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3D Numerical Simulation of the Var Consumable Electrode Melting Process

  • Topical Collection: Liquid Metal Processing & Casting Conference 2019
  • Published:
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Abstract

A 3D numerical model was set up to simulate the formation and dynamics of the liquid metal film under the consumable electrode during VAR process. In the present paper, the implementation of this model is described. It was developed using the open source computational fluid dynamics (CFD) software OpenFOAM. The model solves coupled momentum and energy equations combined with a volume of fluid (VOF) method to track the liquid metal free surface. The melting of the electrode material is modeled with an enthalpy-porosity approach. The electric power supplied by the arc is supposed to be uniformly distributed over the surface of the electrode tip. For a given electric arc power, the model enables to quantitatively predict the dripping rate and hence the overall melt rate. Besides the thermal behavior of the electrode, simulation results illustrate the dynamics of the liquid film and the transfer mechanisms of the liquid metal during VAR melts performed with short and long interelectrode gaps.

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Abbreviations

α m :

Metal volume fraction (–)

β :

Dilatation coefficient (K−1)

γ :

Solid volume fraction (–)

ε :

Turbulent kinetic energy dissipation rate (m2 s−3)

λ 2 :

Secondary dendrite arm spacing (m)

µ :

Dynamic viscosity (Pa s−1)

µ t :

Turbulent dynamic viscosity (Pa s−1)

ρ :

Density (kg m−3)

σ :

Surface tension (N m−1)

σ ST :

Stefan Boltzmann constant (W m−2 K−4)

Cp:

Specific heat (J K−1 kg−1)

f σ :

Volumetric surface tension force (N m−3)

h :

Total enthalpy (J m−3)

k :

Turbulent kinetic energy (m2 s−2)

k c :

Curvature (m−1)

k :

Thermal conductivity (W m−1 K−1)

k t :

Turbulent thermal conductivity (W m−1 K−1)

L :

Latent heat of melting (J kg−1)

P arc :

Power delivered by the arc to the electrode

P rad :

Power radiated from the electrode lateral wall

P :

Pressure

T :

Temperature (K)

T sol :

Solidus temperature (K)

T liq :

Liquidus temperature (K)

U :

Velocity vector (m s−1)

m:

Metal

VOF:

Volume of fluid

CSF:

Continuum surface force

CFL:

Courant–Friedrich–Lewy

MULES:

Multidimensional universal limiter with explicit solution

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Acknowledgments

The authors would like to thank Y. Millet and J. Jourdan from TIMET Savoie, France, who have supported the acquisition of the experimental data shown in Figure 5 of the present work.

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Authors and Affiliations

  1. Institut Jean Lamour – UMR CNRS 7198, LabEx DAMAS, Université de Lorraine, allée André Guinier 2, Campus Artem, 54011, Nancy Cedex, France

    R. Bhar, A. Jardy & P. Chapelle

  2. Aperam Alloys Imphy – Avenue Jean Jaurès, BP-1, 58160, Imphy, France

    R. Bhar & V. Descotes

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  1. R. Bhar
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  2. A. Jardy
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  3. P. Chapelle
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  4. V. Descotes
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Correspondence to P. Chapelle.

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Manuscript submitted December 20, 2019.

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Bhar, R., Jardy, A., Chapelle, P. et al. 3D Numerical Simulation of the Var Consumable Electrode Melting Process. Metall Mater Trans B 51, 2492–2503 (2020). https://doi.org/10.1007/s11663-020-01966-x

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