Publications

Effect of processing parameters on temperature profiles, fluid flow, and pool shape in the ESR process

Viswanathan, Srinath; Melgaard, David K.; Patel, Ashish D.; Evans, David G.

A numerical model of the ESR process was used to study the effect of the various process parameters on the resulting temperature profiles, flow field, and pool shapes. The computational domain included the slag and ingot, while the electrode, crucible, and cooling water were considered as external boundary conditions. The model considered heat transfer, fluid flow, solidification, and electromagnetic effects. The predicted pool profiles were compared with experimental results obtained over a range of processing parameters from an industrial-scale 718 alloy ingot. The shape of the melt pool was marked by dropping nickel balls down the annulus of the crucible during melting. Thermocouples placed in the electrode monitored the electrode and slag temperature as melting progressed. The cooling water temperature and flow rate were also monitored. The resulting ingots were sectioned and etched to reveal the ingot macrostructure and the shape of the melt pool. Comparisons of the predicted and experimentally measured pool profiles show excellent agreement. The effect of processing parameters, including the slag cap thickness, on the temperature distribution and flow field are discussed. The results of a sensitivity study of thermophysical properties of the slag are also discussed.