The Development and Application of an Integrated VAR Process Model

The VAR ingot has been the focus of several modelling efforts over the years with the result that the thermal regime in the ingot can be simulated quite realistically. Such models provide important insight into solidification of the ingot but present some significant challenges to the casual user such as a process engineer. To provide the process engineer with a tool to assist in the development of a melt practice, a comprehensive model of the complete VAR process has been developed. A radiation heat transfer simulation of the arc has been combined with electrode and ingot models to develop a platform which accepts typical operating variables (voltage, current, and gap) together with process parameters (electrode size, crucible size, orientation, water flow, etc.) as input data. The output consists of heat flow distributions and solidification parameters in the form of text, comma-separated value, and visual toolkit files. The resulting model has been used to examine the relationship between the assumed energy distribution in the arc and the actual energy flux which arrives at the ingot top surface. Utilizing heat balance information generated by the model, the effects of electrode-crucible orientation and arc gap have been explored with regard to the formation of ingot segregation defects. (paper)