Effect of Electrode Immersion Depth on the Electrical Resistance and Heat Generation in the Electroslag Remelting Process

A numerical simulation based on the coupling of electromagnetic-fluid-thermal analysis was developed to investigate the effects of electrode immersion depth (EID) on the electrical resistance and heat generation in the electroslag remelting (ESR) process. The total electric current was obtained by integrating the current density at the slag/metal interface, and the electrical resistance is the ratio of potential to current. It indicates that the EID variation changes the shape, size, and current path of the slag pool, and, as a result, the current density, heat generation, and melting power are directly proportional to the EID, while the electrical resistance of the slag pool is inversely proportional to the EID. The distance between the electrode and the molten-metal pool and the contact areas between the electrode and the slag are the main factors affecting the distribution of voltage, current density, Joule heating, and temperature in the slag pool of the ESR process. A change in the current density affects the electrical resistance and heat generation, which has a direct effect on the ESR process.