Forging for advanced trubine applications: Development of multiple alloy rotor forging for turbine application

Kawasaki, Koji; Ganesh, S.; Kimura, Kimio; Kudo, H.; Nakamura, Takeshi; Tanaka, Yasuhiko; Schwant, R.C.; Gatazka, F.; Yang, Ling

doi:10.1179/174328107x174690

Cited by 17 publications

(12 citation statements)

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“…In experiments, the magnetic flux density is measured by the Gauss Meter WT10E, and the temperature is measured every 10 minutes by the disposable W3Re/W25Re thermocouple. [2,[9][10][11] III. MATHEMATICAL MODELING Figure 4(a) displays the mesh model and computation domain.…”

Section: Methodsmentioning

confidence: 99%

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A General Coupled Mathematical Model of Electromagnetic Phenomena, Two-Phase Flow, and Heat Transfer in Electroslag Remelting Process Including Conducting in the Mold

Wang

et al. 2014

Metall Mater Trans B

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A transient three-dimensional finite-volume mathematical model has been developed to investigate the coupled physical fields in the electroslag remelting (ESR) process. Through equations solved by the electrical potential method, the electric current, electromagnetic force (EMF), and Joule heating fields are demonstrated. The mold is assumed to be conductive rather than insulated. The volume of fluid approach is implemented for the two-phase flow. Moreover, the EMF and Joule heating, which are the source terms of the momentum and energy sources, are recalculated at each iteration as a function of the phase distribution. The solidification is modeled by an enthalpy-porosity formulation, in which the mushy zone is treated as a porous medium with porosity equal to the liquid fraction. An innovative marking method of the metal pool profile is proposed in the experiment. The effect of the applied current on the ESR process is understood by the model. Good agreement is obtained between the experiment and calculation. The electric current flows to the mold lateral wall especially in the slag layer. A large amount of Joule heating around the metal droplet varies as it falls. The hottest region appears under the outer radius of the electrode tip, close to the slag/metal interface instead of the electrode tip. The metal pool becomes deeper with more power. The maximal temperature increases from 1951 K to 2015 K (1678°C to 1742°C), and the maximum metal pool depth increases from 34.0 to 59.5 mm with the applied current ranging from 1000 to 2000 A.

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Section: Methodsmentioning

confidence: 99%

“…[11], the velocity field must be blocked in the solid phase with the termF p . An enthalpy-porosity formulation was used.…”

Section: B Fluid Flowmentioning

confidence: 99%

A General Coupled Mathematical Model of Electromagnetic Phenomena, Two-Phase Flow, and Heat Transfer in Electroslag Remelting Process Including Conducting in the Mold

Wang

et al. 2014

Metall Mater Trans B

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“…Nevertheless, few have significant effects. [4][5][6] The efficiently relative movement between the electrode and molten slag, resulting in homogenizing organization and increasing melting rate, has been demonstrated and verified in the past…”

Section: Introductionmentioning

confidence: 99%

Comparison of Thermo-electromagneto-hydrodynamic Multi-physical Fields in ESR Furnace with Vibrating and Traditional Electrodes

Wang

2017

ISIJ Int.

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“…In the past, efforts have been devoted to study the coupled electromagnetic, flow and temperature fields in the ESR process. [6][7][8] Kelkar et al developed a comprehensive mathematical model for the simulation of the transient ESR process. 9) Their model can provide the fields of current density, Joule heating, EMF, fluid flow, liquid fraction, temperature and inclusion motion at various times, as well as the evolution of the metal pool profile, i.e.…”

Section: Introductionmentioning

confidence: 99%

Effect of Rotating Electrode on Magnetohydrodynamic Flow and Heat Transfer in Electroslag Remelting Process

Wang

Gosselin

2014

ISIJ Int.

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A transient three-dimensional (3D) coupled mathematical model has been developed to explore the effect of the rotating electrode on the electromagnetic, flow, temperature fields as well as solidification in the electroslag remelting (ESR) process. Maxwell's equations are solved by the finite volume formulation. The Joule heating and electromagnetic force (EMF), which are the source terms in the energy and momentum equations, are recalculated at each iteration as a function of the phase distribution. The movement of metal droplets is described by the volume of fluid (VOF) approach. Additionally, the solidification of the metal is modeled by an enthalpy-based technique, in which the mushy zone is treated as a porous medium with porosity equal to the liquid fraction. The rotation speed of the electrode is imposed on the inlet, and the melt rate changes with time proportionally to the Joule heating. The present work is the first attempt to investigate the innovative technology of ESR process with rotating electrode by a transient 3D comprehensive mathematical model. The metal droplets are thrown out by the centrifugal force without enough time to grow up in the process with rotating electrode. The melting rate increases because of the enhanced heat transfer in the vicinity of the electrode tip. With a 800A current, the melt rate increases from 0.0078 kg/s to 0.0114 kg/s, while the rotation speed ranges from 120 rpm to 160 rpm. Besides, the metal pool not only keeps the same depth, but also becomes wider in spite of a higher melting rate.

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Forging for advanced trubine applications: Development of multiple alloy rotor forging for turbine application

Cited by 17 publications

References 0 publications

A General Coupled Mathematical Model of Electromagnetic Phenomena, Two-Phase Flow, and Heat Transfer in Electroslag Remelting Process Including Conducting in the Mold

A General Coupled Mathematical Model of Electromagnetic Phenomena, Two-Phase Flow, and Heat Transfer in Electroslag Remelting Process Including Conducting in the Mold

Comparison of Thermo-electromagneto-hydrodynamic Multi-physical Fields in ESR Furnace with Vibrating and Traditional Electrodes

Effect of Rotating Electrode on Magnetohydrodynamic Flow and Heat Transfer in Electroslag Remelting Process

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