Melt Flow and Solidification Behavior of Large Ingot Casting Process with Annular Vertical Linear Electromagnetic Stirring in Ingot Riser
摘要
A novel method of Annular Vertical Linear Electromagnetic Stirring in Ingot Riser (Riser-AV-LEMS) was proposed for driving the flow and mixing of molten steel in the riser and central zone of large ingot during the final solidification period of ingot casting process, so as to improve the solidifying feeding ability and casting defects in the central zone of large ingot. Firstly, the casting experiment of Incoloy 800H superalloy applying a Vertical Linear Electromagnetic Stirring (V-LEMS) at the top of ingots was carried out to physically simulate the effectiveness of the proposed Riser-AV-LEMS method. The experimental results show that V-LEMS at the top of the ingot can effectively promote the melt flow and mixing of molten steel, and transforms the morphology of liquid core from a deep V-shape profile to a shallower U-shape and effectively improve the central quality of ingot. Secondly, a three-dimensional numerical simulation model coupled with electromagnetic field, melt flow and solidification was established to study the molten steel flow and solidification behavior of Φ800 mm × 1.56 m large ingot under Annular V-LEMS in Riser (Riser-AV-LEMS). The numerical simulations results show that the maximum electromagnetic force generated by Riser-AV-LEMS in the molten steel of ingot riser reaches 5.75 × 103 N·m−3, which can effectively drive melt flow in riser and forms a stable circulating flow in the liquid core of the large ingot. The circulating melt flow promotes the homogenization of temperature at the solidification front, make the morphology of liquid–solid front flat, so that the intersection angle of the tangent line of liquid–solid front increases from 83 to 102 deg. Moreover, the width of the liquid core at the 0.45 m height from the top of large ingot increases from 0.394 to 0.44 m, and the depth difference of the liquid core in the center of large ingot is decreased from 0.404 to 0.271 m, which presents that the solidification feeding ability of molten steel in riser to the central zone of large ingot is significantly improved during the final solidification period of large ingot casting process. The experimental and numerical simulation results show that the proposed Riser-AV-LEMS method can effectively promote the flow and mixing of molten steel in the riser and the central part of ingot, homogenize the distribution of temperature during the final solidification period of large ingot casting process, which is beneficial to effectively reduce the casting defects such as the shrinkage cavities, porosity and macrosegregation in large ingots, thereby improving the metal yield of large ingot.