Control of Macrosegregation in Titanium Alloy VAR Ingots via Alternating Magnetic Fields: Governing Roles of Field Strength and Frequency

Vacuum arc remelting (VAR) is essential for producing premium titanium alloys, where an externally applied alternating magnetic field enables circumferential stirring to control ingot homogeneity. However, current magnetic field parameter design relies on empirical trial-and-error approaches, lacking systematic theoretical guidance. To address this issue, this study establishes a comprehensive multi-physics framework through a two-dimensional axisymmetric swirl model integrating electromagnetic, fluid dynamics, thermal, and solute transport phenomena. Our findings demonstrate that both the magnetic field strength and period exhibit optimal operating ranges, which directly influence ingot homogeneity. As magnetic field strength increases progressively, ingot uniformity shows a distinctive non-monotonic response—initially improving before subsequently deteriorating. Correspondingly, with increasing stirring period, macrosegregation undergoes a distinct three-stage evolution: initial mitigation, subsequent aggravation, and final alleviation. These phenomena originate from the small-scale circulatory flow generated by the external magnetic field on the surface of the VAR molten pool. The interactions among the flow, the solute diffusion layer, and the mushy zone collectively alter elemental diffusion behavior, ultimately determining the homogeneity of the ingot. This study provides a theoretical foundation for precise control of ingot homogeneity in titanium alloy VAR processes and demonstrates significant potential for engineering applications.