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Acta Metall Sin  2018, Vol. 54 Issue (2): 228-246    DOI: 10.11900/0412.1961.2017.00360
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Study and Development on Numerical Simulation for Application of Electromagnetic Field Technologyin Metallurgical Processes
Qiang WANG1(), Ming HE1,2, Xiaowei ZHU1,2, Xianliang LI1,3, Chunlei WU1,2, Shulin DONG1, Tie LIU1
1 Key Laboratory of Electromagnetic Processing of Materials (Ministry of Education),Northeastern University, Shenyang 110819, China
2 School of Metallurgy, Northeastern University, Shenyang 110819, China
3 School of Materials Science and Engineering, Northeastern University, Shenyang 110819, China
Cite this article: 

Qiang WANG, Ming HE, Xiaowei ZHU, Xianliang LI, Chunlei WU, Shulin DONG, Tie LIU. Study and Development on Numerical Simulation for Application of Electromagnetic Field Technologyin Metallurgical Processes. Acta Metall Sin, 2018, 54(2): 228-246.

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Abstract  

The application of electromagnetic fields is an important way to control the physical and chemical changes of heat transfer, mass transfer, fluid flow and solidification in metallurgical and material preparation processes. It is of great significance to improve the production efficiency and product quality. In this paper, the authors summarize the research contents and progress of numerical simulation on several typical applications of electromagnetic technology in metallurgical fields in recent years, including the electromagnetic steel-teeming technology using induction heating and induction heating technology of a tundish, the applications of electromagnetic force such as the electromagnetic swirling technology in submerged entry nozzle, the soft-contact mold electromagnetic continuous casting technology and the electromagnetic metallurgical technology for tundish, the influence and control of electromagnetic force on so lidified structure evolution, and also the electromagnetic cold crucible technology with comprehensive utilization of induction heat and electromagnetic force. Numerical simulation, as an important research method, is a very important tool in finding out the mechanism and rules of electromagnetic fields during metallurgical and material preparation processes to predict, analyze, and optimize metallurgical processes.
Key words:  electromagnetic field      metallurgical process      numerical simulation      continuous casting      transport phenomenon     
Received:  30 August 2017     
Fund: Supported by National Natural Science Foundation of China (No.U1560207)
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Qiang WANG
Ming HE
Xiaowei ZHU
Xianliang LI
Chunlei WU
Shulin DONG
Tie LIU

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https://www.ams.org.cn/EN/10.11900/0412.1961.2017.00360     OR     https://www.ams.org.cn/EN/Y2018/V54/I2/228

Fig.1  Schematic of electromagnetic steel teeming technology
Fig.2  Distribution and change of temperature of Fe-C alloy and upper nozzle with different time t [27]
(a) temperature distribution(b) temperature change of Fe-C alloy outer surface
Fig.3  Influence of electromagnetic steel-teeming system on temperature distribution of ladle bottom shell[28]
Fig.4  Growth rates of inclusions due to turbulent collision in rotation chamber[36]
Fig.5  Three-dimensional streamlines in the tundish with (a) and without (b) rotation[36]
Fig.6  Geometric diagram of tundish from front view (a) and top view (b)[39]
Fig.7  Comparison of RTD curves for tundish with pouring chamber and tundish with three electromagnetic dams[42] (RTD—residence time distribution)
Fig.8  Schematic of electromagnetic swirling technology in the submerged entry nozzle
Fig.9  Simulation results of swirling flow nozzle with blade and electromagnetic swirling in the submerged entry nozzle (SEN)[8](a) swirling flow nozzle with blade(b) electromagnetic swirling in the submerged entry nozzle(c) simulation result of swirling flow nozzle with blade (d) simulation result of electromagnetic swirling in the submerged entry nozzle
Fig.10  Flow fields (a, c) and temperature fields (b, d) in round billet mold without (a, b) and with (c, d) electromagnetic swirling in the submerged entry nozzle[8]
Fig.11  Flow field and temperature field in slab mold without (a) and with (b) electromagnetic swirling in the submerged entry nozzle[8]
Fig.12  Flow fields in mold without (a) and with (b) modified nozzle[8]
Fig.13  Schematic of electromagnetic braking (EMBR)
Fig.14  Schematic of two-stage soft-contact mold
Fig.15  Magnetic flux density (Bz) distributions on the section of mold system (a) and the surface of strand (b)[73]
Fig.16  Effect of the length (L) of top half of mold on thickness of initial solidified shell[9]
Fig.17  Simulated solidification microstructures of continuous casting billet with electromagnetic stirring (EMS)[84](a) growth of nucleation towards liquid phase(b) growth of columnar crystals(c) transition from columnar crystals to equiaxed crystals(d) formation of fine equiaxed crystals(e) solidification of continuous casting square billet completed
Fig.18  Simulated microstructures of continuous casting billet without (a) and with (b) EMS[84]
Fig.19  Computed flow field of central cross section[85]
Fig.20  Magnetic force distributions in melt during pulsed period at the charging stage (a) and discharging stage (b)[89]
Fig.21  Fluid patterns under pulsed magnetic field in rectangular samples at 25 s with the aspect ratios of 1.0 (a), 2.0 (b), 4.5 (c) and 5.5 (d)[90]
Fig.22  Distributions of electromagnetic force (a) and flow field (b) in melt under pulse magneto oscillation[93]
Fig.23  Comparison of average solute concentration distribution in radial direction between electromagnetic centrifugal solidification (B=0.05 T) and conventional centrifugal casting (B=0 T) at t=4 s[98]
Fig.24  Schematic of structure and principle in electromagnetic cold crucible (F—Lorentz force)
Fig.25  Temperature fields for Ti6Al4V alloys at different time[110](a) 45 s (b) 60 s (c) 70 s (d) 115 s (e) 200 s (f) 500 s
Fig.26  Optimum process window for cold crucible directionally solidifying TiAl alloys[105](Ls—the line for start-up heating and melting. The charge can be melted only when the power exceeds Ps; Lt1 and Lt2—the line for turbulence flow; Pt1 and Pt2—the turbulence flow power, when the power is over Pt1, the EMS effect in the melting pool is more intensive, and the heat flow ahead of the solidification interface is turbulent and disordered, which will disturb the continuous growth of columnar grains; f1 and f2—the current frequency; L1 and L2—the limited region for obtaining a planar interface; L3 and L4—the limited region to obtain enough superheat)
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