Modeling of electromagnetic casting in two and three dimensions

This dissertation discusses an investigation of electromagnetic continuous casting. In this process, electromagnetic phenomena and fluid flow phenomena are both present and coupled, and thus the governing equations which describe an electromagnetic casting system are not amenable to analytic solution. The primary goal of this research was the development of a mathematical model which could calculate from first principles the behavior of the phenomena occurring within an electromagnetic caster. This model could then be used to further the understanding of the interaction of these phenomena, and from this greater understanding, aid in the development of design and operational practices in the metals industry for this and other processes utilizing magnetohydrodynamic effects.; In this dissertation the development of this mathematical model from the equations which govern electromagnetic and fluid flow phenomena, i.e. Maxwell's equations and the Navier-Stokes equations, is first discussed. The mathematical model is then validated by comparison of the calculated results with data measured on a laboratory scale physical model of an electromagnetic caster. The measurements were made over a range of shield positions, which produced a changing fluid flow profile within the liquid metal. The agreement between the calculated and measured data is seen to be very good for all cases. The mathematical model is then used to study two different industrial electromagnetic caster configurations, billet casting and thin strip casting, in order to determine some of the parameters which have a significant effect on the operation of these types of casters. In the case of billet casting, it is seen that the size of the inductor was the parameter which had the greatest effect on both the shape of the liquid metal/air interface, and the recirculatory flow within the metal. For thin strip casting, is it seen that the position of the inductor with respect to the solidification front effects the shape of the liquid metal meniscus the most, and that increasing the inductor current frequency produces a more uniformly flat liquid metal shape irrespective of inductor position.