Multi-physics coupled numerical simulation study to optimize process parameters for electromagnetic stirring of semi-solid A356 aluminum alloy under the influence of skin effect

The electromagnetic stirring (EMS) method stands as a widely used technique in creating semi-solid aluminum alloy slurry due to its convenience and precision in parameter control compared to other methods. In this study, a comprehensive model that combines electromagnetics, flow, heat transfer and solidification was formed. By analyzing the influence of input current and frequency on the electromagnetic force, the behavior of various process parameters in velocity field and temperature field under influence of the skin effect is investigated. The aim is to find the optimal process parameters for production of slurry using the low-frequency EMS. The results show that within the investigated range, by adjusting the input current and frequency to 150 A and 15 Hz, higher fluid velocities and appropriate distribution of vortex zones can be observed, while achieving a uniform temperature field, the highest cooling rate and the minimum radial temperature difference. In addition, the sample prepared under the optimal process parameters shows that the melt edge is least affected by the skin effect, which leads to a higher stirring strength and a smaller overall grain size, which is consistent with the theoretical skin effect research found within the simulation section.