Metal

Chemical physics

Non-metallic inclusions

Metallurgy

Materials science

Mineralogy

Inclusion (mineral)

Economics

Drag

Grain boundary

Physical chemistry

Physics

Position (finance)

Microstructure

Composite material

Chemistry

Electrode

Finance

Solvent drag

Mechanics

Metals

Electroslag remelting (ESR) is an effective method for removing nonmetallic inclusions from steels or alloys. The main stage of inclusion removal during ESR is the aggregation of liquid metal film (LMF) to form droplets at the consumable electrode tip. In this study, a lab-level ESR experiment was carried out. The number and size of inclusions at the characteristic position of the electrode were quantitatively counted. The number of inclusions in the center position of LMF were larger than that in other regions. To elucidate these phenomena, a two-dimensional mathematical model was established to study the migration of inclusions in LMF. The results indicate that due to the large velocity gradient in LMF, the Saffman force is strong enough to offset the buoyant force and drag the inclusions toward the slag/LMF interface (SFI), where the inclusions will be dissolved in the SFI region by the molten slag. This study demonstrates that the Saffman force plays a key role in the removal of nonmetallic inclusions in LMF during the ESR process.

Numerical Simulation on Saffman Force Controlled Inclusions Removal during the ESR Process