Generation of Reverse Meniscus Flow by Applying An Electromagnetic Brake

• Published in: Metallurgical and materials transactions. B, Process metallurgy and materials processing science Process metallurgy and materials processing science, 2021-10, Vol.52 (5), p.3193-3207
• Main Authors: Vakhrushev, Alexander, Kharicha, Abdellah, Karimi-Sibaki, Ebrahim, Wu, Menghuai, Ludwig, Andreas, Nitzl, Gerald, Tang, Yong, Hackl, Gernot, Watzinger, Josef, Eckert, Sven
• Format: Article
• Language: English
• Subjects: Characterization and Evaluation of Materials; Chemistry and Materials Science; Damping; Electrical resistivity; Field strength; Flow distribution; Fluid flow; Hartmann number; Kinetic energy; Lorentz force; Magnetic fields; Magnetism; Magnetohydrodynamic turbulence; Magnetohydrodynamics; Materials Science; Mathematical models; Metallic Materials; Molds; Nanotechnology; Numerical models; Original Research Article; Structural Materials; Surfaces and Interfaces; Thin Films; Turbulent flow; Vortices
• ISSN: 1073-5615; 1543-1916
• DOI: 10.1007/s11663-021-02247-x

A numerical study is presented that deals with the flow in the mold of a continuous slab caster under the influence of a DC magnetic field (electromagnetic brakes (EMBrs)). The arrangement and geometry investigated here is based on a series of previous experimental studies carried out at the mini-LIMMCAST facility at the Helmholtz-Zentrum Dresden-Rossendorf (HZDR). The magnetic field models a ruler-type EMBr and is installed in the region of the ports of the submerged entry nozzle (SEN). The current article considers magnet field strengths up to 441 mT, corresponding to a Hartmann number of about 600, and takes the electrical conductivity of the solidified shell into account. The numerical model of the turbulent flow under the applied magnetic field is implemented using the open-source CFD package OpenFOAM®. Our numerical results reveal that a growing magnitude of the applied magnetic field may cause a reversal of the flow direction at the meniscus surface, which is related the formation of a “multiroll” flow pattern in the mold. This phenomenon can be explained as a classical magnetohydrodynamics (MHD) effect: (1) the closure of the induced electric current results not primarily in a braking Lorentz force inside the jet but in an acceleration in regions of previously weak velocities, which initiates the formation of an opposite vortex (OV) close to the mean jet; (2) this vortex develops in size at the expense of the main vortex until it reaches the meniscus surface, where it becomes clearly visible. We also show that an acceleration of the meniscus flow must be expected when the applied magnetic field is smaller than a critical value. This acceleration is due to the transfer of kinetic energy from smaller turbulent structures into the mean flow. A further increase in the EMBr intensity leads to the expected damping of the mean flow and, consequently, to a reduction in the size of the upper roll. These investigations show that the Lorentz force cannot be reduced to a simple damping effect; depending on the field strength, its action is found to be topologically complex.