Master thesis I: Simulation of distribution of non-metallic inclusions in an ESR ingot

Electroslag remelting (ESR) is a secondary metallurgical process aiming at further purification after completion of the primary extraction and refining operations. The process, as shown in the figure, is a method of refining a consumable metal electrode through a molten slag that is electrically heated. Distribution, type and size of non-metallic inclusions in the final ingot are of great interest. It is generally believed that they can have a significant impact on the mechanical properties and corrosion resistance of the final ingot.

Objective

The goal of this project is to establish advanced models in which the coupling between behavior of inclusions and magnetohydrodynamics (MHD) phenomena in the ESR process is taken into account. The final results might be considered to be published in a scientific journal authored by the student and supporting faculty. The following tasks are identified as project milestones:

• An extensive literature review on the origin, distribution, type, and size of inclusions in the ESR process.
• Modeling distribution of inclusions in the ESR ingot using computational fluid dynamics (CFD) tools.
• A parameter study on the effect of process parameters such as AC applied frequency or slag electrical conductivity on the distribution of inclusions in the ingot.
• Validation of results against the experiment.

Prerequisites

The student must have a background in applied mathematics or physics or engineering e.g. mechanical, chemical, metallurgical engineering, etc. A basic knowledge of numerical modeling as well as CFD simulation using the commercial software ANSYS-FLUENT is required.

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Master thesis II: Simulation of ESR processes with current source through the mold (ESRR/CCM)

Background

Nowadays, the standard electroslag remelting process (ESR) might be slightly modified to produce ingots with special characteristics. The demand to apply the well-known industrial processes such as electroslag rapid remelting (ESRR) and current conductive mold (CCM) is rapidly growing. As shown in the figure, a T-shaped mold is used in the ESRR process including a graphite ring that takes major amount of current through the mold. Furthermore, a certain amount of input power is introduced to the slag through the mold by applying a stirring current in the CCM process.

Objective

The goal of this project is to refine the previously developed computational fluid dynamics (CFD) model for the standard ESR process. Then, the newly refined model is applied to study ESRR/CCM process. The final results are considered to be published in a scientific journal or to be presented in an international conference authored by the student and supervisors. The following tasks must be performed:

• 2D/3D Modeling of the electromagnetic field in the ESRR/CCM process using ANSYS-FLUENT or ANSYS-MECHANICAL APDL
• Investigation of temperature and flow fields in the ESRR/CCM process using CFD tools.
• Validation of results against the experiment.

Prerequisites

The student must have a background in applied mathematics or physics or engineering e.g. mechanical, chemical, metallurgical engineering, etc. A basic knowledge of numerical modeling as well as CFD simulation using the commercial software ANSYS-FLUENT is required.

Please contact us under "ebrahim.karimi-sibaki@unileoben.ac.at"