Modelling the physical properties of electrofluxes through the lens of experimental data

Electroslag remelting (ESR) and vacuum arc remelting (VAR) are widely employed techniques for producing defect-free ingots in ferroalloys, nonferrous metals, and superalloys. These technologies find applications in sectors like military, aerospace, and aeronautics, where high performance is of paramount importance. Given the critical nature of these applications, a comprehensive understanding of the smelting process is imperative. Therefore, developing precise models for predicting the physical properties of the involved slag used in the ESR process is crucial, as it enables operators to simulate and optimise process parameters effectively. This study comprehensively modelled three premelted commercial electrofluxes from Wacker and compared these models with experimental data. Key properties such as viscosity, density, electrical conductivity, specific heat (Cp), heat of fusion, and linear and volumetric thermal expansion coefficients were modelled through precise mathematical expressions, which can be subsequently integrated into process simulations. Moreover, the Roscoe-Einstein expression, traditionally used for correcting viscosity during solid-liquid phase transitions, was adapted to model electrical conductivity across the entire temperature range, from solid to liquid phase. The created models strongly correlated with the experimental data, providing operators with reliable and accurate information about Wacker Electrofluxes in their production processes.