zhihong Zhu, Kangshuai Yang, and Yue Gu. "Kinetic study of control of alloy elements during electroslag remelting of Incoloy825." Metallurgical Research & Technology 119, no. 4 (2022): 418. http://dx.doi.org/10.1051/metal/2022047.
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The present study was motivated to reveal the oxidation mechanism of Al, Ti and Si elements during electroslag remelting (ESR) and propose methods to control them. Three small-scale ESR experiments were carried out with Incoloy 825 alloy as consumable electrode and three groups of slags with different TiO2 contents as raw materials. A kinetic model of slag-steel reaction was established based on ions and molecules coexistence theory (IMCT), film theory and penetration theory. The results show that Al and Si contents increase compared to that of the electrode but Ti content decreases. The increase of Al and the loss of Ti decrease with the increase of TiO2 in slag. The calculated values of the model are in good agreement with the experimental values. In the early stage of ESR process, FeO content increases apparently, so it is more effective to control oxidation in order to obtain uniform ingot. The restricted link of the reaction in the mass transfer of Al + Al2O3, Si + SiO2 and Ti + TiO2 is on the metal side, on the slag side and both sides, respectively. When TiO2 content in slag is lower than 12%, TiO2 addition is more effective. When TiO2 content is higher, adding Al deoxidizer is more effective to control Al and Ti contents.
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Schneider, Reinhold S. E., Manuel Molnar, Gerald Klösch, and Christopher Schüller. "Effect of the Al2O3 Content in the Slag on the Chemical Reactions and Nonmetallic Inclusions during Electroslag Remelting." Metallurgical and Materials Transactions B 51, no. 5 (July 6, 2020): 1904–11. http://dx.doi.org/10.1007/s11663-020-01896-8.
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Abstract The service life of roller bearings is extremely sensitive to large and hard nonmetallic inclusions (NMIs), requesting the highest standards in their production. To determine the metallurgical possibilities, the effect of Al2O3 contents between 0 and 33 pct in the remelting slag was investigated by remelting a roller bearing steel in an experimental electroslag remelting (ESR) plant. Thereby, changes in the chemical composition of the materials (electrode vs ingots) and in the remelting slag during remelting, as well as the amount and composition of the NMIs prior to and after remelting, were investigated. Changes in the chemical composition can largely be explained by equilibrium reactions between the slag and the metal, thereby low Al contents in the remelted materials could only be achieved with the lowest Al2O3 contents in the slag. Furthermore, higher Al2O3 contents in the slag also lead to higher oxygen and sulfur contents in the steel as well as higher amounts of NMIs after remelting. The composition of the NMIs changed from alumina type for high Al2O3 contents to spinel type and other mixed MgO-SiO2 oxides for low Al2O3 contents. The results indicate solutions for the production of bearing steels with the lowest amounts of undesired large and hard NMIs.
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Yan, Wei, Yang Zhang, Weiqing Chen, and Jing Li. "Characteristics and Formation Tendency of Freckle Segregation in Electroslag Remelted Bearing Steel." Metals 10, no. 2 (February 12, 2020): 246. http://dx.doi.org/10.3390/met10020246.
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Undesirable macro segregation defects, freckles, restrict the commercial production of large-sized electroslag remelting (ESR) bearing steel ingots through degradation of the mechanical properties and service lifetime. In order to clarify the freckle characteristics and formation tendency as well as the formation mechanism, freckles from an industrial large-sized GCr15SiMn ESR ingot were investigated through structural and compositional analysis, along with simulation calculation. The results show that freckles consist of (Si, Mn, Cr)-enriched equiaxed grains and occur in about the 1/2 radius region at the middle-upper part of the ESR ingot, where the secondary dendritic arm spacing (SDAS) and solidification front angle are large but cooling rate is small. The absolute value of relative Rayleigh number, Ra, also reaches its maximum in the 1/2 radius region, with a liquid fraction of 0.3–0.5, corresponding to the region where freckles form. Based on the experimental and simulation results, to evaluate the freckle formation in industrial-scale GCr15SiMn ESR ingots, the threshold value of relative Ra, a freckle criterion considering the compositional and thermal effects, was determined to be about −0.023.
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Li, Shijian, Guoguang Cheng, Yu Huang, Weixing Dai, and Zhiqi Miao. "Kinetics of Phosphorus Transfer during Industrial Electroslag Remelting of G20CrNi2Mo Bearing Steel." Metals 9, no. 4 (April 22, 2019): 467. http://dx.doi.org/10.3390/met9040467.
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Phosphorus is undesirable in steel for it greatly decreases ductility and causes embrittlement in most cases. The kinetic behavior of phosphorus transfer was investigated during electroslag remelting (ESR) of G20CrNi2Mo bearing steel. Four heat treatments were carried out using an industrial furnace with a capacity to refine 2400 kg ingot. It was found the P content in the four ingots were all higher than that in the electrodes, indicating rephosphorization occurs during ESR. A kinetic model based on film and penetration theory was developed to elucidate the variation of phosphorus from metal film to droplet and metal pool. The model indicates that the rate-determining step of phosphorus transfer is at the slag side. Rephosphorization mainly occurs in the metal film and falling droplet. In addition, the effect of P in the slag and electrode, as well as the temperature of the slag pool on the P content in the metal pool were discussed. In order to achieve a low-P ingot of no more than 0.015%, the corresponding maximum P content in slag under the condition of a certain P content in the electrode was proposed.
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Shi, Xiaofang, Lizhong Chang, and Jianjun Wang. "Effect of Ultrasonic Treatment on Solidification Quality of ESR Ingots." High Temperature Materials and Processes 35, no. 5 (May 1, 2016): 449–56. http://dx.doi.org/10.1515/htmp-2015-0016.
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AbstractA novel electroslag furnace with the ultrasonic treatment was fabricated in this study. The effect of ultrasonic treatment on the compact density and segregation degree of alloys were studied. Results show that the distribution of carbon, silicon, manganese, chromium and phosphorus become uniform with increase of the ultrasonic power when the ultrasonic power is between 0 and 700 W. But when the ultrasonic power increases to 1,000 W, segregation of alloy elements increases instead. The reasonable ultrasonic power is favorable for improvement of compact density of electroslag remelting (ESR) ingots. When the ultrasonic power increases to 700 W from 0, compact density of ESR ingots increases to 0.9618 from 0.9479 and decreases to 0.9517 when the ultrasonic power increases to 1,000 W. This occurrence is attributed to the cavitation and acoustic flows effect of the ultrasonic which break off the dendritic crystal in the mushy zone and increase crystal nucleus. At the same time, the heat transfer and mass transfer are accelerated which make the distribution of temperature and alloying element more homogeneous. But the excessive ultrasonic power is not conducive to the improvement of solidification structure.
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Wang, Xijie, Guangqiang Li, Yu Liu, Yulong Cao, Fang Wang, and Qiang Wang. "Investigation of Primary Carbides in a Commercial-Sized Electroslag Remelting Ingot of H13 Steel." Metals 9, no. 12 (November 21, 2019): 1247. http://dx.doi.org/10.3390/met9121247.
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The characteristics of primary carbides in a commercial-sized (one ton) electroslag remelting (ESR) ingot of AISI H13 steel were investigated. The interaction between the primary carbides and inclusions was also clarified. The results indicate that there are two types of primary carbides, V-rich and Mo-rich primary carbides, in the H13 ESR ingot. The quantity, the area fraction, and the size of the two primary carbides tend to decrease from the center of the H13 ESR ingot to the outer surface. Additionally, the V-rich primary carbide is obviously larger than the Mo-rich primary carbide. The Al2O3 inclusion can promote the precipitation of the V-rich primary carbide, while the MnS inclusion encourages the precipitation of Mo-rich primary carbide. The CaO∙Al2O3 inclusion cannot act as the nucleation site for the precipitation of the two primary carbides. The solid fraction that the V-rich primary carbide begins to precipitate ranges from 0.965 to 0.983, and that for the Mo-rich primary carbide and the MnS inclusion change from 0.9990 to 0.9998 and from 0.989 to 0.990, respectively.
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Ali, Mohammed, David Porter, Jukka Kömi, Mamdouh Eissa, Hoda El Faramawy, and Taha Mattar. "The Effect of Electroslag Remelting on the Microstructure and Mechanical Properties of CrNiMoWMnV Ultrahigh-Strength Steels." Metals 10, no. 2 (February 17, 2020): 262. http://dx.doi.org/10.3390/met10020262.
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The effect of electroslag remelting (ESR) with CaF2-based synthetic slag on the microstructure and mechanical properties of three as-quenched martensitic/martensitic-bainitic ultrahigh-strength steels with tensile strengths in the range of 1250–2000 MPa was investigated. Ingots were produced both without ESR, using induction furnace melting and casting, and with subsequent ESR. The cast ingots were forged at temperatures between 1100 and 950 °C and air cooled. Final microstructures were investigated using laser scanning confocal microscopy, field emission scanning electron microscopy, electron backscatter diffraction, electron probe microanalysis, X-ray diffraction, color etching, and micro-hardness measurements. Mechanical properties were investigated through measurement of hardness, tensile properties and Charpy-V impact toughness. The microstructures of the investigated steels were mainly auto-tempered martensite in addition to small fractions of retained austenite and bainite. Due to the consequences of subtle modifications in chemical composition, ESR had a considerable impact on the final microstructural features: Prior austenite grain, effective martensite grain, and lath sizes were refined by up to 52%, 38%, and 28%, respectively. Moreover, the 95th percentiles in the cumulative size distribution of the precipitates decreased by up to 18%. However, ESR had little, if any, the effect on microsegregation. The variable effects of ESR on mechanical properties and how they depend on the initial steel composition are discussed.
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Tong, Wenjie, Wanming Li, Ximin Zang, Huabing Li, Zhouhua Jiang, and Yu Han. "Droplet Formation and Dripping Behavior during the Electroslag Remelting Process with Two Series-Connected Electrodes." Metals 10, no. 3 (March 18, 2020): 386. http://dx.doi.org/10.3390/met10030386.
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The formation and dripping behavior of droplets in the process of the electroslag remelting with two series-connected electrodes (TSCE-ESR) has an important influence on the optimization of power supply parameters and the purity of the electroslag ingot. In this article, through numerical simulation based on the VOF (volume of fluid) model, combined with the transparent experimental device for physical simulation, the mechanism of metal droplet formation and the effect of the filling rate on its droplet behavior were studied. The results showed that the proximity effect, instead of the skin effect, is a major factor influencing droplet formation in TSCE-ESR process. The proximity effect makes the region inside the two electrode tip melt first, and the molten steel converges at the electrode tips to form a droplet source. The process of droplet formation and dropping can be divided into three stages: formation of molten layer, droplet stretching and necking, and detachment. In the stage of droplet stretching and necking, the increase in the contact area between the droplet and the slag and the instantaneous increase of the current provide good thermodynamic and dynamic conditions for the removal of non-metallic inclusions. After the droplet drops into the slag pool, it promotes the flow of slag and improves the heat and mass transfer efficiency of the slag/metal interface. The relatively large filling rate can form smaller and dispersed droplets, which improves the refining effect. At the same time, the increase of the filling rate can improve the input power and the electrode remelting rate.
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Liang, Qiang, Xi Chun Chen, Hao Ren, Cheng Bin Shi, and Han Jie Guo. "Numerical Simulation of Electroslag Remelting Process for Producing GH4169 under Different Current Frequency." Advanced Materials Research 482-484 (February 2012): 1556–65. http://dx.doi.org/10.4028/www.scientific.net/amr.482-484.1556.
Full textAbstract:
A comprehensive analysis of the physical processes that occur in Electroslag Remelting (ESR) process under steady state conditions and axisymmetric was performed using the simulation software MeltFlow. The detailed plots of current distribution, volumetric heating, flow, temperature and turbulent mixing provide insight into the various physical phenomena that occur in ESR process. The effect of current frequency on various physical fields was analyzed. It is shown that, the current in the slag tends to become more uniform due to the low electrical conductivity of the slag; after the current enters the ingot, the skin effect increases with the increase of the current frequency; the Joule heating and the Lorentz force are highest near the tip of the electrode in the slag, and increase with the increase of the current frequency; the velocities in the slag are slightly higher than those in the molten metal pool; with the increase of the current frequency, the liquidus temperature moves down, and the molten metal pool is deepened. Simulation results agree well with experimental results. Therefore, the generation and extent of defects could be predicted in different process.
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Peng, Leizhen, Zhouhua Jiang, Xin Geng, Fubin Liu, and Huabing Li. "Effect of B2O3 on the Crystallization Behavior of CaF2-Based Slag for Electroslag Remelting 9CrMoCoB Steel." Metals 9, no. 12 (December 10, 2019): 1331. http://dx.doi.org/10.3390/met9121331.
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The non-isothermal crystallization characteristics of the electroslag remelting (ESR)-type slag with varied B2O3 contents were investigated by non-isothermal differential scanning calorimetry (DSC), field emission scanning electron microscopy (SEM-EDS), and X-ray diffraction (XRD). The crystallization mechanism of the B2O3-bearing slag was also identified based on kinetics analysis. The results showed that the primary crystalline phase was CaF2, there was no change in the type of the primary crystal as B2O3 content increased, and the morphology of the CaF2 crystal was mainly dendritic. The sequence of crystal precipitation during the cooling process was CaF2 to Ca12Al14O32F2 and MgO/MgAl2O4, followed by Ca3B2O6. The activation energy of CaF2 crystallization increased firstly, then decreased and reached stability, while the activation energy of Ca3B2O6 crystallization increased continuously with the increasing B2O3 content. The crystallization behavior of CaF2 was three-dimensional growth with a constant nucleation rate. The proper B2O3 content added into the CaF2-based ESR slag should be around 1.0% to limit the precipitation of the CaF2 crystal to attain good surface ingot quality and stable ESR operation.
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Medovar, Lev, Ganna Stovpchenko, Artem Sybir, Jianjun Gao, Liguo Ren, and Dmytro Kolomiets. "Electroslag Hollow Ingots for Nuclear and Petrochemical Pressure Vessels and Pipes." Metals 13, no. 7 (July 18, 2023): 1290. http://dx.doi.org/10.3390/met13071290.
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The paper presents ground reasoning and results of experiments and modeling of heavy hollow ingot manufacturing using advanced electroslag technology. The requirements for ingots for huge diameter reactor pressure vessels include high density, homogeneity, and minimal segregation, which are very difficult to achieve by traditional casting. In the electroslag remelting process (ESR), hollow ingots form in between two copper water-cooled molds under effective heat removal. This improves the solidification pattern due to the shortening of a solidifying volume thickness more than twice compared with a solid ingot of the same diameter. The shallow liquid metal pool and narrow mushy zone at the ESR hollow ingot solidification assure their high metallurgical quality. Due to the dense and low segregation structure, ESR hollow ingots proved to be used for as-cast pipes and heavy wall billets for further forging. The results of a mathematical simulation within the range of simulated dimensions (the outer diameter up to 2900 mm, wall thickness up to 750 mm) also predict the favorable solidification pattern for thick-wall hollow ingots of big diameters. The analysis made and the modeling results provide a framework for scaling up the sizes of hollow ingots produced by ESR and widening their application for manufacturing heavy wall large diameter shells for nuclear and petrochemical industries. The higher reachable productivity of hollow ingot formation and lower capacity of power supply source than that for solid ingots of the same diameter and weight are also preconditions of their energy saving and cost-effective manufacturing.
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Karimi-Sibaki, E., A. Kharicha, A. Vakhrushev, M. Wu, A. Ludwig, and J. Bohacek. "Investigation of effect of electrode polarity on electrochemistry and magnetohydrodynamics using tertiary current distribution in electroslag remelting process." Journal of Iron and Steel Research International 28, no. 12 (December 2021): 1551–61. http://dx.doi.org/10.1007/s42243-021-00686-z.
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AbstractTransport phenomena including the electromagnetic, concentration of ions, flow, and thermal fields in the electroslag remelting (ESR) process made of slag, electrode, air, mold, and melt pool are computed considering tertiary current distribution. Nernst–Planck equations are solved in the bulk of slag, and faradaic reactions are regarded at the metal–slag interface. Aiming at exploring electrochemical effects on the behavior of the ESR process, the calculated field structures are compared with those obtained using the classical ohmic approach, namely, primary current distribution whereby variations in concentrations of ions and faradaic reactions are ignored. Also, the influence of the earth magnetic field on magnetohydrodynamics in the melt pool and slag is considered. The impact of the polarity of electrode, whether positive, also known as direct current reverse polarity (DCRP), or negative, as known as direct current straight polarity (DCSP), on the transport of oxygen to the ingot of ESR is investigated. The obtained modeling results enabled us to explain the experimental observation of higher oxygen content in DCSP than that of DCRP operated ESR process.
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Liu, Yang, Jing Li, Wei Liang, Jiawei Gao, Yongfeng Qi, and Chengjia Shang. "Precipitation Behaviors of Carbides in High Speed Steel during ESR and Heat Treatment." Metals 11, no. 11 (November 5, 2021): 1781. http://dx.doi.org/10.3390/met11111781.
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The microstructure and carbides evolution of high-speed steel after electroslag remelting and solution treatment were studied. The thermodynamic precipitation mechanism of carbides in solid phase was discussed and the characteristic parameters of carbides in different processes were also investigated. The results show that there were large lamellar and fibrous Mo2C and a small amount of VC in the ESR ingot. Mo2C are metastable carbides, which can be decomposed into VC and Fe2Mo4C during the solution treatment. The average diameter of the carbides is reduced to 1.28 μm and the space distance is reduced to 3.23 μm after forging and hot rolling, which means carbides are completely spheroidal and dispersed in matrix.
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Karimi-Sibaki, Ebrahim, Abdellah Kharicha, J. Korp, Meng Huai Wu, and Andreas Ludwig. "Influence of Crystal Morphological Parameters on the Solidification of ESR Ingot." Materials Science Forum 790-791 (May 2014): 396–401. http://dx.doi.org/10.4028/www.scientific.net/msf.790-791.396.
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Electroslag remelting (ESR) is an advanced process to produce high quality steel. During the ESR process, the steel electrode is melted and then solidified directionally in a water-cooled mold. The quality of the ingot is strongly dependent on the shape of melt pool, i.e. the depth and thickness of mushy zone, which is in turn influenced by the bulk and interdendritic flow. Here, we perform a numerical study to investigate the effect of crystal morphological parameter such as primary dendrite arm spacing on the solidification of the ESR ingot ( 750 mm). The crystal morphology is dominantly columnar and dendritic, thus a mixture enthalpy-based solidification model is used. Accordingly the mushy zone is considered as a porous media where the interdendritic flow is calculated based on the permeability. The permeability is determined as function of the liquid fraction and primary dendrite arm spacing according to Heinrich and Poirier [Comptes Rendus Mecanique, 2004, pp. 429-44]. The modeling results were verified against experimental results.
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Liu, Xingyu, Guotao Zhou, Yangyang Shen, Wei Yan, and Jing Li. "Numerical Investigation on the Electroslag Remelting of High Carbon Martensitic Stainless Steels." Metals 13, no. 3 (February 26, 2023): 482. http://dx.doi.org/10.3390/met13030482.
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Control of solidification structure and segregation is crucial to improve the service performance of high carbon martensitic stainless steels. Design of the electroslag remelting (ESR) process based on the essential parameters of melting rate, filling ratio, and slag thickness is a precondition to achieve optimal control of solidification structure and segregation of the steels. However, there is still a lack of coupled works giving deep insight into the overall effect of the parameters on the expected control. With this background, a 2D numerical model was established to probe into the effect of process parameters. The results showed that: (1) With the increase of melting rate from 90 kg/h to 180 kg/h, the molten metal pool depth increased by about 4 cm. Meanwhile, the center LST, PDAS, and SDAS increased by about 450 s, 100 μm, and 12 μm. The segregation index of C and Cr increased by about 0.15 and 0.09. (2) As the filling ratio increased from 0.16 to 0.43, the depth of the metal pool decreased by about 4.5 cm, LST and SDAS received a slight increase of about 41 s and less than 5 μm, but PDAS had little change. The segregation index of C had an increase of about 0.03, but the segregation index of Cr demonstrated tiny changes. (3) As the slag thickness increased from 0.08 to 0.14 m, the metal pool depth presented a first increase of about 1 cm and then a slight decrease. The center LST, PDAS, and SDAS first increased by 148 s, 30 μm, and 4 μm and then decreased slightly. The changes of the segregation index of C and Cr presented a similar tendency than that of LST, but the changes are extremely small. (4) A low melting rate less than 120 kg/h, a filling ratio of about 0.23–0.33, and a slag thickness of 0.08–0.10 m were appropriate to obtain good performance for ESR of high carbon stainless steels in this study.
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Huang, Xuechi, Yiru Duan, Zhongqiu Liu, Baokuan Li, and Fang Wang. "Role of Electrode Rotation on Improvement of Metal Pool Profile in Electroslag Remelting Process." Metals 11, no. 11 (October 20, 2021): 1675. http://dx.doi.org/10.3390/met11111675.
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A comprehensive transient model is developed to study the effect of electrode rotation on the evolution of metal pool profiles and the solidification quality of ESR ingots. Magnetohydrodynamic flow, heat transfer, solidification, and electrode melting are considered simultaneously in the model. The growth of the ESR ingot is predicted using the dynamic layering method. The numerical results show that the productivity reaches a maximum of 15.97% at the rotating speed of 40 rpm without increasing power. With the increasing rotating speed, the maximum temperature of the melt decreases, and the temperature distribution becomes more uniform. Compared with the static one, the pool profiles are flattened by −1.19%, −8.52%, and 12.44% at the rotating speeds of 20, 40, and 60 rpm, respectively. The metal pool profile was improved remarkably, but only at the higher speed (i.e., 60 rpm). The effect of rotating speed on the metal pool profile depends on the competition between the melting rate and slag temperature. Meanwhile, the local solidification time and the secondary dendrite arm spacing are slightly improved at lower rotating speeds but are significantly worse at higher rotating speeds.
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Sun, Chuxiong, Yifeng Guo, Qiang Li, Zhe Shen, Tianxiang Zheng, Huai Wang, Weili Ren, Zuosheng Lei, and Yunbo Zhong. "Numerical Simulation on Saffman Force Controlled Inclusions Removal during the ESR Process." Metals 10, no. 5 (May 17, 2020): 647. http://dx.doi.org/10.3390/met10050647.
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Electroslag remelting (ESR) is an effective method for removing nonmetallic inclusions from steels or alloys. The main stage of inclusion removal during ESR is the aggregation of liquid metal film (LMF) to form droplets at the consumable electrode tip. In this study, a lab-level ESR experiment was carried out. The number and size of inclusions at the characteristic position of the electrode were quantitatively counted. The number of inclusions in the center position of LMF were larger than that in other regions. To elucidate these phenomena, a two-dimensional mathematical model was established to study the migration of inclusions in LMF. The results indicate that due to the large velocity gradient in LMF, the Saffman force is strong enough to offset the buoyant force and drag the inclusions toward the slag/LMF interface (SFI), where the inclusions will be dissolved in the SFI region by the molten slag. This study demonstrates that the Saffman force plays a key role in the removal of nonmetallic inclusions in LMF during the ESR process.
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Liu, Yu, Zhao Zhang, Guangqiang Li, Yang Wu, Xijie Wang, and Baokuan Li. "Effect of SiO2 containing slag for electroslag remelting on inclusion modification of 42CrMo steel." Metallurgical Research & Technology 116, no. 6 (2019): 627. http://dx.doi.org/10.1051/metal/2019063.
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Five heats were carried out to study the effects of SiO2 containing slag for electroslag remelting (ESR) on inclusion characteristics of 42CrMo steel. Fluoride vaporization at elevated temperature from slags was also explored by thermogravimetric analysis. The results show that fluoride vaporization is dominated by slag viscosity and component activities in the melt. Slag composition has an important effect on the composition of the oxide inclusion. For 70 wt% CaF2–30 wt% Al2O3 slag, the compositions of oxide inclusions in remelted steel show no obvious differences compared with the virgin steel. Whereas, SiO2 content in oxide inclusions of steel processed by slag bearing SiO2 show an increasing trend with increase of SiO2 content in 50 wt% CaF2–CaO–SiO2 slag, and the MgO · Al2O3 inclusions are modified to (Al,Ca,Mg,Si)O inclusions with low melting temperature. Al2O3 contents in oxide inclusions are also closely related to the Al2O3 concentration in the molten slag, which increase with the addition of Al2O3 in slag bearing SiO2. In testing various slags, the incorporation of slag T2 with 50 wt% CaF2–30 wt% CaO–20 wt% SiO2 shows the highest cleanliness in remelted steel. This implies that slag T2 can be a promising slag for ESR process of alloy steel requiring Al content refinement due to less fluoride vaporization from slag and better inclusions modification.
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Tridello, A., D. S. Paolino, G. Chiandussi, and Massimo Rossetto. "Different Inclusion Contents in H13 Steel: Effects on VHCF Response of Gaussian Specimens." Key Engineering Materials 665 (September 2015): 49–52. http://dx.doi.org/10.4028/www.scientific.net/kem.665.49.
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The effect of different inclusion contents on the VHCF strength of H13 tool steels is presented. Two different H13 tool steels were investigated: the Uddeholm Orvar® 2 Micronized obtained by conventional casting, and the Uddeholm Orvar® Supreme obtained by electroslag remelting (ESR). Ultrasonic tests were performed on Gaussian specimens (risk volume about 2300 mm3) up to 1010 cycles or up to failure and fracture surfaces were investigated with SEM in order to analyze the inclusions from which VHCF crack nucleated. Experimental results show that the VHCF strength estimated by using the Murakami’s model of the H13 Uddeholm Orvar® Supreme steel is about 15% larger than that of the H13 Uddeholm Orvar® 2 Micronized steel.
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Williamson, Rodney L., and Joseph J. Beaman. "Modern Control Theory Applied to Remelting of Superalloys." Materials Science Forum 706-709 (January 2012): 2484–89. http://dx.doi.org/10.4028/www.scientific.net/msf.706-709.2484.
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Over the past several years we have worked to develop tools to improve the quality of superalloy ingots produced by vacuum arc remelting (VAR) and electroslag remelting (ESR). Part of this work has focused on developing model-based process controllers that employ predictive, dynamic, low-order electrode melting and ingot solidification models to estimate important process variables. These estimated variables (some of which are not subject to measurement) are used for feedback and to evaluate the health of the processes. Modern controllers are capable of detecting and flagging various process upsets and sensor failures, and can take remedial action under some circumstances. Model-based variable estimates are continuously compared with measurements when available, and the residuals are used to correct the next generation of estimates. This technology has led to improved VAR and ESR melt rate controllers and is currently being used to develop a VAR ingot solidification controller. A first generation ingot pool depth controller has been tested on a laboratory VAR furnace and the results are very encouraging. In this test, a 152 mm diameter Alloy 718 electrode was remelted into a 216 mm diameter ingot, but the technology is easily scaled to industrial sizes. Successful development of this technology could allow for melting at higher powers without the formation of channel segregates (freckles) by stabilizing the ingot solidification zone. It may also allow for the production of larger diameter VAR superalloy ingots than is possible to produce with the current generation of VAR controllers for the same reason.
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Geng, Xing, Zhou Hua Jiang, Fu Bin Liu, and Hao Peng. "Manufacturing of Heavy Plates with Excellent Mechanical Properties by a 40t ESR Furnace for Slab Products." Advanced Materials Research 79-82 (August 2009): 1747–50. http://dx.doi.org/10.4028/www.scientific.net/amr.79-82.1747.
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A special bifilar 40t electroslag remelting(ESR) furnace for slab products has been fabricated to produce heavy plates for special application. The slab ingots were rolled to heavy plates, and then the mechanical properties of which were investigated. The impact toughness of heavy plates with different position, directions and under welding condition were performed at the temperature ranging from -70°C to room temperature. The tensile experiments at room temperature were carried out to check the tensile properties of heavy plates in different position, directions and under welding condition. The secondary cooling technology developed improves greatly the quality of solidification. Adjusting taper of the mold and using CaF2-CaO-Al2O3-SiO2-MgO slag are necessary for improving surface quality of the ESR slab. The ESR slabs with the maximum thickness of the world in size of 980 mm thickness, 2000 mm wideness and 2800 mm length have been produced successfully. The heavy plates with 410 mm in thickness can be obtained after rolling the 40 tons ESR slabs. The results of mechanical properties show that the heavy plates produced by ESR furnace for slab products exhibits excellent ductility, impact and isotropic properties in different position, directions and under welding condition.
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Wang, Zhongwei, Chengbin Shi, Shijun Wang, Jing Li, and Xin Zhu. "Evolution and Formation of Non-Metallic Inclusions during Electroslag Remelting of Ce-Bearing 15Cr-22Ni-1Nb Austenitic Heat-Resistant Steel." Metals 12, no. 12 (December 6, 2022): 2094. http://dx.doi.org/10.3390/met12122094.
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The evolution of inclusions in austenitic heat-resistant steel with different Ce content during protective argon gas atmosphere electroslag remelting (ESR) was studied. All oxide inclusions in the Ce-free consumable electrode are MgO·Al2O3. A part of these MgO·Al2O3 inclusions was removed before metal droplets entered the liquid metal pool during the ESR. The soluble oxygen (arising from the reoxidation) reacted with soluble aluminum, calcium, and magnesium in liquid steel to form MgO·Al2O3 and CaO–Al2O3 inclusions in liquid steel. All oxide inclusions in the electrode with 0.016 mass% Ce are Ce2O2S. A portion of these Ce2O2S inclusions was dissociated into soluble oxygen, cerium, and sulfur in liquid steel during the ESR process, whereas the others were removed by absorbing them into molten slag. The oxide inclusions in the liquid metal pool and remelted ingot were Ce2O3, CeAlO3, and Ce2O2S. The CeAlO3 and Ce2O3 inclusions were reoxidation products formed by the chemical reaction between the soluble oxygen, soluble aluminum, and cerium. The oxide inclusions in the electrode with 0.300 mass% Ce are CeS and Ce2O2S. These CeS inclusions were removed by molten slag adsorption during the ESR. A part of these Ce2O2S inclusions was removed by slag adsorption, and the remaining entered into the liquid metal pool. The oxide inclusions in the liquid metal pool and the ingot were Ce2O3 and Ce2O2S. The Ce2O3 inclusions were formed through the chemical reaction between the soluble oxygen and cerium in the liquid metal pool. The Ce2O2S inclusions in the liquid pool originate from reoxidation products during the ESR process and the relics from the electrode.
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Chumanov, I. V., I. M. Yachikov, M. I. Yachikov, М. А. Matveeva, and D. V. Sergeev. "INFLUENCE OF THE CONSUMABLE ELECTRODE ROTATION DURING ELECTROSLAG REMELTING ON HYDRODYNAMICS OF A SLAG BATH." Vestnik Tomskogo gosudarstvennogo universiteta. Matematika i mekhanika, no. 73 (2021): 121–34. http://dx.doi.org/10.17223/19988621/73/11.
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Slag melt is a current-carrying medium with intense currents induced by gravitational and electromagnetic forces. The remelted electrode rotation leads to a change in hydrodynamic processes proceeding in a slag bath of the ESR installation and associated primarily with the occurrence of a centrifugal force. The flow pattern, which is developed in the slag bath under this force action, is different from that developed at a stationary consumable electrode. A mathematical model is proposed to assess the impact of consumable electrode rotation on hydrodynamics in a slag bath during electroslag melting. A computer program is created to determine the projections of the flow velocities for a liquid flux near a rotating electrode, the moment of its hydraulic resistance, and the renewal time for the slag bath while being stirred. The critical speed of the rotation of the electrode is determined as a function of its diameter at a transitional flow regime for ANF-6 flux. The dependence of the flux flow velocity on the electrode rotation speed is presented. The moment of the rotating electrode resistance in a slag bath is determined at various electrode diameters and various depths of the electrode immersion into the slag. An expression is proposed for estimating the time of the slag bath renewal. It is also shown that at a small depth in the bath due to its intensive mixing under the action of centrifugal forces, the temperature and chemical composition over the slag bath volume during the ESR process can be considered as constant. The ratio of centrifugal and electromagnetic forces is estimated. The results determine a flow pattern of the liquid slag and th
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An, Xueliang, Zhiyue Shi, Haifeng Xu, Cunyu Wang, Yuhui Wang, Wenquan Cao, and Jinku Yu. "Quantitative Examination of the Inclusion and the Rotated Bending Fatigue Behavior of SAE52100." Metals 11, no. 10 (September 23, 2021): 1502. http://dx.doi.org/10.3390/met11101502.
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This study investigated the effect of maximum inclusion on the life of SAE52100 bearing steel processed by two different melting routes, vacuum induction melting plus electroslag remelting (VIM + ESR), and basic oxygen furnace plus ladle furnace plus vacuum degassing process (BOF + LF + RH) by the metallographic method, Aspex explorer, and rotated bending fatigue test. The rotated bending method was applied to examine the maximum inclusion size in a satisfactory manner, whereas both the metallographic method and Aspex explorer underestimated the result. Regardless of the characterization methods, the results show that the total number of inclusions in VIM + ESR melted steel is significantly higher than that in BOF + LF + RH processed steel, but the maximum inclusion size of VIM + ESR melted steel is significantly smaller than that of the BOF + LF + RH degassed steel. The distribution of the maximum inclusion size could be well fitted by the inverse Weibull distribution and could be well applied to reveal the different inclusion size distribution based on the data examined by the rotated bending fatigue method. Finally, a new equation was proposed to establish the relationship among the loading stress amplitude, rotated bending fatigue number, and the maximum inclusion size.
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Liu, Yu, Zhao Zhang, Guangqiang Li, Qiang Wang, and Baokuan Li. "Effect of Current on Segregation and Inclusions Characteristics of Dual Alloy Ingot Processed by Electroslag Remelting." High Temperature Materials and Processes 38, no. 2019 (February 25, 2019): 207–18. http://dx.doi.org/10.1515/htmp-2017-0144.
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AbstractThree dual alloy ingots were processed by electroslag remelting with 1500 A, 1800 A and 2100 A. The compositions and inclusions of ingots were analyzed by means of various analytical techniques. The results show that the segregation becomes severer with the increase of current. With the current increasing, the proportion of inclusions with large size, the T.[O] and sulfur content in the ingot increase, showing a worse cleanliness due to the severer electrode surface oxidation and shorter interaction time between slag pool and film of molten steel at the electrode tip. The single (Mn,Cr)S inclusion can precipitate in transition zone of each ingot and NiCrMoV zone of ingot with 1800 A and 2100 A due to higher sulfur content and the solute segregation during solidification. The ingot processed by ESR with 1500 A performed a balanced quality.
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Zeng, Tianyi, Shuzhan Zhang, Xianbo Shi, Wei Wang, Wei Yan, Yan Tian, Mingchun Zhao, and Ke Yang. "Effects of the Primary NbC Elimination on the SSCC Resistance of a HSLA Steel for Oil Country Tubular Goods." Materials 14, no. 18 (September 14, 2021): 5301. http://dx.doi.org/10.3390/ma14185301.
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Sulfide stress corrosion cracking (SSCC) has been of particular concern in high strength low alloyed (HSLA) steels used in the oil industry, and the non-metallic inclusions are usually considered as a detrimental factor to the SSCC resistance. In the present work, continuous casting (CC) and electroslag remelting (ESR) were adopted to fabricate a 125 ksi grade steel in order to evaluate the effect of microstructure with and without primary NbC carbides (inclusions) on the SSCC resistance in the steel. It was found that ESR could remove the primary NbC carbides, and hence, slightly increase the strength without deteriorating the SSCC resistance. The elimination of primary NbC carbides caused two opposite effects on the SSCC resistance in the studied steel. On the one hand, the elimination of primary NbC carbides increased the dislocation density and the proportion of high angle boundaries (HABs), which was not good to the SSCC resistance. On the other hand, the elimination of primary NbC carbides also induced more uniform nanosized secondary NbC carbides formed during tempering, providing many irreversible hydrogen traps. These two opposite effects on SSCC resistance due to the elimination of primary NbC carbides were assumed to be offset, and thus, the SSCC resistance was not greatly improved using ESR.
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Birol, Burak, and Muhlis Nezihi Saridede. "The Effect of Slag Optical Basicity on Alloying Element Losses of Steel by Electroslag Remelting (ESR)." Transactions of the Indian Institute of Metals 69, no. 3 (May 30, 2015): 751–57. http://dx.doi.org/10.1007/s12666-015-0549-1.
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Liu, Yu, Guangqiang Li, Qiang Wang, Ru Lu, Xijie Wang, and Yufeng Tian. "Effect of slag composition on desulfurization during recycling rejected electrolytic manganese metal by electroslag remelting." Metallurgical Research & Technology 118, no. 2 (2021): 206. http://dx.doi.org/10.1051/metal/2021019.
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To reduce the Mn vaporization during recycling rejected electrolytic manganese metal by electroslag remelting, it is proposed to reduce the temperature of molten slag pool, but which leads to the degradation of slag desulfurization. The desulfurization by interaction between CaF2–CaO–Al2O3–Na2O slag and rejected electrolytic manganese metal scrap was studied from the view of thermodynamics in this study. The results show that sulfur distribution ratio decreases with increase of CaF2 content, and increases with the increase of Na2O content and temperature. Na2O increases sulfur distribution ratio of slag by increasing CaO activity. Na2O addition in CaF2–CaO–Al2O3–Na2O slag can enhance desulfurization ability of slag due to the larger sulfur distribution ratio and lower viscosity. Thus, sulfur content in test of slag T3 bearing 45.8 wt% CaF2-23.2 wt% CaO-22.7 wt% Al2O3-8.3 wt% Na2O is much lower than that of slag without Na2O, implying that 45.8 wt% CaF2-23.2 wt% CaO-22.7 wt% Al2O3-8.3 wt%Na2O slag is the promising slag for recycling rejected electrolytic manganese metal by ESR.