Abstract
A transient 2D axisymmetric mathematical model that couples the pulse electromagnetic field with fluid flow and solidification was established by using the COMSOL Multiphysics software. Based on the measured pulse currents under different electromagnetic parameters, the model was firstly validated, and then the solidification processes of direct-chill (DC) casting in the absence and presence of pulse magnetic field (PMF) were simulated and discussed, including the variations in fluid flow, heat transfer, and solidification characteristics at different locations of the melt. Finally, effects of pulse electromagnetic parameters (current intensity, electromagnetic frequency, and duty cycle) on Lorentz force, flow field, temperature field, and solidification during DC casting of AZ80 magnesium alloy were studied systematically. The forced convection induced by PMF can significantly accelerate the melt flow and heat extraction. As the increase of current intensity, Lorentz force, melt convection, and heat extraction are strengthened considerably, and the increase of frequency has the opposite effect on them. The effect of duty cycle on solidification process is extremely limited. For billets with different magnesium alloy systems and sizes, a fined and uniform solidified structures can be obtained by adjusting the current intensity and electromagnetic frequency in pulse electromagnetic DC casting.
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