Review on Macrosegregation in Electroslag Remelting Ingot

Electroslag remelting (ESR) has become an essential technique for producing high‐quality alloys due to its capabilities in inclusion removal, compositional homogenization, and microstructure refinement. However, macrosegregation, caused by complex interactions among thermal, solutes, and convective phenomena during solidification, remains a persistent issue affecting ingot quality. This review summarizes the current understanding of macrosegregation formation mechanisms in ESR, including reactions between droplets and slag, thermal and solutal convection, and solute redistribution. The effects of key process parameters such as melting rate, power frequency, filling ratio, cooling intensity, slag thickness, and ingot size on segregation behavior are discussed in detail. Furthermore, advanced control strategies are reviewed, including optimizing electrode design, applying magnetic control, adjusting current pathways, and modifying slag composition. These methods have proven effective in improving solute distribution and reducing macrosegregation. This work aims to provide theoretical guidance and practical references for refining ESR process parameters and developing high‐performance remelted alloys.