Issues on Puddle Formation During Rapid Solidification of Fe–Si–B–Nb–Cu Alloy Using Planar Flow Melt Spinning Process

Abstract

The present investigation deals with the processing of rapidly solidified 10–40 mm wide, 30–50 μm thick and 10–30 m long continuous amorphous ribbons of Fe–Si–B–Nb–Cu alloy using a planar flow melt spinning (PFMS) equipment. As the formation of quality amorphous ribbon depends on the melt puddle formed between the nozzle and the rotating copper wheel, the effect of different processing parameters such as nozzle wheel gap, ejection pressure etc. on the shape and stability of puddle has been studied using a high-speed imaging system and correlated with ribbon formation. Simultaneously, a two-dimensional numerical model has been developed to simulate the puddle formation during the PFMS process. The model is based on a computational fluid dynamics technique, called volume of fluid using transient heat transfer and fluid flow equations with the evolution of free boundaries. Different simulations have been performed to study the effect of process parameters on the puddle formation. The simulated results have been verified with the experimental observations considering same set of process parameters. It has been observed that the present simulations have produced exact replica of the experimental observations. Further parametric analysis as well as analysis of simulated result has been carried out to understand how the different process parameters affect the formation of quality amorphous ribbons during PFMS process.