Numerical simulation of electromegnetic casting of aluminum alloys

Abstract EN

This work deals with the improvement of surface quality, microstructure of the aluminum alloy ingot by electromagnetic casting using finite element method with the help of Ansys program.

Magnetic flux density and magnetic flux density gradient are used as indicators for uniform temperatures distribution and new liquid metal flow.

Two models are simulated in this study ; the first one represents a solid cylinder with a single coil where the effects of current intensity and frequency on the melt metal are studied.

The second model is a hollow cylindrical with outer / inner coils.

The effects of current intensity, due to the interaction between the outer and inner coil are studied.

The results of the first model simulation indicate three stages with the current increasing.

The first one near the center of the ingot enhanced approximately homogeneous behavior, while the increasing occurs gradually in the second and third stages.

Also with decreasing of frequency the magnetic flux density at the center of ingot increasing.

The second model results of hollow ingot show that the magnetic flux density increases linearly with outer coil current increasing from (85–380) A at the same inner coil current value, and the homogeneous behavior enhanced in 0.55 outer / inner coil current ratio also illustrates homogeneous behavior at different current values but with the same ratio.