The effect of harmonic magnetic field (HMF), pulse magnetic field (PMF), differential phase harmonic magnetic field (DHMF), and differential phase pulse magnetic field (DPMF) on liquid and mushy zones of crystallizing metal was investigated by numerical simulation referring to electromagnetic DC (direct chill) casting process. Firstly, the experimental pulse current for electromagnetic casting was obtained by a digital oscilloscope. The physical and finite element models of Φ300-mm cylindrical crystallization for the electromagnetic field simulation were established. Then, the distribution of magnetic flux density (B) and electromagnetic forces (FMAG) generated by the four types of magnetic fields were obtained in a period (T). Actions of HMF, PMF, DHMF, and DPMF on molten melt were discussed based on radial and axial electromagnetic forces. Finally, the effects of electromagnetic parameters (current intensity, frequency, and duty cycle) on electromagnetic forces under PMF and DPMF were studied. The effect of electromagnetic forces on metal flow has been discussed. The results indicate that compared with harmonic current, the pulse current can generate a stronger magnetic field with the same conditions. Single-coil magnetic field can easily cause the molten metal radial vibration. The differential phase magnetic field can not only cause radial vibration but also produce axial convection, while the vibration effect is weaker. The electromagnetic forces increase with the increase of current intensity and duty cycle under PMF and DPMF. Moreover, the electromagnetic force has low sensitivity to frequency under DPMF.
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