Dimensionless parameters controlling fluid flow in electromagnetic cold crucible

A 3-D numerical model was established for predicting the flow field in a square electromagnetic cold crucible (EMCC) used for melting and directionally solidifying TiAl alloys. Four dimensionless parameters that characterise the melt flow in the EMCC were derived, those being the Hartman (Ha), magnetic Reynolds (Rω), coils-melt position (h) and the ratio of the melt height to length (H/L) numbers. Parametric simulations and experiments were carried out to understand the effects of processing parameters such as the intensity and frequency of the current, the relative coils-melt position and the melt shape on the flow field. The meridional flow normally consists of two vortices in the half meridian plane, the lower vortex decreases with increasing Ha, Rω and h (hb>hm), as well as decreasing H/L. Higher Ha, H/L and lower h induce intensive fluid flow in the melt due to the stronger EM coupling, which could promote the uniformity of solute in the melt. The turbulence kinetic energy is significantly influenced by the length scale of the turbulent flow and the flow velocity in the melt, it increases with increasing Ha, h and H/L, while reduces and tends to be stable at higher Rω. Relatively higher flow velocity and turbulence kinetic energy can be obtained when Rω is close to 10. The weakened flow in the vicinity of solid/liquid interface under lower Ha and Rω, as well as higher h and H/L is beneficial for continuous growth of columnar crystals during the directional solidification process.