Numerical investigation of in-mold electromagnetic stirring process for fluid flow and solidification

Purpose - The purpose of present investigation is to analyze the in-mold electromagnetic stirring (M-EMS) process and the effect of stirrer frequency on fluid flow and solidification in a continuous casting billet caster mold. Design/methodology/approach - A hybrid approach involving finite element and finite volume method has been used for the study. Finite element model is used to calculate time variable magnetic field, which is further coupled with fluid flow and solidification equations for magneto-hydrodynamic analysis with finite volume model. Findings - Results show that though superheat given to steel before its entry into the mold is quickly removed, solid shell formation is delayed by the use of M-EMS. Final solid shell thickness, however, is slightly reduced. Increase in frequency is found to increase the magnetic flux density and tangential velocity of liquid steel and decrease in diameter of liquid core. Practical implications - The work is of great industrial relevance. The model may be used to design industrial setup of in-mold electromagnetic stirrer and process could be analyzed and optimized numerically. Originality/value - The paper evaluates the influence of M-EMS and its frequency on solidification and flow behavior in the continuous casting mold. The iso-surface temperatures from pouring temperature to liquidus temperature inside the mold have been shown. The findings may be useful for the steelmakers to reduce the defect in continuous casting.