Mathematical modeling of coupled turbulent flow and solidification in a single belt caster with electromagnetic brake

A mathematical model has been developed to simulate turbulent fluid flow and solidification in the presence of a DC magnetic field in an extended nozzle for metal delivery to a single belt caster. This paper reports on predicted effects of DC magnetic field conditions in modifying flows and solidification behavior in the metal delivery system. It is shown that the application of a DC magnetic brake to the proposed system can result in a reasonably uniform feeding of melt onto the cooled moving belt. This, in turn, optimises the rate of even shell growth along the chilled substrate. In order to account for the effects of turbulence, a revised low-Reynolds k–ε turbulent model was employed. A Darcy-porosity approach was used to simulate fluid flow within the mushy solidification region. Simulations were carried out for plain carbon steel strip casting. The fully coupled transport equations were numerically solved using the finite volume method. The computed flow patterns were compared with those reported in the literature. The performance of the magnetic flow control device proposed in this work is evaluated and compared with flow modifications obtained by inserting a ceramic filter within the reservoir.