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The electroslag casting with liquid metal (ESC LM) is a new technology for producing composite roll of high quality based on electroslag metallurgy. In the present work, a two-dimensional quasi-steady state mathematical model of just one half of the ESC LM facility is developed due to the axial symmetry. Influences of operating voltage and pouring temperature on the heat transfer of the composite roll system have been studied. The Lorentz forces and Joule heat are combined with the turbulent flow and energy equations via additional source terms in these equations by the user-defined functions (UDF) based on Fluent software. Simulation results indicate that the distributions of electric potential, current density, Lorentz forces, and Joule heat are concentrated on the upper area of slag bath and a much shallower molten steel pool is obtained. By using the current carrying mold, the heat transfer from slag bath and superheat of the molten steel pool are lower than the conventional ESR process, which is beneficial to a vertical crystallization and an excellent bonding interface between the roll core and working layer of the composite roll. The study of this paper gives us a better understanding of the ESC LM process. [ABSTRACT FROM AUTHOR]

The laboratory experiments have been carried out to investigate the effects of different power supply circuits on the solidification quality of GCr15 manufactured by the single‐power, two‐circuit electroslag remelting process. According to the previous research, the different power supply circuits are named as conventional electroslag remelting withdrawal process (ESRW), single power two circuits electroslag remelting process (ESR‐STCCM) with up power process (ESR‐STCCM‐U) and down power process (ESR‐STCCM‐D), respectively. The profile and depth of the molten pool, macroscopic and microscopic solidification structure, macrosegregation and microsegregation (macro‐/microsegregation) are analyzed. Compared with the ESRW process, ESR‐STCCM process can obtain a flatter and shallower molten pool. Besides, experimental and numerical results adequately prove ESR‐STCCM process can reduce the width of the mushy zone and the local solidification time (LST), therefore, the macro‐/microsegregation of segregation elements for ESR‐STCCM process are dramatically improved compared with ESRW process, especially for ESR‐STCCM‐D process. The remelting ingots are manufactured by ESRW and the single‐power, two‐circuit electroslag remelting process with different power supply circuits with the dimensions of Φ250 mm × 450 mm. Compared with ESRW process, ESR‐STCCM can significantly improve the solidification quality of remelting ingot, especially for ESR‐STCCM‐D process. ESR‐STCCM‐D process is suitable for remelting large‐scale ingot and high alloy ingot. [ABSTRACT FROM AUTHOR]