Masters Theses

Date of Award

12-1981

Degree Type

Thesis

Degree Name

Master of Science

Major

Engineering Science

Major Professor

Bruce R. Dewey

Committee Members

M Parang, J. E. Stoneking

Abstract

To aid in the design and development of equipment for the electroslag casting of graded-composition transition spool pieces, a finite element model has been developed. This model encompasses the electrode, slag, molten metal, solidified ingot, skin layer, and mold wall.

Solution of the electrical potential problem in the slag region gives the volumetric heat generation due to resistance (or joule) heating. Then, a heat transfer model is used to solve the conduction equations, with convection in the molten slag and molten metal treated by the use of effective conductivity valves. Several detailed features of the electroslag casting process have been taken into account, including the transport of heat from the slag to the molten metal by metal droplets. Predictions are made of temperature distribution as related to the metal pool profile, input power, proper-ties and amount of slag, and other geometrical factors.

A parametric study on the effect of electrode penetration depth shows that power consumption and slag temperature increases as the electrode becomes nearer the metal pool. The temperature profile in the mold wall may be used to measure slag depth, location of the metal pool and other geometrical factors. Thus, control information is available from the wall temperature distribution.

Results developed in this study favorably agree with those from a prototypic collar mold operated at the Oak Ridge National Laboratory. Extension of the analysis techniques developed here appears feasible for development of the process for casting hollow ingots.

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