The availability of a simulator for the remelt processes provides a tool for the examination of a remelt practice from start to finish of melting. Recent years have seen the development of several models of the electroslag and vacuum arc remelting processes through the application of sophisticated generic equation solvers combined with boundary conditions representative of the remelt processes. These models provide useful insights into the solidification processes in ingots, however their use presents a significant challenge to the user and can require a substantial amount of computing resources. The efficiency in the application of these models can be enhanced through the use of a simulation tool which can be used to screen potential remelt practices prior to more detailed evaluation by either extensive modelling or experimental studies.

ESRsim and SLABsim for the ESR process, and VARsim for the VAR process are process simulation tools designed for use by a manufacturing engineer. They can be used to explore and compare potential melt practices leading to selection of an optimal candidate which can then be evaluated in greater detail. Their use is simplified by means of a menu-based interface and embedded default boundary conditions. Input data are expressed in terms of furnace operating parameters (voltage, current, melt rate, etc) and normal processing variables (electrode and crucible sizes, etc). Execution times are very short (usually 1-2 minutes) such that many practice scenarios can be explored quite quickly.

For each process, an input data file for a base case remelt practice may be generated and used as a template for specifying other melting scenarios of interest. Default boundary conditions suitable for the base case are incorporated into the software. These boundary conditions may also apply to other melting cases and may be left as default options, or they may be over-written if more suitable boundary condition data are available.

ESRsim, SLABsim, and VARsim are designed for the simulation of superalloy and high-alloy steel remelting processes, and are not recommended for high current titanium melting.