Influence of electromagnetic stirrer position on fluid flow and solidification in continuous casting mold

Abstract

• Numerical investigation of solidification behavior with EMS position is proposed. • Breaking of solidified layer was observed by shifting the EMS position downward. • With EMS application, liquid fraction values were decreased in mold core region. • Tangential velocity values were found to be maximum near solidified shell. A computational study of the effect of stirrer position on fluid flow and solidification in a continuous casting billet mold with in-mold electromagnetic stirring has been carried out. The numerical investigation uses a full coupling method in which alternating magnetic field equations are solved simultaneously with the governing equations of fluid flow and heat transfer. An enthalpy-porosity technique is used for the solidification analysis while the magnetohydrodynamics technique is used for studying the fluid flow behavior under the electromagnetic field. The streamline, liquid fraction, and solid shell thickness at the mold wall have been predicted with and without EMS application at different positions along the length of the mold. Recirculation loops are seen to be formed above and below the stirrer position when fluid flow and electromagnetic field equations were solved, without incorporating the solidification model. Application of the solidification model interestingly resulted in the reduction of the size of the recirculation loops formed. The tangential component of velocity of the fluid near the solidification front, stirring intensity and the effective length of stirring below the stirrer decrease as the stirrer position is moved downwards. Significant changes in characteristics of solid shell formation like delay in initiation of solidification at the mold wall and formation of a gap in the re-solidified shell have been observed with change in stirrer position.