Abstract
This article describes the initial development of fluid flow and heat transfer in a planar flow casting (PFC) process for amorphous ribbon formation using a two-dimensional (2-D) model of fluid flow with free surface and surface tension, and heat transfer with phase transformation. The heat transfer in the rotating copper roller is incorporated into the model. A coupled fluid-solid (the puddle/roller surface) solution is employed for identifying the ideal interfacial heat transfer. The initial developments of puddle shape and flow and temperature distribution, including the air and the melt in the puddle zone, over time are presented. The time-dependent theoretical interfacial heat-transfer-coefficient and temperature profiles in the rotating roller are investigated. The effect of the varying roller speed, the PFC configurations (slit width and gap distance), and the roller parameters (roller radius and roller layer thickness) on the development of the melt flow and heat transfer in a PFC process are discussed. Numerical results show that a stable puddle shape can be formed within a very short period of time (on the order of milliseconds). The time evolution of the upstream meniscus is different from that of the downstream meniscus. The recirculation flows both in the surrounding air and in the melt of the puddle zone can be observed at a quasi-steady-state condition, but show different flow and thermal behaviors. The interfacial heat-transfer coefficient and temperature distribution of the rotating roller change with different cycles of the roller revolution until the heat-flux balance is reached. The varying parameters associated with the roller speed, slit width, gap distance, roller radius, and roller layer thickness affect the time evolution of the flow and thermal behavior in the puddle and the temperature distribution in the rotating roller.
Published Version
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