Fundamental of constant electrode melting rate control for electroslag fusion welding
In order to solve the problem of horizontal depth of fusion fluctuation during electroslag fusion welding (ESFW) as well as to improve the uniformity of the distribution of grain size, solute elements and non-metallic inclusions, the present study establishes a fundamental theory of constant electro...
Saved in:
| Main Authors: | , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2025-05-01
|
| Series: | Journal of Materials Research and Technology |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785425013845 |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1850246211729096704 |
|---|---|
| author | Haoran Xu Baokuan Li Xuechi Huang Yu Wang Yanchun Lou Zhongqiu Liu |
| author_facet | Haoran Xu Baokuan Li Xuechi Huang Yu Wang Yanchun Lou Zhongqiu Liu |
| author_sort | Haoran Xu |
| collection | DOAJ |
| description | In order to solve the problem of horizontal depth of fusion fluctuation during electroslag fusion welding (ESFW) as well as to improve the uniformity of the distribution of grain size, solute elements and non-metallic inclusions, the present study establishes a fundamental theory of constant electrode melting rate control of ESFW based on basic principles of heat transfer, proposes for the first time a mechanism for regulating the voltage and slag, and develops an experimentally validated transient 2D multiphysics field coupling model (2.2 % error in molten pool width). Key findings show the electrode melting rate, influenced by slag temperature, electrode geometry, and immersion depth, increases from 4.04 kg/min (0 mm immersion, intermittent clicking slag pool) to 42.4 kg/min (15 mm immersion). Both regulation mechanisms can maintain the stability of slag pool temperature throughout the entire process. Slag regulation mechanism stabilizes slag pool depth (18.93 % reduction during stabilization) but reduces horizontal melting depth (10.42 % decrease at 42.4 kg/min). As ESFW proceeds, the trapezoidal slag pool generates downward molten metal flow and bidirectional vortices (10−3 m/s for molten pool and stronger convection in slag pool), which is exacerbated by accelerated droplet formation (0.3 m/s) at higher melting rate. Lower melting rates (4.04–8.07 kg/min) reduce molten pool depth growth (89.66 % increase), improving solidification quality, whereas high rates (42.4 kg/min) enhance depth (223.81 % increase) and energy efficiency. The electrical parameters obtained in this study can be proportionally applied to electroslag fusion welded components of other geometric dimensions. |
| format | Article |
| id | doaj-art-16bcff3cbec3492089fd7f4fee0dacf3 |
| institution | OA Journals |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-16bcff3cbec3492089fd7f4fee0dacf32025-08-20T01:59:14ZengElsevierJournal of Materials Research and Technology2238-78542025-05-0136100641007910.1016/j.jmrt.2025.05.228Fundamental of constant electrode melting rate control for electroslag fusion weldingHaoran Xu0Baokuan Li1Xuechi Huang2Yu Wang3Yanchun Lou4Zhongqiu Liu5School of Metallurgy, Northeastern University, Shenyang, Liaoning Province, 110819, ChinaSchool of Metallurgy, Northeastern University, Shenyang, Liaoning Province, 110819, China; Corresponding author.School of Metallurgy, Northeastern University, Shenyang, Liaoning Province, 110819, China; Corresponding author.State Key Laboratory of Advanced Casting Technologies, Shenyang, Liaoning Province, 110819, ChinaState Key Laboratory of Advanced Casting Technologies, Shenyang, Liaoning Province, 110819, ChinaSchool of Metallurgy, Northeastern University, Shenyang, Liaoning Province, 110819, ChinaIn order to solve the problem of horizontal depth of fusion fluctuation during electroslag fusion welding (ESFW) as well as to improve the uniformity of the distribution of grain size, solute elements and non-metallic inclusions, the present study establishes a fundamental theory of constant electrode melting rate control of ESFW based on basic principles of heat transfer, proposes for the first time a mechanism for regulating the voltage and slag, and develops an experimentally validated transient 2D multiphysics field coupling model (2.2 % error in molten pool width). Key findings show the electrode melting rate, influenced by slag temperature, electrode geometry, and immersion depth, increases from 4.04 kg/min (0 mm immersion, intermittent clicking slag pool) to 42.4 kg/min (15 mm immersion). Both regulation mechanisms can maintain the stability of slag pool temperature throughout the entire process. Slag regulation mechanism stabilizes slag pool depth (18.93 % reduction during stabilization) but reduces horizontal melting depth (10.42 % decrease at 42.4 kg/min). As ESFW proceeds, the trapezoidal slag pool generates downward molten metal flow and bidirectional vortices (10−3 m/s for molten pool and stronger convection in slag pool), which is exacerbated by accelerated droplet formation (0.3 m/s) at higher melting rate. Lower melting rates (4.04–8.07 kg/min) reduce molten pool depth growth (89.66 % increase), improving solidification quality, whereas high rates (42.4 kg/min) enhance depth (223.81 % increase) and energy efficiency. The electrical parameters obtained in this study can be proportionally applied to electroslag fusion welded components of other geometric dimensions.http://www.sciencedirect.com/science/article/pii/S2238785425013845Electroslag fusion weldingConstant electrode melting rateVoltage regulation mechanismSlag regulation mechanismMultiphase flow |
| spellingShingle | Haoran Xu Baokuan Li Xuechi Huang Yu Wang Yanchun Lou Zhongqiu Liu Fundamental of constant electrode melting rate control for electroslag fusion welding Journal of Materials Research and Technology Electroslag fusion welding Constant electrode melting rate Voltage regulation mechanism Slag regulation mechanism Multiphase flow |
| title | Fundamental of constant electrode melting rate control for electroslag fusion welding |
| title_full | Fundamental of constant electrode melting rate control for electroslag fusion welding |
| title_fullStr | Fundamental of constant electrode melting rate control for electroslag fusion welding |
| title_full_unstemmed | Fundamental of constant electrode melting rate control for electroslag fusion welding |
| title_short | Fundamental of constant electrode melting rate control for electroslag fusion welding |
| title_sort | fundamental of constant electrode melting rate control for electroslag fusion welding |
| topic | Electroslag fusion welding Constant electrode melting rate Voltage regulation mechanism Slag regulation mechanism Multiphase flow |
| url | http://www.sciencedirect.com/science/article/pii/S2238785425013845 |
| work_keys_str_mv | AT haoranxu fundamentalofconstantelectrodemeltingratecontrolforelectroslagfusionwelding AT baokuanli fundamentalofconstantelectrodemeltingratecontrolforelectroslagfusionwelding AT xuechihuang fundamentalofconstantelectrodemeltingratecontrolforelectroslagfusionwelding AT yuwang fundamentalofconstantelectrodemeltingratecontrolforelectroslagfusionwelding AT yanchunlou fundamentalofconstantelectrodemeltingratecontrolforelectroslagfusionwelding AT zhongqiuliu fundamentalofconstantelectrodemeltingratecontrolforelectroslagfusionwelding |