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<p>We propose two novel combined ElectroMagnetic (EM) devices for ultra-high-speed continuous casting of steel billets. The first device uses a High-Frequency (HF) ElectroMagnetic Casting (EMC) system beneath the melt free-surface in the mold, an EM Brake (EMBr) under the submerged entry nozzle, and a Low-Frequency (LF) EM Stirrer (EMS) around the middle part of the mold. The second configuration replaces the EMC with an HF-EMS. The adopted rectangular iron cores allow mounting the coils along the billet periphery to provide a more uniform Lorentz force distribution. To study these devices, a multi-physics numerical model is detailed, implemented in OpenFOAM, and carefully validated against several benchmarks. The results reveal that both EMC and HF-EMS are capable of creating a hot-active meniscus region and enhancing superheat transport while keeping the surface velocity and turbulent kinetic energy within the standard range. Both technologies, through the repulsive component of the Lorentz force, can push the initial solidified shell away from the wall, reducing deep oscillation marks, and shape the meniscus into a curved surface, facilitating the mold flux lubrication. The HF-EMS in the second device generates a swirling flow at the top free-surface, providing a higher temperature uniformity and a smaller dead zone.</p>

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Novel Combined Electromagnetic Devices for Ultra-High-Speed Billet Continuous Casting

  • 期刊论文

  • 发表日期：

    2025年11月4日

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  • S. M. Hosseini,
  • N. K. Mahabadi,
  • E. Amani

摘要

We propose two novel combined ElectroMagnetic (EM) devices for ultra-high-speed continuous casting of steel billets. The first device uses a High-Frequency (HF) ElectroMagnetic Casting (EMC) system beneath the melt free-surface in the mold, an EM Brake (EMBr) under the submerged entry nozzle, and a Low-Frequency (LF) EM Stirrer (EMS) around the middle part of the mold. The second configuration replaces the EMC with an HF-EMS. The adopted rectangular iron cores allow mounting the coils along the billet periphery to provide a more uniform Lorentz force distribution. To study these devices, a multi-physics numerical model is detailed, implemented in OpenFOAM, and carefully validated against several benchmarks. The results reveal that both EMC and HF-EMS are capable of creating a hot-active meniscus region and enhancing superheat transport while keeping the surface velocity and turbulent kinetic energy within the standard range. Both technologies, through the repulsive component of the Lorentz force, can push the initial solidified shell away from the wall, reducing deep oscillation marks, and shape the meniscus into a curved surface, facilitating the mold flux lubrication. The HF-EMS in the second device generates a swirling flow at the top free-surface, providing a higher temperature uniformity and a smaller dead zone.