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A Review of Permanent Magnet Stirring During Metal Solidification

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Abstract

Rather than using conventional electromagnetic stirring (EMS) with three-phase alternating current, permanent magnet stirring (PMS), based on the use of sintered NdFeB material which has excellent magnetic characteristics, can be employed to generate a magnetic field for the stirring of liquid metal during solidification. Recent experience with steel casting indicates that PMS requires less than 20 pct of the total energy compared with EMS. Despite the excellent magnetic density properties and low power consumption, this relatively new technology has received comparatively little attention by the metal casting community. This paper reviews simulation modeling, experimental studies, and industrial trials of PMS conducted during recent years. With the development of magnetic simulation software, the magnetic field and associated flow patterns generated by PMS have been evaluated. Based on the results obtained from laboratory experiments, the effects of PMS on metal solidification structures and typical defects such as surface pinholes and center cavities are summarized. The significance of findings obtained from trials of PMS within the metals processing sector, including the continuous casting of steel, are discussed with the aim of providing an overview of the relevant parameters that are of importance for further development and industrial application of this innovative technology.

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Abbreviations

EMS:

Electromagnetic stirring

PMS:

Permanent magnet stirring

AC:

Alternating current

RMF:

Rotating magnetic field

n :

Rotation speed or rotating velocity, rpm

B :

Magnetic flux densities, T

B 0 :

Magnetic flux density associated with magnet, T

T m :

Modulation period, s

ψ(x, y, z):

Shape function of magnet

x :

Distance from the magnet, m

f :

Stirring frequency, Hz

μ :

Magnetic permeability of the melt, H/m

σ :

Electrical conductivity, 1/(Ω·m)

ω :

Angular frequency, rad/s

R :

Radius, m

δ :

Electromagnetic skin depth, m

q :

The number of pairs of poles

F :

Magnetic body force, kN/m3

F θ :

Tangential component of Lorentz force, kN/m3

Ha :

Hartmann number

Ta :

Magnetic Taylor number

Re w :

Magnetic Reynolds number

ρ :

Density of the melt, kg/m3

v :

Kinematic viscosity, m2/s

CET:

Columnar to equiaxed transition

DC:

Direct current

M-EMS:

Mold electromagnetic stirring

F-EMS:

Final electromagnetic stirring

F-PMS:

Final position permanent magnet stirring

UDV:

Ultrasonic Doppler velocimetry

DAS:

Dendrite arm spacing, μm

\( \overrightarrow {H} \) :

Magnetic field intensity, A/m

\( \overrightarrow {J} \) :

Induction current intensity, A/m2

\( \overrightarrow {D} \) :

Electric displacement vector, C/m2

\( \overrightarrow {E} \) :

Electric field intensity, V/m

\( \overrightarrow {F} \) :

Electromagnetic force per unit volume, N/m3

\( \overrightarrow {V} \) :

Velocity of metal, m/s

P :

Pressure, Pa

μ eff :

Effective viscosity, Pa s

μ t :

Turbulent viscosity, Pa s

\( \overrightarrow {g} \) :

Gravitational acceleration, m/s2

\( \overrightarrow {F}_{\text{M}} \) :

Time averaged electromagnetic force, N/m3

\( \overrightarrow {F}_{\text{other}} \) :

Other interaction force, N/m3

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Acknowledgments

Financial support from the China Scholarship Council for Jie Zeng’s study at the University of Toronto is gratefully acknowledged.

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Authors and Affiliations

  1. State Key Laboratory of Advanced Metallurgy, University of Science and Technology Beijing, Beijing, 100083, China

    Jie Zeng & Weiqing Chen

  2. Department of Materials Science & Engineering, University of Toronto, Toronto, ON, M5S 3E4, Canada

    Jie Zeng, Yindong Yang & Alexander Mclean

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  1. Jie Zeng
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Correspondence to Jie Zeng.

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Manuscript submitted February 20, 2017.

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Zeng, J., Chen, W., Yang, Y. et al. A Review of Permanent Magnet Stirring During Metal Solidification. Metall Mater Trans B 48, 3083–3100 (2017). https://doi.org/10.1007/s11663-017-1077-7

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