A method for determining process parameters of seven-system aluminum alloy electroslag remelting
By establishing a three-dimensional geometric model and performing electromagnetic field and fluid dynamics simulations, the electroslag remelting process parameters of the VII series aluminum alloy were optimized, solving the casting defects problem in the traditional process and achieving a significant improvement in the quality of the aluminum alloy.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- CHONGQING UNIV
- Filing Date
- 2026-02-24
- Publication Date
- 2026-05-29
AI Technical Summary
Traditional smelting processes are ineffective at removing non-metallic inclusions and gases from VII series aluminum alloys, leading to casting defects. Furthermore, existing electroslag remelting experience cannot be directly applied, resulting in insufficient research on the process parameters for aluminum alloy electroslag remelting, which affects material quality.
By establishing a three-dimensional geometric model and meshing it, the electroslag remelting process of aluminum alloy is simulated using electromagnetic field and computational fluid dynamics software. The temperature field and flow field distribution are optimized, the voltage and slag layer thickness are adjusted, and the optimal process parameters are determined.
It enables accurate prediction of the electroslag remelting process of VII series aluminum alloys, optimizes the flow field and temperature field distribution in the crystallizer, improves production efficiency, enhances the quality of aluminum alloys, and reduces ingot defects.
Smart Images
Figure CN122105134A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of non-ferrous metal metallurgy technology, specifically relating to a method for determining process parameters of electroslag remelting of VII series aluminum alloys. Background Technology
[0002] 7-series aluminum alloys (Al-Zn-Mg-Cu series) are widely used in aerospace, automotive, construction, and shipbuilding industries due to their low density, high strength, and good corrosion resistance. However, traditional smelting processes are difficult to effectively remove non-metallic inclusions and gases, which can easily lead to various casting defects.
[0003] In recent years, with the increasing demands for material purity and microstructure uniformity in high-performance aluminum alloys, electroslag remelting technology has been gradually introduced into the aluminum alloy field, demonstrating significant advantages such as purification capabilities, grain refinement, reduction of segregation, and improvement of mechanical properties. As a secondary metallurgical process that combines metal purification, inclusion removal, and microstructure control, electroslag remelting has been successfully applied in high-temperature alloys, mold steels, and special steels.
[0004] Electroslag remelting is a highly complex metallurgical process, encompassing electrode melting, molten metal refining, and metal solidification. The interactions and influences between electromagnetic, temperature, and flow fields make this process extremely complex, posing significant challenges to experimental observation and measurement. Currently, research on electroslag remelting of aluminum alloys is relatively recent, and the thermal properties of aluminum alloys differ considerably from those of steel and high-temperature alloys. For example, the melting point of VII-series aluminum alloys is 475–660℃, while that of steel is 1400–1600℃. The thermal conductivity of VII-series aluminum alloys is 120–160 W / m·K, while that of steel is 40–50 W / m·K. Therefore, previous experience with electroslag remelting of steel can only serve as a reference and cannot be fully applied to the electroslag remelting of aluminum alloys. The limited research on the process parameters for aluminum alloy electroslag remelting further hinders the application of this technology. Therefore, determining the process parameters for electroslag remelting of VII series aluminum alloys to optimize the flow field and temperature field distribution of the molten aluminum in the crystallizer, thereby effectively improving the quality of VII series aluminum alloys, has become a pressing technical problem to be solved in this field. Summary of the Invention
[0005] The purpose of this invention is to provide a method for determining the process parameters of electroslag remelting of VII series aluminum alloys. The method provided by this invention can determine the process parameters for electroslag remelting of VII series aluminum alloys, optimize the flow field and temperature field distribution of the molten aluminum in the crystallizer, thereby effectively improving the quality of VII series aluminum alloys.
[0006] To achieve the above-mentioned objectives, the present invention provides the following technical solution: This invention provides a method for determining the process parameters of electroslag remelting of 7-series aluminum alloys, comprising the following steps: (1) Based on the actual structural parameters of aluminum alloy electroslag remelting, a three-dimensional geometric model including consumable electrode, slag layer and aluminum ingot region is established, and then the three-dimensional geometric model is meshed to obtain a mesh model; (2) Import the mesh model obtained in step (1) into the electromagnetic field simulation software, then set the physical property parameters and boundary conditions, and then calculate the magnetic field distribution of aluminum alloy electroslag remelting under given conditions to obtain magnetic field data. (3) Import the magnetic field data obtained in step (2) and the mesh model obtained in step (1) into the software of computational fluid dynamics, and then set the physical property parameters and boundary conditions to simulate the electroslag remelting process of aluminum alloy and obtain the temperature field, flow field and molten pool distribution characteristics. (4) Adjust the voltage and slag layer thickness respectively, repeat steps (1) to (3) to obtain the temperature field, flow field and molten pool distribution characteristics under different process parameters, compare and analyze the molten pool depth and melting rate, and obtain the optimal aluminum alloy electroslag remelting process parameters.
[0007] Preferably, the structural parameters in step (1) include the diameter of the remelted aluminum ingot, the depth of electrode insertion into the slag layer, the voltage, and the thickness of the slag layer.
[0008] Preferably, the diameter of the remelted aluminum ingot is 500~700mm.
[0009] Preferably, the electrode is inserted into the slag layer to a depth of 10-40 mm.
[0010] Preferably, the voltage is 24~50V.
[0011] Preferably, the thickness of the slag layer is 100~300mm.
[0012] Preferably, the size of the mesh in step (1) is 4~8mm.
[0013] Preferably, the electromagnetic field simulation software in step (2) includes COMSOL software or Ansys Maxwell software.
[0014] Preferably, the physical property parameters in steps (2) and (3) independently include the liquidus, solidus, viscosity, thermal conductivity, electrical conductivity, density, and specific heat of the VII series aluminum alloy and the matching slag system.
[0015] Preferably, the computational fluid dynamics software used in step (3) includes COMSOL software or Fluent software.
[0016] This invention provides a method for determining the process parameters of electroslag remelting (ESR) of VII-series aluminum alloys, comprising the following steps: Based on the structural parameters of actual aluminum alloy ESR, a three-dimensional geometric model including a consumable electrode, a slag layer, and an aluminum ingot region is established; then, the three-dimensional geometric model is meshed to obtain a mesh model; the mesh model is imported into electromagnetic field simulation software, and then physical property parameters and boundary conditions are set; the magnetic field distribution of aluminum alloy ESR under given conditions is calculated to obtain magnetic field data; the magnetic field data and the mesh model are imported into computational fluid dynamics (CFD) software, and then physical property parameters and boundary conditions are set to simulate the aluminum alloy ESR process, obtaining the temperature field, flow field, and molten pool distribution characteristics; the voltage and slag layer thickness are adjusted respectively, and the aforementioned steps are repeated to obtain the temperature field, flow field, and molten pool distribution characteristics under different process parameter conditions; the molten pool depth and melting rate are compared and analyzed to obtain the optimal aluminum alloy ESR process parameters. This invention is based on a multi-dimensional simulation approach. First, a three-dimensional geometric model is established, followed by a mesh model. Then, electromagnetic field simulation is performed to obtain magnetic field data. Next, fluid dynamics simulation is performed to obtain temperature field, flow field, and molten pool distribution characteristics. Then, voltage and slag layer thickness are adjusted as single variables, and the operation is repeated to obtain temperature field, flow field, and molten pool distribution characteristics under different process parameters. Finally, the optimal data for voltage and slag layer thickness are obtained, thereby achieving accurate prediction of the quality of electroslag remelted aluminum ingots under specific process conditions. This improves production efficiency, optimizes the flow field and temperature field distribution of aluminum liquid in the crystallizer, and effectively improves the quality of VII series aluminum alloys. Attached Figure Description
[0017] Figure 1 This is a schematic diagram of the three-dimensional geometric model in Example 1; Figure 2 This is a schematic diagram of the mesh model in Example 1; Figure 3 The current density distribution of the VII series aluminum alloy electroslag remelting in step (3) of Example 1; Figure 4 The Joule heat distribution of the VII series aluminum alloy electroslag remelting in step (3) of Example 1; Figure 5 The temperature field of the electroslag remelting of the VII series aluminum alloy in step (3) of Example 1; Figure 6 The flow field of the electroslag remelting of the VII series aluminum alloy in step (3) of Example 1; Figure 7 The phase fraction distribution diagram of the electroslag remelting liquid of the VII series aluminum alloy in step (3) of Example 1; Figure 8 This is an experimental diagram showing the application of the optimized aluminum alloy electroslag remelting process parameters from Example 1 to actual production. Figure 9The ingot diagram is obtained by applying the optimized aluminum alloy electroslag remelting process parameters from Example 1 to actual production. Figure 10 Low-magnification image of ingots obtained by applying the optimized aluminum alloy electroslag remelting process parameters from Example 1 to actual production. Figure 11 Microstructure of ingots obtained by applying the optimized electroslag remelting process parameters of aluminum alloy in Example 1 to actual production; Figure 12 Low-magnification image of ingots obtained from the actual production of other aluminum alloy electroslag remelting process parameters in Example 1; Figure 13 The image shows a low-magnification view of the ingot obtained from the actual production of other aluminum alloy electroslag remelting process parameters in Example 1. Detailed Implementation
[0018] This invention provides a method for determining the process parameters of electroslag remelting of 7-series aluminum alloys, comprising the following steps: (1) Based on the actual structural parameters of aluminum alloy electroslag remelting, a three-dimensional geometric model including consumable electrode, slag layer and aluminum ingot region is established, and then the three-dimensional geometric model is meshed to obtain a mesh model; (2) Import the mesh model obtained in step (1) into the electromagnetic field simulation software, then set the physical property parameters and boundary conditions, and then calculate the magnetic field distribution of aluminum alloy electroslag remelting under given conditions to obtain magnetic field data. (3) Import the magnetic field data obtained in step (2) and the mesh model obtained in step (1) into the software of computational fluid dynamics, and then set the physical property parameters and boundary conditions to simulate the electroslag remelting process of aluminum alloy and obtain the temperature field, flow field and molten pool distribution characteristics. (4) Adjust the voltage and slag layer thickness respectively, repeat steps (1) to (3) to obtain the temperature field, flow field and molten pool distribution characteristics under different process parameters, compare and analyze the molten pool depth and melting rate, and obtain the optimal aluminum alloy electroslag remelting process parameters.
[0019] The method provided by this invention is applicable to 7-series aluminum alloys.
[0020] All the software used in this invention are commonly used in the field.
[0021] Based on the structural parameters of actual aluminum alloy electroslag remelting, this invention establishes a three-dimensional geometric model including consumable electrode, slag layer and aluminum ingot region, and then performs mesh division on the three-dimensional geometric model to obtain a mesh model.
[0022] In this invention, the structural parameters preferably include the diameter of the remelted aluminum ingot, the electrode insertion depth into the slag layer, the voltage, and the slag layer thickness; the diameter of the remelted aluminum ingot is preferably 500~700mm; the electrode insertion depth into the slag layer is preferably 10~40mm; the voltage is preferably 24~50V; and the slag layer thickness is preferably 100~300mm.
[0023] In one embodiment, the diameter of the remelted aluminum ingot can be 600 mm; the electrode can be inserted into the slag layer to a depth of 20 mm; the voltage can be 24 V; and the slag layer thickness can be 200 mm.
[0024] The present invention does not impose any special limitations on the operation of establishing the three-dimensional geometric model including the consumable electrode, slag layer and aluminum ingot region, and any operation known to those skilled in the art can be used.
[0025] In this invention, the size of the mesh is preferably 4-8 mm. As one embodiment, the mesh size can be 5 mm.
[0026] The present invention does not have any special limitations on the meshing operation of the three-dimensional geometric model, and any operation known to those skilled in the art can be used.
[0027] After obtaining the mesh model, the present invention imports the mesh model into electromagnetic field simulation software, then sets the physical property parameters and boundary conditions, and then calculates the magnetic field distribution of aluminum alloy electroslag remelting under given conditions to obtain magnetic field data.
[0028] In this invention, the electromagnetic field simulation software preferably includes COMSOL software or Ansys Maxwell software, more preferably Ansys Maxwell software; the physical property parameters preferably include the liquidus, solidus, viscosity, thermal conductivity, electrical conductivity, density, and specific heat of the VII series aluminum alloy and its matching slag system.
[0029] In this invention, it is preferred to set the physical property parameters and boundary conditions based on Maxwell's equations, Lorentz's law and Joule's law.
[0030] The present invention does not impose any special limitations on the setting of the boundary conditions; the setting of magnetic field boundary conditions can be carried out using methods familiar to those skilled in the art.
[0031] The present invention does not have any special limitations on the operation of calculating the magnetic field distribution of aluminum alloy electroslag remelting under given conditions; any operation known to those skilled in the art can be used.
[0032] After obtaining the magnetic field data, the present invention imports the magnetic field data and the mesh model into computational fluid dynamics software, and then sets the physical property parameters and boundary conditions to simulate the electroslag remelting process of aluminum alloy, and obtains the temperature field, flow field and molten pool distribution characteristics.
[0033] In this invention, the computational fluid dynamics software preferably includes COMSOL or Fluent software, more preferably Fluent software; the physical property parameters preferably include the liquidus, solidus, viscosity, thermal conductivity, electrical conductivity, density, and specific heat of the VII series aluminum alloy and its matching slag system. In this invention, Fluent software performs exceptionally well in flow simulation, therefore it is preferred to use Fluent software.
[0034] The present invention does not impose any special limitations on the setting of the boundary conditions; the setting of boundary conditions can be carried out using methods familiar to those skilled in the art.
[0035] In this invention, it is preferred to set the physical property parameters and boundary conditions based on the NS equation, the κ-ε turbulence model, the VOF model, the MHD module, the Lorentz law, and the Joule law.
[0036] The present invention does not have any special limitations on the operation of obtaining the temperature field, flow field and molten pool distribution characteristics in the simulated aluminum alloy electroslag remelting process; any operation known to those skilled in the art can be used.
[0037] After obtaining the temperature field, flow field, and molten pool distribution characteristics, the present invention adjusts the voltage and slag layer thickness respectively, repeats the above operation, obtains the temperature field, flow field, and molten pool distribution characteristics under different process parameter conditions, compares and analyzes the molten pool depth and melting rate, and obtains the optimal aluminum alloy electroslag remelting process parameters.
[0038] The present invention does not impose any special limitations on the operation of adjusting the voltage and slag layer thickness; any operation known to those skilled in the art can be used.
[0039] The present invention does not impose any special limitation on the depth of the molten pool. When the melting rate meets the requirements, the shallower the molten pool, the better.
[0040] The present invention does not impose any special limitation on the value of the melting rate, which can be determined based on literature and production experiments in the field.
[0041] In this invention, the temperature distribution and shape of the slag pool and molten metal pool are quantified by the pool depth. The molten pool of this invention is typically U-shaped or V-shaped, and the shallower the pool, the better. The electrode melting rate is matched with the process parameters; the melting rate cannot be too high, as this will lead to poor refining effect; the melting rate cannot be too low, as this will lead to low production efficiency.
[0042] This invention is based on a multi-dimensional simulation approach. First, a three-dimensional geometric model is established, followed by a mesh model. Then, electromagnetic field simulation is performed to obtain magnetic field data. Next, fluid dynamics simulation is performed to obtain temperature field, flow field, and molten pool distribution characteristics. Then, voltage and slag layer thickness are adjusted as single variables, and the operation is repeated to obtain temperature field, flow field, and molten pool distribution characteristics under different process parameters. Finally, the optimal data for voltage and slag layer thickness are obtained, thereby achieving accurate prediction of the quality of electroslag remelted aluminum ingots under specific process conditions. This improves production efficiency, optimizes the flow field and temperature field distribution of aluminum liquid in the crystallizer, and thus effectively improves the quality of VII series aluminum alloys.
[0043] This invention is based on a multi-dimensional simulation method to obtain the distribution characteristics of the temperature field and flow field of aluminum alloy electroslag remelting. Then, by performing corresponding simulations using this model, the quality of electroslag remelted aluminum ingots under a specific process condition can be accurately predicted, thereby improving production efficiency.
[0044] This invention determines the process parameters for electroslag remelting of aluminum alloys through numerical simulation. Its main advantages and functions are reflected in the following aspects: (1) Provide a reference for determining the process parameters of electroslag remelting of aluminum alloys: Apply electroslag remelting to the field of VII series aluminum alloys to provide definite process parameters for electroslag remelting of aluminum alloys and provide a reference for industrial smelting. (2) Significantly reduce experimental costs and cycle: After the multi-dimensional simulation model is established, the optimal process parameters can be screened directly through simulation within the range of process parameters, avoiding a large number of experiments and improving the quality prediction efficiency of electroslag remelted aluminum ingots. (3) Precise quantitative control of process parameters: Numerical simulation can quantify the influence of different process parameters and accurately determine the influence of process parameters such as voltage magnitude and slag layer thickness on aluminum alloy electroslag remelting. (4) Application of multi-physics coupling mechanism: numerical simulation can simultaneously solve the interaction between electromagnetic field, temperature field and flow field, and couple multiple fields to the field of aluminum alloy electroslag remelting to ensure the accuracy of simulation calculation.
[0045] The method of this invention enables the determination of electrode voltage and slag layer thickness for electroslag remelting of aluminum alloys, improving the uniformity of the temperature field and effectively reducing the depth of the molten metal pool. This technology is simple to operate and highly effective, reducing industrial costs and improving process efficiency. It is suitable for the production of aluminum alloy electroslag remelting and has significant industrial application value and promising prospects.
[0046] The technical solutions of this invention will be clearly and completely described below with reference to the embodiments thereof. Obviously, the described embodiments are only a part of the embodiments of this invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.
[0047] Example 1 A method for determining the process parameters of electroslag remelting of 7050 series aluminum alloy is as follows: (1) Establishment of mathematical model: Based on the actual structural parameters of aluminum alloy electroslag remelting (the diameter of the remelted aluminum ingot is 600mm, the electrode insertion depth into the slag layer is 20mm, the voltage range is 24V, and the slag layer thickness is 200mm), a three-dimensional geometric model containing consumable electrode, slag layer and aluminum ingot area is established using Ansys Spaceclaim software. Then, fluentmeshing is used to mesh the three-dimensional geometric model to ensure that the mesh size is 5mm, and a mesh model is obtained. (2) Magnetic field simulation calculation: The mesh model obtained in step (1) is imported into Ansys Maxwell software. Based on Maxwell's equations, Lorentz's law and Joule's law, the physical property parameters and magnetic field boundary conditions are set, and the magnetic field distribution of aluminum alloy electroslag remelting under given conditions is calculated to obtain magnetic field data. (3) Import the magnetic field data obtained in step (2) and the mesh model obtained in step (1) into Fluent software. Based on the NS equation, κ-ε turbulence model, VOF model, MHD module, Lorentz law and Joule law, set the physical property parameters and boundary conditions, and perform coupled simulation of magnetic field, flow field and temperature field to obtain the temperature field, flow field and molten pool distribution characteristics. (4) Adjust the voltage in the range of 24~50V and the slag layer thickness in the range of 100~300mm respectively. At this time, the electrode is inserted into the slag layer at a depth of 10~40mm. Repeat steps (1)~(3) to obtain the temperature field, flow field and molten pool distribution characteristics under different process parameters. Compare and analyze the molten pool depth and melting rate to obtain the optimal aluminum alloy electroslag remelting process parameters.
[0048] The schematic diagram of the three-dimensional geometric model in Example 1 is as follows: Figure 1 As shown, the schematic diagram of the mesh model in Example 1 is as follows. Figure 2 As shown.
[0049] The physical property parameters in steps (2) and (3) of Example 1 are shown in Table 1.
[0050] Table 1. Thermophysical properties of VII series aluminum alloys and their matching slag systems
[0051] The current density distribution of the VII series aluminum alloy electroslag remelting in step (3) of Example 1 is as follows: Figure 3 As shown; the Joule heat distribution of the VII series aluminum alloy electroslag remelting in step (3) of Example 1 is as follows. Figure 4 As shown.
[0052] The temperature field of the electroslag remelting of the VII series aluminum alloy in step (3) of Example 1 is as follows: Figure 5 As shown; the flow field of the electroslag remelting of the VII series aluminum alloy in step (3) of Example 1 is as follows: Figure 6 As shown.
[0053] The phase fraction distribution diagram of the electroslag remelting liquid of the VII series aluminum alloy in step (3) of Example 1 is shown below. Figure 7 As shown. The main characteristic of the molten pool distribution is the shape of the liquid phase in the molten pool, which should be U or V-shaped. The shape of the molten pool needs to be shown through the distribution of the liquid phase at the aluminum ingot.
[0054] The effects of adjusting the slag layer thickness and voltage in step (4) of Example 1 on electroslag remelting are shown in Tables 2-5.
[0055] Table 2
[0056] Table 3
[0057] Table 4
[0058] Table 5
[0059] As can be seen from Tables 2-5, with the increase of voltage, the depth of the molten pool, the electrode insertion speed and the electrode melting speed will also increase; with the increase of slag layer thickness, the thermal efficiency will gradually decrease, and the depth of the molten pool, the electrode insertion speed and the electrode melting speed will gradually decrease.
[0060] During production, the melting rate should be kept within a reasonable range. Too high a rate will result in insufficient refining time, while too low a rate will result in low efficiency. Based on literature and production experiments, for 7050 aluminum alloy with a diameter of 600mm, the electrode melting rate should be controlled at around 150Kg / h.
[0061] By observing the flow field, temperature field, and molten pool morphology under different voltages and slag thicknesses, it was found that when thermal efficiency is similar, a smaller slag thickness results in higher local Joule heating, leading to faster electrode melting and a greater molten pool depth. Therefore, under controlled thermal efficiency, the following processes are suitable: slag thickness 200mm, voltage 24V, molten pool depth 60mm, melting rate 160Kg / h; slag thickness 250mm, voltage 36V, molten pool depth 56mm, melting rate 150Kg / h; slag thickness 300mm, voltage 48V, molten pool depth 55mm, melting rate 147Kg / h.
[0062] The results showed that the 200mm / 24V process produced the deepest molten pool, while the 250mm / 36V and 300mm / 48V processes exhibited more uniform temperature distribution and shallower, more similar molten pool depths. However, for similar performance, the 300mm / 48V process resulted in greater energy loss and higher cost. Therefore, the optimal process parameters were determined to be: 250mm slag layer thickness and 36V voltage.
[0063] The optimized electroslag remelting process parameters for aluminum alloys, as simulated in Example 1, were applied to actual production. Experimental diagrams from the actual production process are shown below. Figure 8 As shown, the actual ingot obtained from production is depicted in the following image. Figure 9 As shown, a low-magnification image of the ingot obtained from actual production is as follows: Figure 10 As shown; the microstructure of the ingot obtained from actual production is shown in the figure. Figure 11 As shown.
[0064] from Figure 9 It can be seen that the surface of the obtained ingot is smooth and flat, without obvious cracks, slag inclusions or other defects, indicating that the smelting process is stable and the slag shell is well formed.
[0065] from Figure 10 It can be seen that the grain distribution conforms to the typical characteristics of directional solidification, and there are no obvious shrinkage cavities or porosity, indicating that the cooling control and feeding effect are ideal.
[0066] from Figure 11 It can be seen that there is no obvious dendrite segregation or aggregation, and the composition is well homogeneous.
[0067] In summary, the macroscopic and microscopic structures of the ingots achieved the expected results, verifying the rationality of the electroslag remelting process parameters used and demonstrating their ability to meet the production requirements of high-quality aluminum alloy ingots.
[0068] The other aluminum alloy electroslag remelting process parameters from Example 1 were applied to actual production (where the low-magnification images of the two sets of ingots are shown in Figure 1). Figure 12 and 13As shown in the figure, the slag on the surface of the ingot was thick and the appearance was rough. A large amount of crystals were easily formed at the bottom, which reflected insufficient cooling control. At the same time, the melting process fluctuated greatly, resulting in poor uniformity of structure and many defects, which could not meet the production requirements of high-quality aluminum alloy ingots.
[0069] In contrast, the simulated and optimized electroslag remelting process parameters for aluminum alloys, through precise control of the solidification process and heat flow distribution, resulted in ingots exhibiting a typical directional solidification structure with uniform grain distribution, no obvious shrinkage cavities, porosity, or segregation, and significantly improved compositional uniformity. This indicates that the simulated and optimized electroslag remelting process parameters for aluminum alloys have achieved substantial breakthroughs in cooling control and melting stability, and can systematically solve various defects in the original process.
[0070] As can be seen from the above embodiments, the method provided by the present invention can determine the process parameters of electroslag remelting of VII series aluminum alloys, optimize the flow field and temperature field distribution of aluminum liquid in the crystallizer, and thus effectively improve the quality of VII series aluminum alloys.
[0071] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.
Claims
1. A method for determining process parameters of electroslag remelting of 7-series aluminum alloys, comprising the following steps: (1) Based on the structural parameters of actual aluminum alloy electroslag remelting, a three-dimensional geometric model including consumable electrode, slag layer and aluminum ingot region is established, and then the three-dimensional geometric model is meshed to obtain a mesh model; (2) Import the mesh model obtained in step (1) into the electromagnetic field simulation software, then set the physical property parameters and boundary conditions, and then calculate the magnetic field distribution of aluminum alloy electroslag remelting under given conditions to obtain magnetic field data. (3) Import the magnetic field data obtained in step (2) and the mesh model obtained in step (1) into the software of computational fluid dynamics, and then set the physical property parameters and boundary conditions to simulate the electroslag remelting process of aluminum alloy and obtain the temperature field, flow field and molten pool distribution characteristics. (4) Adjust the voltage and slag layer thickness respectively, repeat steps (1) to (3) to obtain the temperature field, flow field and molten pool distribution characteristics under different process parameters, compare and analyze the molten pool depth and melting rate, and obtain the optimal aluminum alloy electroslag remelting process parameters.
2. The method according to claim 1, characterized in that, The structural parameters in step (1) include the diameter of the remelted aluminum ingot, the depth of electrode insertion into the slag layer, the voltage, and the thickness of the slag layer.
3. The method according to claim 2, characterized in that, The diameter of the remelted aluminum ingot is 500~700mm.
4. The method according to claim 2, characterized in that, The electrode is inserted into the slag layer to a depth of 10~40mm.
5. The method according to claim 2, characterized in that, The voltage is 24~50V.
6. The method according to claim 2, characterized in that, The thickness of the slag layer is 100~300mm.
7. The method according to claim 1, characterized in that, The size of the mesh in step (1) is 4~8mm.
8. The method according to claim 1, characterized in that, The electromagnetic field simulation software in step (2) includes COMSOL software or Ansys Maxwell software.
9. The method according to claim 1, characterized in that, The physical properties in steps (2) and (3) independently include the liquidus, solidus, viscosity, thermal conductivity, electrical conductivity, density, and specific heat of the VII series aluminum alloy and its matching slag system.
10. The method according to claim 1, characterized in that, The computational fluid dynamics software used in step (3) includes COMSOL software or Fluent software.