Experimental and Numerical Modeling of Fluid Flow Processes in Continuous Casting: Results from the LIMMCAST-Project

Timmel, Klaus; Kratzsch, Christoph; Asad, Amjad; Schurmann, Dennis; Schwarze, Rüdiger; Eckert, Sven

doi:10.1088/1757-899x/228/1/012019

Cited by 16 publications

(21 citation statements)

References 54 publications

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“…The flow of the electrically-conductive molten steel in the magnetic fields generates an electromagnetic force opposing the motion, and thus should be self-stabilizing. Experimental studies using low-melting-point metallic melts on the magnetohydrodynamic (MHD) flow have been reported by some researchers [8,10,[19][20][21]. Harada et al [8] investigated the effect of different types of EMBrs on the fluid flow using the mercury model.…”

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confidence: 99%

“…Optimum conditions of the upper and lower magnetic flux densities were present based on the free surface fluctuation and the flow recirculation profiles. Considering the risks of mercury, the ternary alloy GaInSn was used by the Helmholtz Zentrum Dresden-Rossendorf (HZDR) to investigate the impact of a level magnetic field on the discharging jet [11,20,21]. Some advanced measurement technology, such as ultrasound Doppler velocimetry (UDV) and contactless inductive flow tomography (CIFT), were used to reconstruct the flow structure of the liquid metal under the influence of one or multiple magnetic fields.…”

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confidence: 99%

“…An electrically-conducting wall is an essential parameter affecting the turbulent flow in the presence of an external magnetic field [11,20,21,[26][27][28]. Recently, Timmel et al [11,20,21] studied the effect of the electrically-conducting wall on the turbulent flow using two brass plates attached to the inner walls to emulate the solidified shell in the real process. The existence of a conducting wall can stabilize the flow by suppressing the unsteady low-frequency oscillation of the jets.…”

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confidence: 99%

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Effect of an Electrically-Conducting Wall on Transient Magnetohydrodynamic Flow in a Continuous-Casting Mold with an Electromagnetic Brake

Liu

Vakhrushev

et al. 2018

Metals

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Large eddy simulation (LES) of transient magnetohydrodynamic (MHD) turbulent flow under a single-ruler electromagnetic brake (EMBr) in a laboratory-scale, continuous-casting mold is presented. The influence of different electrically-conductive boundary conditions on the MHD flow and electromagnetic field was studied, considering two different wall boundary conditions: insulating and conducting. Both the transient and time-averaged horizontal velocities predicted by the LES model agree well with the measurements of the ultrasound Doppler velocimetry (UDV) probes. Q-criterion was used to visualize the characteristics of the three-dimensional turbulent eddy structure in the mold. The turbulent flow can be suppressed by both configurations of the experiment’s wall (electrically-insulated and conducting walls). The shedding of small-scale vortices due to the Kelvin–Helmholtz instability from the shear at the jet boundary was observed. For the electrically-insulated walls, the flow was more unstable and changed with low-frequency oscillations. However, the time interval of the changeover was flexible. For the electrically-conducting walls, the low-frequency oscillations of the jets were well suppressed; a stable double-roll flow pattern was generated. Electrically-conducting walls can dramatically increase the induced current density and electromagnetic force; hence they contribute to stabilizing the MHD turbulent flow.

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Effect of an Electrically-Conducting Wall on Transient Magnetohydrodynamic Flow in a Continuous-Casting Mold with an Electromagnetic Brake

Liu

Vakhrushev

et al. 2018

Metals

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“…A more accurate method is to use low melting temperature alloys such as mercury, Sn60Bi40, or eutectic Ga68In20Sn12 alloy, in physical models, which have the benefits of being conductive to simulate induced flow from electromagnetic fields, having high surface tension and nonwettability of molten steel to simulate multiphase flow, and being liquid at or near room temperature for easy measurements (Table 1) [86]. Lab scale modeling with these liquid metals can use Ultrasound Doppler Velocimetry (UDV) and Mutual Inductance Tomography (MIT) probes to map internal velocity fields, as applied to single-ruler EMBr fields in a slab casting mold [86][87][88], such as shown in Figure 6 [87]. To maintain similarity between the low melting temperature alloy modeling and real caster conditions with electromagnetic forces, magnetohydrodynamics (MHD) dimensionless numbers, Step milling measurement of particles captured by the solidifying steel shell [82].…”

Section: Lab Scale Modelingmentioning

confidence: 99%

Electromagnetic Forces in Continuous Casting of Steel Slabs

Cho

Thomas

2019

Metals

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This paper reviews the current state of the art in the application of electromagnetic forces to control fluid flow to improve quality in continuous casting of steel slabs. Many product defects are controlled by flow-related phenomena in the mold region, such as slag entrapment due to excessive surface velocity and level fluctuations, meniscus hook defects due to insufficient transport of flow and superheat to the meniscus region, and particle entrapment into the solidification front, which depends on transverse flow across the dendritic interface. Fluid flow also affects heat transfer, solidification, and solute transport, which greatly affect grain structure and internal quality of final steel products. Various electromagnetic systems can affect flow, including static magnetic fields and traveling fields which actively accelerate, slow down, or stir the flow in the mold or strand regions. Optimal electromagnetic effects to control flow depends greatly on the caster geometry and other operating conditions. Previous works on how to operate electromagnetic systems to reduce defects are discussed based on results from plant experiments, validated computational models, and lab scale model experiments.

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“…A verification based on both the experimental and numerical results reported elsewhere is performed. [15][16][17] Recently, the experimental results were improved with respect to the measurement technique and by varying the location of the EMBr system, as reported in Schurmann et al, [18] providing unique data for the future MHD model developments.…”

Section: Introductionmentioning

confidence: 99%

Electric Current Distribution During Electromagnetic Braking in Continuous Casting

Vakhrushev

Kharicha

Liu

et al. 2020

Metall Mater Trans B

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The electromagnetic brake (EMBr) is a well-known and widely applied technology for controlling the melt flow in the continuous casting (CC) of the steel. The effect of a steady (DC) magnetic field (0.31 T) in a CC mold is numerically studied based on the GaInSn experiment. The electrical boundary conditions are varied by considering a perfectly insulating/conductive mold or the presence of a conductive solid shell, which is experimentally modeled by 0.5 mm brass plates. An intense current density (up to 350 kA/m 2) is induced by the EMBr magnetic field in the form of loops. The electric current loop tends to close either inside the liquid bulk or through the conductive solid. Based on the character of the induced current loop closures, the turbulent flow is affected as follows: (i) it becomes unstable in the insulated mold, forming 2D self-inducing vortex structures aligned with the magnetic field; (ii) it is strongly damped for the conductive mold; and (iii) it exhibits transitional behavior with the presence of a solid shell. The application of the obtained results for the real CC process is discussed and validated.

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Experimental and Numerical Modeling of Fluid Flow Processes in Continuous Casting: Results from the LIMMCAST-Project

Cited by 16 publications

References 54 publications

Effect of an Electrically-Conducting Wall on Transient Magnetohydrodynamic Flow in a Continuous-Casting Mold with an Electromagnetic Brake

Effect of an Electrically-Conducting Wall on Transient Magnetohydrodynamic Flow in a Continuous-Casting Mold with an Electromagnetic Brake

Electromagnetic Forces in Continuous Casting of Steel Slabs

Electric Current Distribution During Electromagnetic Braking in Continuous Casting

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