Pericleous, Koulis ORCID: 0000-0002-7426-9999 , Djambazov, Georgi ORCID: 0000-0001-8812-1269 , Ward, Mark, Yuan, Lang and Lee, Peter D. (2013) A multiscale 3D model of the vacuum arc remelting process. Metallurgical and Materials Transactions A, 44 (12). pp. 5365-5376. ISSN 1073-5623 (Print), 1543-1940 (Online) (doi:https://doi.org/10.1007/S11661-013-1680-4)

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Abstract

A three-dimensional, transient, multiscale model of the VAR process is presented, allowing novel simulations of the influence of fluctuations in arc behavior on the flow and heat transfer in the molten pool and the effect this has on the microstructure and defects. The transient behavior of the arc was characterized using the external magnetic field and surface current measurements,which were then used as transient boundary conditions in the model. The interactions of the magnetic field, turbulent metal flow, and heat transfer were modeled using CFD techniques and this ‘‘macro’’ model was linked to a microscale solidification model. This allowed the transient fluctuations in the dendritic microstructure to be predicted, allowing the first coupled three dimensional correlations between macroscopic operational parameters and microstructural defects to be performed. It was found that convection driven by the motion of the arc caused local remelting of the mushy zone, resulting in variations in permeability and solute density. This causes variations in the local Rayleigh number, leading to conditions under which freckle solidification defects will initiate. A three-dimensional transient tracking of particle fall-in was also simulated, enabling predictions of "white spot" defects via quantification of the trajectory and dissolution of inclusions entering the melt.

Item Type:	Article
Uncontrolled Keywords:	Vacuum Arc Remelting, defect prediction, arc/meltpool interaction, multi-scale modelling
Subjects:	T Technology > TN Mining engineering. Metallurgy
Pre-2014 Departments:	School of Computing & Mathematical Sciences School of Computing & Mathematical Sciences > Centre for Numerical Modelling & Process Analysis > Computational Science & Engineering Group School of Computing & Mathematical Sciences > Department of Computer Science
Last Modified:	02 Mar 2019 15:53
URI:	http://gala.gre.ac.uk/id/eprint/10209

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