Influence of Melting Parameters on the Electroslag Remelting Process of GH4151 Alloy

GH4151 is a high-performance precipitation strengthened new nickel-based high temperature alloy， suitable for the manufacture of aviation engine turbine disc forgings. Based on the industrially validated MeltFlow software， the effects of different smelting process parameters on the electroslag remelting process of GH4151 alloy were studied. The results revealed with the process of the electroslag remelting， the morphology distribution of the molten pool exhibited a deep central region and shallow periphery at different smelting stages. Ultimately， the melt pool solidified at the center of the slag pool-liquid metal interface. ；As the melt speed was increased from 1.5 kg/min to 4.5 kg/min， the maximum depth of the melt pool increased from 360 mm to 474 mm， and the maximum width of the paste zone expanded from 60 mm to 99 mm. Furthermore， the local solidification time， the spacing of secondary dendrites， and the probability of black spot formation all exhibited a notable increase. As the electrode diameter increased （with the filling ratio rising from 0.27 to 0.94）， the depth of the melt pool and the width of the mushy zone showed no change. However， the volume of the melt pool decreased by 0.001 5 m³， and the thickness of the slag skin reduced by approximately 1 mm. The probability of black spot formation and the local solidification time both decreased as the electrode diameter increased. Therefore， the melting speed should have been reduced， and the electrode diameter （filling ratio） should have been increased， which would have been more favorable for the solidification quality of alloy.