Mechanisms of Formation and Evolution of Slag Shells in the Electroslag Remelting Process Utilizing Two Series‐Connected Electrodes

The evolution and formation mechanism of slag shells during the process of electroslag remelting (ESR) is crucial for optimizing the conditions of heat transfer and enhancing both the surface and internal quality of the ingot. This study uses Maxwell and Fluent software to develop a 3D model for ESR with two series‐connected electrodes, exploring the slag shell formation mechanism. During the process, when the mold diameter is Φ130 mm and the initial slag shell thickness is 5 mm, slag on the mold sidewall solidifies into a slag shell. Intense water cooling forms a crescent‐shaped slag shell near the slag–metal interface. As the temperatures of the slag bath and molten metal rise, the slag shell melts and thins. When the thickness of the slag shell reaches 2.6 mm, it enters a dynamic equilibrium state, thereby forming a homogeneous slag shell. As the steel ingot grows and is withdrawn, the slag shell continues to thin. Compared with two‐dimensional models, the three‐dimensional model exhibits higher heat transfer efficiency. Moreover, the curved morphology of the solidification boundary of the slag shell in the three‐dimensional model is more complex and asymmetric.