A three-dimensional fluid flow model for puddle formation in the single-roll rapid solidification process

Abstract

The single-roll rapid solidification process (SRRSP) is considered to be a process of perspective to produce a Fe-Si-B ribbon of amorphous microstructure and near net shape products such as thin strips of stainless steel. The condition of a melt puddle between the nozzle and rotating wheel in the single-roll rapid solidification process significantly affects the quality and dimensional uniformity of the products as well as the smoothness of the operation. The purpose of this study was to develop a three-dimensional fluid flow analysis system to model the formation of puddle and flow conditions of molten metal in the puddle for the single-roll rapid solidification processes which include the planar flow casting (PFC) process and the single-roll strip casting process. The model is based on a computational fluid dynamics technique called the SOLA-VOF scheme, which possesses the capability of treating transient fluid flow problems with the evolution of free boundaries. Furthermore, the SOLA-VOF scheme is extended from two dimensions to three dimensions. The simulated results reveal how the melt puddle is formed between the nozzle and the rotating substrate and its corresponding fluid flow behavior for the PFC process as well as the single-roll strip casting process. The test results also demonstrate that two-dimensional analysis cannot properly consider the actual flow condition in the puddle.