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Meeting 2025 TMS Annual Meeting & Exhibition
Symposium Validation of Computational Tools - Industrial Perspectives
Presentation Title Validation of Electro-slag Remelting Process Simulations for the production of commercial HAYNES® 282® Alloy Ingots
Author(s) Ram Krishnamurthy, Michael Fahrmann
On-Site Speaker (Planned) Ram Krishnamurthy
Abstract Scope Electro-slag Remelting (ESR) is a commonly employed process for the secondary melting of advanced alloys. Following an overview of approaches used to model this process, we present results from a trial conducted to validate the numerical simulation of the melt process for producing a commercial-sized ingot of 282 alloy using a software package, MeltFlow-ESR™. As part of this trial, the solidification front at various times during the process, marked by deliberately dropping in pellets, was compared with those predicted by simulation. Other characteristics, including slag skin thickness and ingot dendritic structure were extracted by ex-situ analysis of the ingot and compared with those predicted by simulation. Physics-based modeling approaches to estimate the risk for formation of macro-segregation related casting defects in the ingots will also be presented. Inferences drawn from this work will be used to highlight the successes of, and opportunities for modeling approaches in advancing commercial ESR production.
Proceedings Inclusion? Planned:
Keywords Process Technology, Modeling and Simulation, Copper / Nickel / Cobalt

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

Accelerating materials innovation in industry using ICME
Development and Validation of Optimization Tool for Continuous Caster Operations Based on CFD Simulations
Finite Element Simulation of Edge and Crack Evolution in Thin Slab Rolling Process
Fluid Dynamics Characterization of a Novel Bifurcated Sumerged Entry Nozzle for Thin Slab Mold in Steel Continuous Casting Process by Mathematical Simulation
Fluidodynamic Analysis In The Continuous Casting Mold For Conventional Slab And Inside The Submerged Entry Nozzle (Sen) Using Mathematical Simulation.
High-Speed Switched Reluctance Motor for Sustainable Crushing Operation through Cone Crusher
Microstructure-Informed Multiscale Structural Analysis and Design Software for Additively Manufactured Metal Alloys
Modeling of Microstructure Evolution during Multi-Pass Hot-Rolling of 316L Stainless Steel
Multiphase Flow, Particle Transport and Capture During a Ladle Exchange in Steel Continuous Casting
Numerical Simulation and Experimental Validation of the Vacuum Arc Remelting Process
Process modeling for predicting micro-structure and properties of investment cast Ni based super alloy
The Evolution of ICME in the Aerospace Industry: Past, Present, and Future
The Role of Process Variability within ICME Tool Development for Aerospace Turbine Applications
Tundish design optimization for inclusion cleanliness before continuous casting
Validation of Electro-slag Remelting Process Simulations for the production of commercial HAYNES® 282® Alloy Ingots
Validation of microstructure evolution and strength prediction models on two commercial gamma-prime strengthened Ni-base superalloys

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