核电用大型钢锭电渣重熔工艺模拟及生产应用

论证了应用于核电主管道和12%Cr 转子钢用百吨级巨型电渣钢锭重熔过程数学模型,形成电渣重熔工艺过程三维数值模拟计算程序ESR3D.模拟了电渣重熔全过程,包括电极熔化,金属熔滴自由下落,金属熔池的形成,金属熔池和渣池的上升、移动,三组电极分别更换,在线安装上结晶器,钢锭在水冷结晶器中凝固等.模拟并优化的电渣重熔工艺应用于生产80～120t大型电渣钢锭,其质量满足核电和超超临界火电机组技术要求.     

电渣熔铸过程的数值模拟研究

利用了前人关于熔滴在渣池中行为的研究成果和渣池中有关传热规律的试验资料,考虑到电渣熔铸过程始终有强电流介入,建立了包括金属熔池、两相区和凝固锭在内的电渣锭凝固传热数学模型,模型预测值与试验值吻合较好.运用此模型可预报金属熔池状况,便于现场调整工艺参数.     

电渣熔铸过程中金属熔池深度的数值模拟研究

利用前人关于熔滴在渣池中行为的研究成果和渣池中有关传热规律的实验资料。考虑到电渣熔铸过程始终有强电流介入,建立了包括金属熔池、两相区和凝固锭在内的电渣锭凝固传热数学模型,模型预测值与实验值吻合较好。运用此模型可预报金属熔池状况,便于现场调整工艺参数。     

电渣重熔中电极熔化过程的模拟研究

将电渣重熔过程分为初始阶段与稳定阶段,并对自耗电极从自初始阶段开始熔化到稳定阶段金属熔滴长成的过程进行了数值模拟分析,结果表明,渣池中的电流密度分布决定了渣池中温度的分布规律,在自耗电极形成金属熔滴时,将会使金属熔滴下方渣池产生高温区,从而有利于电渣过程中杂质的去除。     

电渣重熔过程中渣池内的电弧放电现象

借助于声音和电流电压的示波照象及模拟试验,研究了电渣重熔过程中电极金属熔滴过渡的特征。发现稳定的电渣重熔过程并非无弧过程,伴随着熔滴的周期断落,产生周期的渣池中电弧放电。提高工作电压或增加CaF_2-Al_2O_3渣系中Al_2O3的含量导致电弧放电强度加大。指出:电弧放电的机械效应及电动力的综合作用引起熔滴分散。     

ЯВЛЕНИЯ ДУГОВОГО РАЗРЯДА В ШЛАКОВОЙ ВАННЕ ПРИ ЭЛЕКТРОШЛАКОВОМ ПЕРЕПЛАВЕ

借助于声音和电流电压的示波照象及模拟试验,研究了电渣重熔过程中电极金属熔滴过渡的特征。发现稳定的电渣重熔过程并非无弧过程,伴随着熔滴的周期断落,产生周期的渣池中电弧放电。提高工作电压或增加CaF_2-Al_2O_3渣系中Al_2O3的含量导致电弧放电强度加大。指出:电弧放电的机械效应及电动力的综合作用引起熔滴分散。     

数值模拟电极缩孔对IN718合金电渣重熔过程的影响

利用自主开发的ESR过程仿真软件,针对直径430 mm的IN718合金铸锭,通过设计不同形状尺寸的电极缩孔,进行电渣重熔过程的数值模拟计算和分析。结果表明,基于电磁场、流场和温度场等多物理场耦合计算自主开发的ESR数学模型及仿真软件,可以用于ESR冶炼全过程数值模拟,模型计算的熔池形状和深度、二次枝晶臂间距分布规律与实际剖锭分析结果接近。电极中存在缩孔改变了电极与渣池的接触面积,从而显著影响渣池的焦耳热和电磁力分布,而缩孔沿电极轴向尺寸的变化对二者分布的影响则很少。在恒熔速条件下,当缩孔半径小于0.025 m时,缩孔对熔炼过程几乎没有影响;当缩孔尺寸继续增大时,渣池温度场和流场发生明显改变,渣池温度逐步升高,中心向下流速相对减弱;电极缩孔尺寸变化对熔池温度场及两相区尺寸影响不明显。缩孔半径尺寸对电流和功率等熔炼参数的影响呈非线性关系,临界变化值约为0.05 m,当缩孔半径低于临界值时,对电流和功率等影响较小;高于临界值时,随着缩孔半径增加,电流和功率显著增加,并且增速不断加快。从工艺过程控制稳定性角度而言,该尺寸电极缩孔半径应控制在0.05 m以下。     

电渣熔铸中渣池热电场的试验和模拟研究

电渣熔铸是一种利用大电流通过渣池区域而产生的高温将自耗电极逐渐熔化的方法,其中渣池的温度分布特点直接决定了电极的熔化速度、提纯度以及铸锭的组织结构等,是熔铸系统中的关键区域.本研究中采用"反向熔铸"试验和"真假双电极熔铸"试验对渣池温度场分布进行了研究,并借用具有极强的分析功能的大型通用有限元软件ANSYS软件,对试验模型进行了数值模拟.试验和模拟计算均证实了电极端部与金属熔池之间的渣池区域存在着一个集中的高温区,该高温区的存在对自耗电极的熔化起了极大的促进作用.     

Mn18Cr18N护环钢电渣重熔工艺的研究

通过对10t电渣炉电气特性的分析,确定了渣池输入功率最大时的临界电流值。理论分析了供电制度、电极直径、渣系和钢种对电渣重熔钢锭表面质量的影响机理。钢锭侧面凝固前沿位置即金属熔池具有无圆柱部分是判断电渣锭表面质量优劣的基本依据。工业试验和理论分析阐明了改善Mn18Cr18N电渣重熔钢锭表面质量的主要措施,并提出了合理的重溶工艺制度。     

金属熔滴连续沉积、凝固重叠工艺及实验验证

金属熔滴均匀连续沉积是一种新型的3D打印技术和快速原型(RP)技术。本文系统研究了铝熔滴连续沉积到基板表面的瞬态传热传质现象,沉积机理主要包括金属熔体的毛细现象及固液界面的传热、凝固、搭接和重熔。采用VOF方法对连续沉积的金属熔滴在水平固定铝基板表面沉积进行3D建模。针对凝固传热过程中不同参数下熔滴在铝基板表面沉积、凝固进行了研究,通过数值计算与实验验证,各种工艺参数的影响,如喷射速度、基板温度、熔滴直径与碰撞最大铺展因子的影响,显示了很好的一致性。基于上述研究,成形形貌和内部微观结构之间的定量关系进一步验证了金属熔滴连续沉积、凝固重叠工艺的可行性。此工艺为金属微沉积制造实施有效的过程控制提供指导。     

3D numerical investigation of effects of density and surface tension on mixing time in bottom-blown gas-stirred ladles

In molten phase metallurgical processes, mixing via gas injection has a vital role in obtaining a homogeneous product. The efficiency of mixing depends on operational variables such as gas flow rate and slag height as well as physical properties of the molten phases. A numerical simulation is conducted to study the above parameters in the flow behavior of a bottom-blown bath. The molten metal and the slag are modeled by water and oil, respectively. The numerical results, particularly the mixing time, are validated against experimental data. The results show that mixing time increases as the slag height increases and decreases as the density of the slag material increases. The mixing time decreases with an increase in the density of the primary phase; however, it increases as the surface tension between air and water increases. A case with properties close to a real molten metal is also modeled. The performance of the system is influenced by the momentum rather than the dissipative forces. Thus, the effect of the density of the molten phase on the mixing process is more pronounced compared to the effect of the surface tension between the air and the molten phase.     

熔渣下金属熔池流动现象的数学模拟SCIEI

应用二维激光测速仪和高速摄影机对带有渣层的金属熔池流场的水模型进行了试验研究。根据研究结果提出熔渣-金属界面处的流动边界条件,用涡量-流函数法求解了有渣金属熔池的湍流特征。结果表明,熔渣下金属熔池的流动速度、湍动能和循环流量均显著低于无渣金属熔池。除包底区外,顶部渣层下近包壁处也有一个湍动能很低的“死区”。     

MATHEMATICAL MODELLING OF FLOW PHENOMENA IN METAL BATH COVERED WITH MOLTEN SLAG

By use of the two-component LDA and high speed camera,the water model of the flow fieldin metal bath under molten slag layer has been tested.On the basis of experimental results,theflow boundary conditions of liquid metal at the slag-metal interface of a gas injecting bathwere deduced.The flow field and the turbulent parameters of the metal bath covered with slagwere solved by the vorticity-stream function method.The results reveal that the flow velocity,turbulent energy and circulating rate of the melt under slag are lower than that of withoutslagcover.Another one “dead zone” of the lowest turbulent energy is formed in the top layerunder cover of slag near the ladle linning.     

Effects of electrode immersion depth and remelting rate on electroslag remelting process

In the electroslag remelting process, the electrode molten state is a critical factor determining the ingot quality, while the electrode immersion depth and melting rate are key factors for the stability of the electroslag re-melting process. Studies were carried out to investigate the microscopic and macroscopic effects of electrode immersion depth and melting rate on the potential distribution and heat density in the slag bath, and on the depth and shape of the molten bath. Based on the finite element method and the numerical solution method, the effect of the electrode immersion depth on the slag bath heat density was researched; the relationship between the electrode immersion depth and the slag resistance was obtained; and the unsteady-state model of the solidification process of the re-melting ingot was solved using the finite difference method. The mathematical model and physical model of the electrode melting process were established and solved; and the corresponding curves between the electrode molten-state and slag-bath physical parameters were obtained. The experimental results verified the simulated results studied in this paper.     

电渣重熔体系内熔渣流场的数学模拟

建立了电渣重熔体系内电磁力作用下熔体流场的数学模型，并将其应用于在结晶器直径为２００ｍｍ的实验室装置上以ＣａＦ_２＋３０ｍａｓｓ％Ａｌ_２Ｏ_３＋２０ｍａｓｓ％ＣａＯ系熔渣进行的低碳低合金钢重熔过程（电极直径７６ｍｍ，３０００Ａ（ｒｍｓ））。合理选取模型参数值，计算了电磁力作用下体系内渣池的流场。结果表明，在电磁力作用下，渣池内形成沿结晶器壁向上，经熔渣自由表面和电极端部锥面又沿体系对称轴向下流动的两个旋涡，最大流速区约位于渣池内体系对称轴中部，涡心基本上位于半渣池中央略偏左、右下方的区域。对一些假想工况下的情形作了模拟，考察了重熔电流、填充比和电极端部形状对重熔体系内渣池流场的影响。与一些物理模拟结果作了比较。     

Effect of vibrating electrode on temperature profiles,fluid flow,and pool shape in ESR system based on a comprehensive coupled model

The vibrating electrode method was proposed in the electro-slag remelting(ESR) process in this paper,and the effect of vibrating electrode on the solidification structure of ingot was studied.A transient threedimensional(3D) coupled mathematical model was established to simulate the electromagnetic phenomenon,fluid flow as well as pool shape in the ESR process with the vibrating electrode.The finite element volume method is developed to solve the electromagnetic field using ANSYS mechanical APDL software.Moreover,the electromagnetic force and Joule heating are interpolated as the source term of the momentum and energy equations.The multi-physical fields have been investigated and compared between the traditional electrode and the vibrating electrode in the ESR process.The results show that the drop process of metal droplets with the traditional electrode is scattered randomly.However,the drop process of metal droplets with the vibrating electrode is periodic.The highest temperature of slag layer with the vibrating electrode is higher than that with the traditional electrode,which can increase the melting rate due to the enhanced heat transfer in the vicinity of the electrode tip.The results also show that when the amplitude and frequency of the vibrating electrode increase,the cycle of drop process of metal droplets decreases significantly.     

基于FLUENT的高压断路器弧触头喷溅侵蚀流动特性分析

高压断路器动作时,触头间会形成电弧,并伴随蒸发和喷溅现象,造成触头材料侵蚀和接触系统的失效.为研究高压断路器烧蚀故障的喷溅机理特征,建立了弧触头熔池的流动与传热模型,并运用FLUENT软件分析了触头在不同弧根下的熔池温度场、流场和压力分布.计算结果表明:在两种弧根条件下,均形成了半圆形的熔池,弧根较小的情形下不利于能量的散发和电弧的运动,导致流速较大,增大电极的侵蚀.熔池的流体流速随电流的增大而增大,且电流越大,弧根区内流体流速由最小值上升到最大值的速度越快,熔池深度方向的熔化速度也加快.     

渣金间辅助外电场提高焊接工艺稳定性分析

为探索焊接过程实现高稳定性工艺的潜在途径,最大限度地减少重要钢结构制造中焊缝咬边及成形缺陷带来的焊后返修工作,提出并试验了一种利用埋弧焊渣金间随焊施加辅助外电场对渣金电导载流进行导流,进而提高焊接工艺稳定性的方法,并应用焊接电信号分析仪对弧压信号进行了采集统计分析.结果表明,以钨电极作阴极利用电场在渣金熔体内部形成稳定的电导载流,可使熔渣电导性能得以改善,并引导电子进入电弧阴极中心以增强电弧的集聚程度.同时外电场作用也使渣金内部的带电粒子形成有序运动并在界面结合成低表面能的活性氧化物,又可改善液态熔渣在焊缝金属表面的润湿铺展性能.实施辅助电场引入的这些有益作用使焊缝形状、表面光洁度、尤其是焊缝边缘平直均匀性得到较好地改观,焊接过程工艺稳定性得以进一步提高.     

The technological properties of molten slag an-ShT2

Conclusion Heating in molten slag AN-ShT2 with no iron oxide at 780–880°C has the following advantages as compared with heating in molten chlorides: decarburizing and corrosion of the parts is prevented, and distortion due to quenching is substantially reduced; cold and wet parts can be placed in the bath without danger of spatter from the hot slag.Certain disadvantages of slag AN-ShT2 as an agent for heating parts should also be noted. The high viscosity and low fluidity increase the carryout as compared with molten salts; the heating rate in the slag bath, and consequently its throughput, is lower. The intensity of the attack of slag AN-ShT2 on refractory materials excludes its use in electrode baths with refractory linings. Since iron oxide sharply impairs the properties of the slag, the crucibles, thermocouple jackets, quenching apparatus, and molds for pouring off the slag must be manufactured from heat resistant steel. The molten slag has a narrower range of operating temperatures (780–880°C) than the chlorides used in medium-temperature salt baths (700–950°C).All-Union Scientific-Research Tool Institute. Translated from Metallovedenie i Termicheskaya Obrabotka Metallov, No. 12, pp. 2–6, December, 1971.     

STUDY ON THE NON－STOICHIOMETRIC METALLURGICAL PROCESS－A MODEL FOR THE BATH－SMELTING PROCESS

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