Influence of Melting Rate on Composite Ingot by Electroslag Remelting Additive Manufacturing

This study used an innovative electroslag remelting additive manufacturing (ESR‐AM) method to produce composite ingots and investigate the effect of melting rate on base metal melting depth and solidification structure. ProCAST simulations were conducted to analyze temperature distribution, melting depth, and dendritic evolution at three melting rates (1, 1.7, and 2.5 mm·s −1 ). The results indicate that the melting rate significantly influences both the base metal melting depth and molten pool morphology. When the melting rate increases from 1 to 2.5 mm·s −1 , the base metal melting depth increases from 13 to 33 mm, while the molten pool depth increases from 54 to 89 mm. Meanwhile, the angle between the columnar grain growth direction and the ingot centerline decreases from 43.8° to 30.4°. The simulated dendrite morphology and columnar‐to‐equiaxed transition agree well with experimental results. A melting rate of 1.7 mm·s −1 is identified as the optimal process window, as it provides a moderate molten pool depth, ensures sufficient metallurgical bonding, and promotes a favorable solidification structure. Lower melting rates lead to insufficient pool depth and surface defects, whereas higher melting rates result in excessive remelting, increased shrinkage risk, and a wider heat‐affected zone.