ESR simulation: prediction of quality and grain size for nickel based ingot

Abstract

ESR (electroslag remelting) process is fundamental in heavy forgings manufacturing, especially for energy and aerospace application. The aim of this paper is to analyze the quality and grain size of a nickel based remelted ingot using casting simulation software ProCAST. Melt pool profile, temperature distribution and solidification structure will be used to analyze quality; focus will be run-out prevention and reduction of ingot piping. Final shape of ingot, microstructure and grain distribution will be finally transferred to forging simulation software DEFORM to show chaining capability and evolution of as-cast structure.