Electroslag Remelting.

This report describes research on macrosegregation in ingots produced by the electroslag remelting ESR process. The work is on determining the severity of segregation in small experimental ingots, and comparing the segregation with calculations using macrosegregation theory. Most experimental ingots were produced in an apparatus which simulates the solidification of an ESR ingot but does not employ slag. Equations for predicting flow of interdendritic liquid and macrosegregation in ESR ingots are given and used in a computer model to numerically calculate the macrosegregation. Agreement between calculations and the experimental ESR ingots of Al-Cu and Sn-Pb alloys is excellent. The influence of important parameters such as the shape and depth of the mushy zone and the local solidification time on the macrosegregation across the ESR ingots is quantitatively demonstrated. The important effect of the dimensionless group on the different types of macrosegregation observed is also discussed. The computer model can be modified to predict the effect of rotation on macrosegregation in ESR ingots and that prediction agrees with experiment. Microsegregation theory and macrosegregation theory are applied to a multicomponent commercial steel.