Controlling liquid pool depth in VAR of a 21.6 cm diameter ingot of Alloy 718

摘要

It is believed that the final microstructure in vacuum arc remelted (VAR) ingots is strongly influenced by the molten metal pool profile. Thus, if the pool profile was properly controlled during the melt then defect-free microstructures would be obtained. The recent development of a reduced-order model of VAR solidification allowed the design of a pool depth controller to accomplish this task. The controller used a linear quadratic regulator and a Kaiman filter to stabilize the melt pool solidification front under the effect of uncertain process dynamics and noisy measurements. Basic Axisymmetric Remelting (BAR), a high-fidelity VAR ingot model, was used in real time to provide pool depth measurements that were incorporated in the control loop. The controller was tested at Los Alamos National Laboratory in a 21.6 diameter Alloy 718 ingot. Details of the controller design will be presented, along with comparisons to experimentally-measured pool depths.