| Abstract Scope |
Many metallurgical processes involve the interaction of fluid flow, heat transfer, solidification, electromagnetism, and chemical transport. External physical fields, such as electric currents, static and rotating magnetic fields, and mechanical rotation, are widely used to control melt flow and solidification in order to improve product quality and process performance. Advanced numerical models are essential for understanding these coupled phenomena and optimizing industrial processes.
This presentation introduces recent developments in multiphase and multiphysics modeling of solidification under external physical fields. Applications include the growth of single-crystal turbine blades, where rotation and Coriolis forces influence melt flow and crystal quality; rotating casting vessels, where forced rotation affects melt convection, the columnar-to-equiaxed transition (CET), and macrosegregation; continuous casting, where static magnetic fields (EMBr) and electromagnetic stirring (EMS) are used to control flow and solidification; and melting and remelting processes, such as electric arc furnaces (EAF), electroslag remelting (ESR), vacuum arc remelting (VAR), and cold crucible induction melting, where electric currents and magnetohydrodynamic (MHD) effects govern heat generation and melt flow.
Since advanced numerical models must accurately predict real industrial processes, experimental validation is an essential part of their development. Examples of validation methods and comparisons with experiments will also be presented.
Finally, a new semi-continuous casting concept using a moving electromagnetic stirring system is introduced. Developed through advanced numerical simulations, this process demonstrates how multiphysics modeling can support the design of innovative metallurgical technologies, improve process control, and reduce the need. |