Liquid Metal Processing & Casting Conference - LMPC 2024

Computational modeling of the Vacuum Arc Remelting (VAR) Process has been developed to provide a deeper physical and metallurgical understanding and assist in the reliable and efficient manufacture of defect-free ingots. While 3D VAR models with transient (time varying) arc behavior have been developed, 2D axisymmetric models with steady-state arc boundary conditions remain the primary tool in...

External transverse magnetic fields were applied during the vacuum arc remelting of 900 mm and 1000 mm Ti6Al4V ingots in order to control the arc dynamics. The overall goal of the industrial experiments were to provide a known arc distribution throughout the melt, including startup and hot topping, that optimizes solidification. Magnetic field sensors (VARmetric) were deployed to continuously...

Segregation in titanium alloy ingots has largely been treated as a macro-segregation problem. The alpha/beta alloy Grade 5 (“6/4”), for example, is sensitive to macro-variations in Al content due to the precise property requirements of the heat-treated structures. In VAR practice, the problem is mitigated through the use of multiple melting techniques, high quality alloys being remelted three...

The Vacuum Arc Remelting (VAR) process is employed in the production of Nickel-based alloys, including Alloy 718. However, challenges arise during the process due to solidification shrinkage, leading to the loss of contact between the ingot and the mold. This phenomenon diminishes the cooling efficiency of the system, resulting in a deeper melt pool and a decline in ingot quality as heat...

This paper conducts an analysis of the Vacuum Arc Remelting (VAR) process to manufacture steel, examining the interplay of factors such as side-arcing, arc distribution types, thermal radiation, magnetohydrodynamics (MHD), and ingot solidification. The proposed numerical model explores how these factors influence the molten metal pool profile, which is a critical aspect in ensuring the...

Vacuum arc remelting is widely recognized for its ability to produce high quality ingots for demanding applications. Since its introduction in the 1940s, great efforts have been undertaken to increase productivity, reliability and furnace safety by different iterations of furnace design accompanied by improvements in process data acquisition and interpretation to allow remelting behavior...

In the field of metallurgy, the optimization of the process has driven the integration of advanced numerical simulations to enhance the efficiency and reliability of industrial systems. This article focuses on the application of 3D numerical simulations to investigate the cooling system of a Vacuum Arc Remelting (VAR) furnace, an essential component in the production of high-quality alloys....