A Multiscale 3D Model of the Vacuum Arc Remelting Process

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.