Numerical simulation of the spheroidization process with cored wire injection in liquid iron using finite volume method

We develop a finite volume method for the simulation of the liquid iron cored wire feeding spheroidization technology, which can realize the visualization of the spheroidization process and provide guidance for parameter optimization. In this work, we first define a two-dimensional unsteady heat-transfer mathematical model for single-core structure cored wire melting in liquid iron and then discretize the governing equation numerically. The present solver is validated by comparing it with the data obtained from experimental studies. Interestingly, in the numerical results we found that the absorption velocity of the magnesium element can be improved to the greatest extent to get the most ideal spheroidizing effect. To further show the melting and boiling characteristics of spheroidization, we also explore the relationship between melting and boiling depth, wire feeding speed, and temperature of liquid iron in the feeding process, and the wire feeding speed-depth function was also obtained.