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Numerical Simulation of Process of Electromagnetic Casting and Technology Features

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Abstract

This paper presents a proposed numerical model of casting process into electromagnetic crystallizer mold and results obtained when applying it to the analysis of the processes of casting aluminum ingots with a diameter of 25 to 30 mm. The numerical model is based on the calculation of the electromagnetic field by means of user-defined function (UDF) in Fluent software combined with the simulation of processes related to free surface using volume of fluid (VOF) method and crystallization on Kozeny-Carman method. The results of solving the search problem on the determination of a set of parameters ensuring the stable formation of an ingot of the required diameter as well as the results of simulation of emergency and special modes are shown. The article also presents application results of the modes identified on the laboratory installation of casting into electromagnetic crystallizer using ElmaCast® technology for the production of ingots from experimental alloys "Nikalin" and "Alcimac".

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Acknowledgments

The study was supported by a grant from the Russian Science Foundation (project No. 22-19-00128 “Evolution of the structure of high-strength aluminum alloys of the Al-Zn-Mg (Ni, Fe, Ca) system obtained by technology of electromagnetic casting”, https://rscf.ru/project/22-19-00128/).

Conflict of interest

The authors declare that they have no conflict of interest.

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Authors and Affiliations

  1. Siberian Federal University, Kirenskogo Str. 26A, Krasnoyarsk, Russia, 660074

    Maksim Khatsayuk, Eduard Vinter, Viktor Timofeev, Nikolay Sergeev & Mikhail Pervukhin

  2. LLC “RPC Magnetic Hydrodynamics”, Kirenskogo Str. 9A, Krasnoyarsk, Russia, 660074

    Maksim Khatsayuk, Eduard Vinter, Viktor Timofeev & Nikolay Sergeev

  3. National University of Science and Technology MISIS, Leninskiy Prospekt 4, Moscow, Russia, 119049

    Nikolay Belov

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  1. Maksim Khatsayuk
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  2. Eduard Vinter
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  4. Nikolay Belov
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Correspondence to Eduard Vinter.

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Appendix

Appendix

Setting of Two-Phase Zone Constant in the Crystallization Model

For the correct choice of the crystallization model parameters the nonequilibrium crystallization curve for the Nikalin and Alcimac alloys was calculated. The curves were obtained based on the composition of the alloys according to the Scheil-Gulliver model.

Figure A1 illustrates the calculated curves, from which it is clear that the total fraction of solid phases has a non-linear character of the temperature dependence. As can be seen, the alloys under study are characterized by a wide crystallization temperature range. However, in the most part of the crystallization range 480 °C…610 °C, the total proportion of solid phases is > 0.5, that is, the melt contains predominantly solid phases. Obviously, the viscosity in this temperature interval increases significantly, which excludes the occurrence of macroscale intense melt flows.

The numerical calculation assumes a linear dependence of the solid phase fraction on temperature in the interval of \({T}_{liq}\dots {T}_{sol}\), and the presence of other phase components in the alloy is not taken into account. In this case, the intensity of macroscale hydrodynamic flows in the crystallization zone depends on the coefficient \({A}_{\beta }\). Consequently, for the problem setting, parameters \({T}_{liq},{T}_{sol}\) and coefficient \({A}_{\beta }\) should be set so as to exclude the occurrence of macroscale melt flows in the area with the temperature below 660 C (solidus point of pure aluminum). This setting corresponds to the selection \({A}_{\beta }\ge {10}^{6}\). This assumption is valid only for melts with a convex curve, similar to the one shown above.

Fig. A1
figure 15

Calculated non-equilibrium crystallization curves for “Nikalin” (a) and “Alcimac” (b) alloys

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Khatsayuk, M., Vinter, E., Timofeev, V. et al. Numerical Simulation of Process of Electromagnetic Casting and Technology Features. Metall Mater Trans B 54, 1768–1783 (2023). https://doi.org/10.1007/s11663-023-02791-8

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