Modeling of MHD edge containment in strip casting with ELEKTRA and CaPS-EM codes

Abstract

This paper presents modeling studies of magnetohydrodynamics analysis in twin-roll casting. Argonne National Laboratory (ANL) and ISPAT Inland Inc. (Inland), formerly Inland Steel Co., have worked together to develop a three-dimensional (3-D) computer model that can predict eddy currents, fluid flows, and liquid metal containment of an electromagnetic (EM) edge containment device. The model was verified by comparing predictions with experimental results of liquid metal containment and fluid flow in EM edge dams (EMDs) that were designed at Inland for twin-roll casting. This mathematical model can significantly shorten casting research on the use of EM fields for liquid metal containment and control. The model can optimize the EMD design so it is suitable for application, and minimize expensive time-consuming full-scale testing. Numerical simulation was performed by coupling a 3-D finite-element EM code (ELEKTRA) and a 3-D finite-difference fluids code (CaPS-EM) to solve heat transfer, fluid flow, and turbulence transport in a casting process that involves EM fields. ELEKTRA can predict the eddy-current distribution and the EM forces in complex geometries. CaPS-EM can model fluid flows with free surfaces. The computed 3-D magnetic fields and induced eddy currents in ELEKTRA are used as input to temperature- and flow-field computations in CaPS-EM. Results of the numerical simulation compared well with measurements obtained from both static and dynamic tests.