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<p>The underlying mechanisms and optimal control strategies of the magnetically controlled vacuum arc remelting (MC-VAR) process remain inadequately unclear, thus leading to poor process transferability, insufficient control precision and operational stability in practical applications. In this work, a two-dimensional axisymmetric Eulerian two-phase model is developed to study the melt flow and macrosegregation formation during MC-VAR process of M50 steel, in which the predicted results show good agreement with experimental data. This model is also adopted to investigate the effects of intensity and frequency for the alternating magnetic field (AMF) on solidification behavior and ingot macrosegregation. The results show that the Ekman pumping induced by the AMF significantly suppresses the circulation flow driven by self-induced Lorentz force. Appropriate electromagnetic stirring can improve macrosegregation, while excessive stirring will exacerbate it. Furthermore, the volume-averaged local solidification time (LST) exhibits an overall decreasing trend with increasing stirring intensity. Based on the concept of synergistic control for both macrosegregation and LST in VAR ingots, the optimal parameter combination for the AMF is determined as an intensity of 15G and a frequency of 0.1 Hz.</p>

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Numerical Study and Experimental Validation for Melt Flow and Macrosegregation During Magnetically Controlled Vacuum Arc Remelting of M50 Bearing Steel

  • 期刊论文

  • 发表日期：

    2026年3月2日

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  • Jiajun Cui,
  • Xiaoqiang Hu,
  • Yanfei Cao,
  • Hongwei Liu,
  • Dianzhong Li

摘要

The underlying mechanisms and optimal control strategies of the magnetically controlled vacuum arc remelting (MC-VAR) process remain inadequately unclear, thus leading to poor process transferability, insufficient control precision and operational stability in practical applications. In this work, a two-dimensional axisymmetric Eulerian two-phase model is developed to study the melt flow and macrosegregation formation during MC-VAR process of M50 steel, in which the predicted results show good agreement with experimental data. This model is also adopted to investigate the effects of intensity and frequency for the alternating magnetic field (AMF) on solidification behavior and ingot macrosegregation. The results show that the Ekman pumping induced by the AMF significantly suppresses the circulation flow driven by self-induced Lorentz force. Appropriate electromagnetic stirring can improve macrosegregation, while excessive stirring will exacerbate it. Furthermore, the volume-averaged local solidification time (LST) exhibits an overall decreasing trend with increasing stirring intensity. Based on the concept of synergistic control for both macrosegregation and LST in VAR ingots, the optimal parameter combination for the AMF is determined as an intensity of 15G and a frequency of 0.1 Hz.