ESRsim is a cylindrical ESR process simulator which incorporates operating parameters and furnace characteristics into electrode, slag, and ingot models to yield a tool suitable for simulating the remelt process from start to finish. Basic input data are expressed in terms of operating parameters (voltage, current, swing depth, slag weight), heat-specific process parameters (electrode dimensions and weight, crucible dimensions) and furnace characteristics (resistance, power factor, water temperature and flow rate, etc). The use of boundary conditions having default values, combined with menu-specified output parameters means that the simulator can be used by a process engineer having little to no modelling background.

A template of an ESRsim data file can be generated from within ESRsim by selecting the Create Data Template button. This will display the following menu from which the desired units and other major process characteristics can be selected and saved for future applications. Additional input data will be generated automatically.

The resulting data file will be applicable for melting a nominal 13.5 in (345 mm) diameter electrode of Alloy 718 into a nominal 16.75 in (425 mm) diameter crucible using a 70F-15-0-15 slag. A sample of an ESRsim data file is displayed below.

Parameters designated by a ‘-1’ invoke a default boundary condition which has been determined based on the simulation of a variety of test cases, but which can be over-written if the user has more suitable data.

Selection of desired output parameters will determine which output files are generated from the calculations. Several parameters will give rise to sub-menus to further select the desired output.

Results are presented in a variety of file formats (text, spreadsheet, plotting) depending on the selected output parameters.

Download ESRsim

To download the latest version of ESRsim (v 5.5.6) uploaded on 2025/11/01, please complete and submit the contact form below.