Impact of Fill Ratio on Temperature Profile and Metal Bath Configuration in Electroslag Remelting Process With Vibrating Electrode

A transient three‐dimensional (3D) coupled model has been developed to investigate the impact of fill ratio on temperature distribution and metal bath configuration in electroslag remelting process with vibrating electrode. Based on the finite volume method, the continuity equation, Navier‐Stockes equations, and energy conservation equation are iteratively solved with full coupling of the Joule heating and Lorentz force. At the same time, the Joule heating and Lorentz force are calculated by the Maxwell's equations. The generation and dripping of metal droplets are simulated by the volume of fluid (VOF) approach. Moreover, an enthalpy‐porosity method is used to describe the metal solidification. The results show that varying fill ratio dramatically changes the temperature distribution of slag layer and metal bath configuration. While the fill ratio rises, both the highest temperature and time‐averaged temperature increase. Meanwhile, the high‐temperature region in the slag becomes larger and the temperature in the centre of slag layer becomes lower. The maximal metal bath depth reduces from 0.099 to 0.087 m while the fill ratio changes from 0.45 to 0.64.