In the field of metal smelting, electroslag remelting is a widely used smelting method. It originated from electroslag welding technology in the 1950s. After decades of development, it has become the main process route for producing high-temperature alloys. In this article, we will take an in-depth look at the fundamentals, equipment and metallurgical characteristics of electroslag furnace remelting and how to optimize the remelting process through quality control and process parameter selection.
The basic principle of electroslag remelting is to use the resistance heat generated when electric current passes through the slag to melt the metal electrode, thereby achieving the purpose of smelting. The heated and melted metal falls in the form of droplets through the slag layer into the molten metal pool of the water-cooled crystallizer, and crystallizes from bottom to top into steel ingots. The heat generated in this process can be calculated by the formula Q = I2R, where Q is the heat generated per unit time, I is the current intensity, and R is the slag resistance.
The equipment for electroslag remelting mainly includes electroslag furnaces, electrodes and water-cooled crystallizers. The electroslag furnace is the main equipment for electroslag remelting. Its main function is to provide current and resistance heat to melt the metal electrode. The electrode is the raw material for electroslag remelting. It is heated and melted in the electroslag furnace to form molten droplets. The water-cooled crystallizer is the key equipment for electroslag remelting. Its main function is to collect molten droplets and crystallize them into steel ingots.
The metallurgical characteristics of electroslag remelting are mainly reflected in purifying high-temperature alloys, reducing segregation in alloys, and improving the crystal structure of alloy ingots. During the electroslag remelting process, during the falling of the molten metal through the slag layer, the molten metal and the molten slag have a large contact surface, which promotes the metallurgical reaction of the slag-metal and allows a large amount of impurities in the metal to be removed. Therefore, the electroslag remelted high-temperature alloy has good forgeability, excellent surface quality of forged materials, and high yield rate.
The quality control of electroslag remelting mainly includes the control of current intensity, the selection of electrodes and slag, and the control of melting temperature. The control of current intensity is the key to electroslag remelting, which directly affects the efficiency and quality of melting. The selection of electrodes and slag determines the smelting raw materials and smelting environment, and their quality directly affects the smelting results. The control of the melting temperature affects the speed and effect of the melting. Too high a temperature will cause the metal to melt too fast, affecting the quality of the melting; too low a temperature will lead to low melting efficiency.
The selection of electroslag remelting process parameters mainly includes current intensity, electrode diameter, melting speed, etc. The choice of current intensity mainly depends on the material and diameter of the electrode. Generally speaking, the greater the resistivity of the electrode material, the greater the current intensity required; the larger the electrode diameter, the greater the current intensity required. The choice of melting speed depends on the melting speed of the electrode and the cooling speed of the crystallizer. Generally speaking, the faster the melting speed of the electrode, the faster the melting speed; the faster the cooling speed of the crystallizer, the slower the melting speed.
Defects that may occur in electroslag remelted high-temperature alloy ingots mainly include segregation, slag inclusions, bubbles, etc. Segregation is caused by the uneven distribution of elements during the melting and solidification process of metal. Slag inclusion is caused by impurities in the slag being trapped into the metal ingot during the smelting process. Bubbles are caused by the gas generated in the metal ingot not being discharged in time during the smelting process.
In general, electroslag remelting is an efficient and high-quality smelting method, which plays an important role in the production of high-temperature alloys. Through in-depth understanding and research on electroslag remelting, we can better master this smelting method and improve our production efficiency and product quality.
Tianjin Anton Metal Manufacture Co., Ltd. is a company specializing in the production of various nickel-based alloys, Hastelloy alloys and high-temperature alloy materials. The company was established in 1989 with a registered capital of 10.0 million, specializing in the production and sales of alloy materials. Anton Metal’s products are widely used in aerospace, chemical industry, electric power, automobile, nuclear energy and other fields, and can also provide customized alloy material solutions according to customer needs. If you need to know the price consultation of alloy materials or provide customized alloy material solutions, please feel free to contact the sales staff.
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Post time: Dec-21-2023
