Production of super-high strength aluminum alloy billets by low frequency electromagnetic casting

The effects of low frequency electromagnetic field on the macro-physical fields in the semi-continuous casting process of aluminum alloys and the microstructure and crack in the billets were studied and analyzed by the numerical and experimental methods.Comparison of the results for the macro-physical fields in the low frequency electromagnetic casting（LFEC） process with the conventional DC casting process indicates the following characters due to the application of electromagnetic field：an entirely changed direction and remarkably increased velocity of melt flow;a uniform distribution and a decreased gradient of temperature;elevated isothermal lines;a reduced sump depth;decreased stress and plastic deformation.Further,the microstructure of the billets is refined remarkably and the crack in the billets is eliminated in LFEC process because of modification of the macro-physical fields induced by the application of low frequency electromagnetic field.

Coupled Modeling of Electromagnetic Fleld,Fluid Flow,Heat Transfer and Solidification During Conventional DC Casting and Low Ftequency Electrmagnetic Casting of 7xxx Aluminum Alloys

A comprehensive mathematical model has been developed to describe the interaction of the multiple physics fields during the conventional DC casting and LFEC (low frequency electromagnetic casting) process. The model is based on a combination of the commercial finite element package ANSYS and the commercial finite volume package FLUENT, with the former for the calculation of the electromagnetic field and the latter for the calculation of the magnetic driven fluid flow, heat transfer and solidification. Moreover, the model has been verified against the temperature measurements obtained from two 7XXX aluminum alloy billets of 200mm diameter, cast during the conventional DC casting and the LFEC casting processes. In addition, a measurement of the sump shape of the billets were carried out by using addition melting metal of Al-30%Cu alloy into the billets during casting process. There was a good agreement between the calculated results and the measured results. Further, comparison of the calculated results during the LFEC process with that during the conventional DC casting process indicated that velocity patterns, temperature profiles and the sump depth are strongly modified by the application of a low frequency electromagnetic field during the DC casting.

LFEC and LFEVC of AZ80 magnesium alloy

The effects of a low frequency electromagnetic field and a low frequency electromagnetic vibration field applied during DC casting of AZ80 Mg on microstructures and alloying element distribution in ingots were investigated.The experiments were performed both in absence and in the presence of the magnetic fields.In DC casting,the ingot exhibited coarse microstructure and severe segregation of Al.In the presence of solo low frequency alternating magnetic field,namely LFEC,the grains of the ingot was effectively refined and the segregation of Al was significantly decreased.In LFEVC,namely low frequency electromagnetic vibration casting,the ingot were significantly refined and the segregation was suppressed.With increasing the vibration intensities,the grain refinement and segregation suppression were increased.

Study on the Grain Refinement of an Al-Zn-Mg-Cu Alloy Prepared by LFEC Process

Low frequency electromagnetic casting(LFEC)process has been developed for years with the application of an induction coil outside the conventional direct chill(DC)casting mould.It has been demonstrated that the LFEC process has a significant grain refining effect on aluminium alloys.However,how it refines the microstructure is still not clearly understood.In the present work,the temperature measurement were carried out to study the temperature field during casting and to understand the mechanism of the grain refining effect of the LFEC process.The results showed that in contrast to the conventional DC casting process,during the LFEC process,the liquid melt flowing from the launder into the mould is cooled with very high cooling rate directly to 3-6 ℃ below the liquidus and the temperature field of the entire melt in the mould and the hot top is quite uniform,which results in enhanced heterogeneous nucleation and improved survival rate of the nuclei.This is believed to be the main reason why the LFEC process can significantly refine the grain size of aluminium alloys.