Simulation of Compound Rolls Produced by Electroslag Remelting Cladding Method

Abstract

Electroslag remelting cladding (ESRC) with a t-shape current carrying mold was adopted to make a compound roll including a working layer and mandrel. A comprehensive coupled transient model was established to reveal the basic phenomena of electromagnetic fields, flow fields, temperature fields, and multiphase flow. Meanwhile, the movement of the mandrel and working layer relative to the slag pool was simulated by dynamic mesh technology to reveal the interface bonding mechanism. The mechanism is as follows: The temperature of the mandrel increases and the mandrel melts slightly when the mandrel passes through the slag pool. The fusion layer is a mixture of molten steel of mandrel and working layer that is the connector between the mandrel and the working layer. Therefore, the interface bonding quality is dependent on a fusion layer that is affected by the voltage/power. The investigation indicates that the fusion layer thickness is between 2 and 4 mm in the condition of 40 V that benefits from obtaining a good interface bonding quality.

Keywords

• compound roll
• electroslag remelting cladding
• dynamic mesh
• interface bonding quality
• multiphase flow
• t-shaped current carrying mold