Influence of M-EMS on Fluid Flow and Initial Solidification in Slab Continuous Casting

Area of Science:

• Materials Science
• Fluid Dynamics
• Electromagnetism

Background:

• Continuous casting is crucial for steel production.
• Controlling solidification and fluid flow in the mold is key to product quality.
• Electromagnetic stirring (EMS) is a technique used to influence melt behavior.

Purpose of the Study:

• To develop and validate a mathematical model for transient turbulent flow and initial solidification in a continuous casting mold.
• To investigate the effects of varying electromagnetic stirring (EMS) currents and casting speeds on mold fluid dynamics and shell formation.
• To determine optimal EMS parameters for uniform solidified shell growth and reduced defects.

Main Methods:

• A mathematical model integrating fluid dynamics and electromagnetic fields was developed.
• Model validation was performed by comparing magnetic flux density and flow field simulations with experimental measurements.
• A uniform index for solidified shell thickness was introduced to quantify shell uniformity.

Main Results:

• The mathematical model accurately predicted flow fields and magnetic flux density.
• EMS induced horizontal recirculation flow and altered flow field regions (acceleration/deceleration).
• High EMS current and low casting speed led to plug flow; optimal EMS promoted uniform shell growth.
• Industrial tests confirmed EMS reduces level fluctuation and inclusion density.

Conclusions:

• The developed model reliably simulates the continuous casting process under EMS.
• Optimizing EMS current is essential for uniform solidified shell growth.
• A rational EMS current range of 500-600 A is identified for a casting speed of 1.2 m/min to enhance slab quality.