Skip to main content
SpringerLink
Log in

Multi-Disciplinary Numerical Analysis of Aluminum Ingot Electromagnetic Casting

  • Published:
Metallurgist Aims and scope

The article represents a multidisciplinary numerical model for electromagnetic casting of aluminum ingots, as well as the results of its application when casting aluminum ingots diam. 25–30 mm. The numerical model is based on a calculation of the electromagnetic field by solving an additional equation in Fluent combined with the modeling of processes connected with free surface crystallization. The obtained electromagnetic field sources are used in motion and energy equations for solving the magneto-hydrodynamics problem. A solution to the problem of determining the set of technological parameters for ensuring the stable formation of an ingot with the required diameter is provided along with the results of emergency mode modeling. In addition, the article presents the results of applying the established emergency modes at the laboratory casting unit with the electromagnetic mold for the production of ingots using Nikolin and Altsimak experimental alloys as part of ElmaCast® technology.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1.
Fig. 2.
Fig. 3.
Fig. 4.
Fig. 5.
Fig. 6.
Fig. 7.
Fig. 8.
Fig. 9.
Fig. 10.
Fig. 11.
Fig. 12.
Fig. 13.

Similar content being viewed by others

References

  1. Z. N. Getselev, G. L. Balakhontsev, F. I. Kvasov, et al., Continuous Casting into Electromagnetic Molds [in Russian], Metallurgiya, Moscow (1983).

    Google Scholar 

  2. N. V. Sergeev, Electromagnetic Mold for Obtaining Aluminum Alloy Rod Billets [in Russian], Diss. Cand. Sci. (Engineering), Krasnoyarskii gos. Tekh. Un-t, Krasnoyarsk (2005).

  3. M. V. Pervukhin, Electrotechnology and Equipment for Obtaining Ingots Continuously Cast in Electromagnetic Molds. Theory and Practice [in Russian], Diss. Dr. Sci. (Engineering), Sibirskii Fed. Un-t, Krasnoyarsk (2012).

  4. M. Yu. Khatsayuk, Induction Unit with MVGD Action on the High-Alloyed Aluminum Alloys in the Process of their Preparation and Casting [in Russian], Diss. Cand. Sci. (Engineering), Sibirskii Fed. Un-t, Krasnoyarsk (2013).

  5. M. Yu. Khatsayuk, M. V. Pervukhin, N. V. Sergeev, et al., Pat. 2477193 RF, MPK V22D 11/01. Method of Manufacturing Ingots Using Nonferrous Metal Alloys [in Russian], No. 2011106625; Appl. 02/22/2011, Publ. 03/10/2013, Bull. No. 7.

  6. Electronic resource: http://elmacast.com (date accessed 08/01/2022).

  7. A. E. Slukhotskii, V. S. Nemkov, N. A. Pavlov, et al., Induction Heating Units [in Russian], Energoizdat, Leningrad (1981).

    Google Scholar 

  8. M. Yu. Khatsayuk, Theory and Modeling of Magnetohydrodynamic Processes in Metallurgical Electrotechnological Complexes [in Russian], Diss. Dr. Sci. (Engineering), SPbGETU “LETI,” St. Petersburg (2019).

  9. V. Bojarevics, “Magnetic levitation fluid dynamics,” Magnetohydrodynamics, 37(1/2), 93–102 (2001).

    Google Scholar 

  10. S. Spitans, E. Baake, B. Nake, and A. Jakovics, “Numerical modeling of free surface dynamics of melt in an alternate electromagnetic field. Part II. Conventional electromagnetic levitation,” Metallurgical and Mater. Trans. B., 47(1), 522–536 (2015).

    Article  Google Scholar 

  11. J. Vencels, P. Raback, and V. Geza, “EOF-Library: Open-Source Elmer FEM and OpenFOAM coupler for electromagnetics and fluid dynamics,” SoftwareX, 9, 68–72 (2019).

    Article  Google Scholar 

  12. V. Geza, Investigation of Stratified Electromagnetically Driven Flows in Electrically Conducting Fluids, Ph. D. Thesis, University of Latvia, Riga (2015).

  13. V. B. Demidovich, M. Yu. Khatsayuk, I. I. Rastvorova, V. N. Timofeev, and A. A. Maksimov, “Numerical simulation of non-crucible melting of titanium alloy in the alternating electromagnetic field,” Magnetohydrodynamics, 51(4), 785–794 (2015).

    Google Scholar 

  14. A. Minakov, M. Khatsayuk, V. Demidovich, and M. Pervukhin, “Mathematical modeling of casting processes in electromagnetics field,” Magnetohydrodynamics, 51(1), 57–65 (2015).

    Article  Google Scholar 

  15. V. N. Timofeev, Electromagnetic Rotators, Agitators, and Dispensers of Aluminum Melts [in Russian], Diss. Dr. Sci. (Engineering), Krasnoyarskii Gos. Tekh. Un-t, Krasnoyarsk (1994).

  16. A. Sabau, K. Kuwana, S. Viswanathan, K. Saito, and L. Davis, “Heat transfer boundary conditions for the numerical simulation of the DC casting process,” In Conf. Proc. “Light Metals 2004”, Charlotte, USA, 667–672 (2004).

  17. V. V. Boyarevich, Ya. Zh. Freiberg, and E. V. Shcherbinin, Electric Eddy Currents [in Russian], Znanie, Riga (1985).

  18. A. V. Minakov, M. V. Pervukhin, D. V. Platonov, and M. Yu. Khatsayuk, “Mathematical model and numerical simulation of aluminum casting and solidification in magnetic fields with allowance for free surface dynamics,” Computational Mathematics and Mathematical Physics, 55(12), 2066–2079 (2015).

    Article  Google Scholar 

  19. G. A. Ostroumov, Free Thermal Convection in the Conditions of an Internal Problem [in Russian], Gostekhizdat, Moscow (1952).

    Google Scholar 

  20. F. R. Menter, “Two-equation eddy-viscosity turbulence models for engineering applications,” AIAA J., 32(8), 1598–1605 (1994).

    Article  Google Scholar 

  21. C. W. Hirt and B. D. Nicholos, “Volume of fluid (VOF). Method for the dynamics of free boundaries,” J. of Computational Physics, 39(31), 201–226 (1981).

    Article  Google Scholar 

  22. A. A. Minakov, Numerical Modeling of Viscous Incompressible Fluid Currents with Movable Boundaries [in Russian], Diss. Cand. Sci. (Engineering), Krasnoyarskii gos. tekh. un-t, Krasnoyarsk, (2008).

  23. V. R. Voller, A. D. Brent, and C. Prakash, “The modeling of heat, mass and solute transport in solidification systems,” Intern. J. Heat Mass Transfer, 32(9), 1719–1731 (1989).

    Article  CAS  Google Scholar 

  24. V. R. Voller and C. Prakash, “A fixed-grid numerical modeling methodology for convection-diffusion mushy region phase-change problems,” Intern. J. Heat Mass Transfer, 30(8), 1709–1720 (1987).

    Article  CAS  Google Scholar 

  25. N. A. Belov, E. A. Naumova, and T. K. Akopyan, Aluminum-Based Eutectic Alloys: New Alloying Systems [in Russian], Ruda i Metally, Moscow (2016).

    Google Scholar 

Download references

The study is supported by the Grant of the Russian Scientific Fund (project № 22-19-00128 “Structural evolution of high-strength Al–Zn–Mg (Ni, Fe, Ca) system aluminum alloys using electromagnetic casting technology”, https://rscf.ru/project/22-19-00128/).

Author information

Authors and Affiliations

  1. Siberian Federal University, Krasnoyarsk, Russian Federation

    M. Yu. Khatsayuk, E. R. Vinter, V. N. Timofeev & N. V. Sergeev

  2. RPC Magnetic Hydrodynamics, Krasnoyarsk, Russian Federation

    M. Yu. Khatsayuk, E. R. Vinter, V. N. Timofeev, N. V. Sergeev & M. M. Motkov

  3. National University of Science and Technology (MISIS), Moscow, Russia

    N. A. Belov

Authors
  1. M. Yu. Khatsayuk
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. E. R. Vinter
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. V. N. Timofeev
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. N. A. Belov
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. N. V. Sergeev
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. M. M. Motkov
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to M. Yu. Khatsayuk.

Additional information

Translated from Metallurg, Vol. 67, No. 3, pp. 84–95, March, 2023. Russian https://doi.org/10.52351/00260827_2023_03_84.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Khatsayuk, M.Y., Vinter, E.R., Timofeev, V.N. et al. Multi-Disciplinary Numerical Analysis of Aluminum Ingot Electromagnetic Casting. Metallurgist 67, 362–379 (2023). https://doi.org/10.1007/s11015-023-01523-2

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11015-023-01523-2

Keywords

Search

Navigation