Process Analysis of Non-contact Continuous Casting of Materials Using Cold Crucible.

Abstract

An axi-symmetric process model for the cold crucible continuous casting is developed based on analyses of elctromagnetic and temperature fields coupled with force balance around the free boundary of melt. The electromagnetic field around the system is predicted by means of a wire model using the vector potential method. A characterstic temperature field in the charge which is electromagnetically repelled by the crucible is given by a finite difference solution of the heat balance equation taking transitional phase change into consideration. The validity of he proposed theoretical model has been confirmed by experimental measurements of the electromagnetic field around the cold crucible and temperature field in the charge. Numerical predictions show that keeping a molten charge without contact of a surrounding crucible is possible when the position and shape of solidification front is properly controlled by a regulated water cooling of the surface in the lower part of the charge. A laboratory experiment has been conducted to support this predicted fact. Theoretical operational criteria as to casting speed, cooling position and its rate which allow a stable and non-contact melting of the charge are shown.