Modeling of molten metal flow in a continuous casting process considering the effects of argon gas injection and static magnetic-field application

A mathematical model has been developed to analyze molten metal flow, consi dering the effects of argon gas injection and static magnetic-field applica tion in the continuous casting process. The k-epsilon turbulence model is u sed to calculate the turbulent variables. A homogeneous fluid model with va riable density is employed to tackle the molten metal-argon gas flow. The e lectromagnetic force is incorporated into the Navier-Stokes equation, and t he effects of boundary conditions of the magnetic field on the velocity dis tribution near the mold wall are included. A good agreement between the num erically obtained flow-field results and measurements is obtained. The argo n gas injection changes the molten metal flow pattern, mainly in the upper portion of the mold. By applying the magnetic field, values of the averaged velocity field in the bulk decrease significantly, and, especially at the top free surface, they become very small, which can cause meniscus freezing . When magnetic-field application and argon gas injection are used together the external flow field out of the gas plume is significantly suppressed; nevertheless, flotation of gas bubbles is still active and is not affected directly by the magnetic field. Although the penetrating length of the gas plume is shortened, the argon gas bubbles in molten steel still cause fluct uation at the top free surface, which prevents the occurrence of freezing.