The paper is devoted to comparison of electroslag remelting (ESR) with consumable electrode and electroslag refining with liquid metal (ESR LM) processes. The possibility of rearrangement of the heat contributions coming from the consumable electrode and current supplying mould (nonconsumable electrode, CSM) makes the core of the ESR process organisation in the CSM. The usage of liquid metal instead of consumable electrodes allows to reduce liquid bath temperature and volume in order to provide low segregation ingot. The formal assessment of physico-chemical conditions and experimental measurements of desulphurisation have shown the same level of refining ability of both processes. Replacing the classic ESR by the ESR LM is a prospective way to produce high-quality ingots from sophisticated and hard-to-deform materials, whereas manufacturing of the consumable electrodes is technically problematic and costly.
In the present study, a new electroslag cladding method by using of the advanced current supplying mold technology was used for manufacturing the high speed steel (HSS)/ductile cast iron (DCI) composite roll. The graphite morphology, matrix microstructure, elements distribution, carbides morphology, and carbides composition have been investigated by means of optical microscope (OM), scanning electron microscope (SEM), and energy dispersive spectroscopy (EDS). With increasing distance from the HSS side, a transition of graphite morphology from naught to existence and from small and dispersed to large and nonuniform was obtained at the interface. It was closely related to the fact that graphite in DCI participated in the phase change and the roll core surface and its nearby positions was heated to a high temperature by the liquid slag during the whole electroslag cladding process. Due to the combined effects of melting and elements diffusion, a significant migration of the alloying elements have occurred through the line scan analysis. Based on this, different types of carbides with the morphology and composition were found at the bonding interface. In addition, no obvious slag inclusions, porosity, shrinkage and other defects at the bonding interface were found. Results of the tensile test also illustrated that the bonding interface had a good quality and it could fully meet the requirements of the roll.
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