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Multi-physics coupling simulation investigation of semi-solid A380 aluminum alloy during intermediate frequency electromagnetic stirring process

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Abstract

Electromagnetic stirring (EMS) is one of the most used techniques for the preparation of aluminum alloy semi-solid slurry. Compared with other EMS methods, the intermediate frequency electromagnetic stirring (IFEMS) method can achieve the stirring of semi-solid slurry by adjusting the process parameters and realizing the heating of the material. In this study, a 2D symmetric model with coupled magnetic field-flow field simulation was used to study the effects of the input current and input frequency of the induction coil on the magnetic induction intensity and EMS effect in the slurry. The increase of the input current significantly increased the velocity of the slurry at each position but had little effect on the change of the flow direction. The increase of the input frequency improved the stirring effect in some positions of the slurry within a certain range, but the overall intensity of the slurry motion decreased, and the edge effect of the magnetic field and velocity field enhanced. The input current of the induction coil should be less than 100A, and the input frequency should be around 2000 Hz. The experimental platform of the IFEMS was also built to investigate the influence of the input current and stirring time on the microstructure of the prepared samples, and the stirring effects at the center and edge positions of the slurry were compared. Lastly, the microscopic near-spherical structure with an average diameter of 46 μm was obtained using this method, which proved the feasibility of IFEMS for the preparation of aluminum alloy semi-solid slurry.

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Funding

The authors are grateful for the support of the National Natural Science Foundation of China (Project No. 51875441), the Fundamental Research Funds for the Central Universities (No. zrzd2017027), and the research funds from Shaanxi Provincial Land Engineering Construction Group.

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Authors and Affiliations

  1. School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an, 710049, China

    Yukai Chen, Miao Cao, Hao Li, Yin Wang & Qi Zhang

  2. School of Marine Science and Technology, Northwestern Polytechnical University, Xi’an, 710049, China

    Miao Cao

Authors
  1. Yukai Chen
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  2. Miao Cao
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  3. Hao Li
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  4. Yin Wang
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  5. Qi Zhang
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Contributions

Yukai Chen: methodology, simulation, test operation, writing-original draft. Miao Cao: conceptualization, resources, test operation. Hao Li: test operation, data analysis. Yin Wang: writing review and editing. Qi Zhang: project administration, funding acquisition.

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Correspondence to Qi Zhang.

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Chen, Y., Cao, M., Li, H. et al. Multi-physics coupling simulation investigation of semi-solid A380 aluminum alloy during intermediate frequency electromagnetic stirring process. Int J Adv Manuf Technol 125, 4329–4339 (2023). https://doi.org/10.1007/s00170-023-11027-7

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  • DOI: https://doi.org/10.1007/s00170-023-11027-7

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