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Numerical Simulation and Industrial Experiment of the Fluid Flow and Heat Transfer in Large Vertical Round Billets with Helical Final Electromagnetic Stirring

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Abstract

The effect of a helical electromagnetic stirring on the magnetic field, liquid steel flow, and heat transfer in 800-mm-diameter vertical round billets has been studied by numerical simulation, and its effectiveness in improving the internal defects has been verified by industrial experiments. The results show that the electromagnetic force drives the liquid steel to produce tangential rotating flow, which is concentrated in the liquid core. The X-velocity value increases first and then decreases at frequencies in the range 1–9 Hz, reaching its maximum value when f = 7 Hz. The higher the current intensity, the stronger the liquid steel flow. The flow range increases and the gradient of X-velocity decreases with the increase of current intensity. The heat transfer of the liquid core interacts with the flow of liquid steel and the effect is limited by the helical F-EMS current parameters. When F-EMS is not applied, the central porosity is porphyritic and dense, gradually dispersing outwards. After applying the helical F-EMS (I = 600 A, f = 7 Hz), the center porosity is dispersed into small pieces and the stirring traces appear in the mushy zone. The center porosity level was significantly reduced, and the center crack range was decreased on average by 26 mm.

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Acknowledgements

The authors are grateful for the financial support from the National Natural Science Foundation of China (Grant 51504130) and Henan Province Key S&T Special Projects (151100212700).

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Authors and Affiliations

  1. School of Material and Metallurgy, University of Science and Technology Liaoning, Anshan, 114051, China

    Hongjian Wu, Changjun Xu, Tao Wang & Xiaobing Zhang

  2. Henan Zhongyuan Special Steel Equipment Manufacturing Co., Ltd, Jiyuan, 459008, China

    Chong Lei, Yingli Gao & Huiye Jin

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  1. Hongjian Wu
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  2. Changjun Xu
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  3. Chong Lei
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  4. Tao Wang
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Correspondence to Changjun Xu.

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Wu, H., Xu, C., Lei, C. et al. Numerical Simulation and Industrial Experiment of the Fluid Flow and Heat Transfer in Large Vertical Round Billets with Helical Final Electromagnetic Stirring. JOM 75, 1439–1449 (2023). https://doi.org/10.1007/s11837-022-05511-w

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