Numerical Assessment on the Mixer in the Combined Application of Intensive Melt Shearing and Magnetic Field

This paper examines the combined effects of intensive melt shearing and magnetic fields on the flow characteristics of molten aluminum alloy during the direct chill (DC) casting process. Using computational fluid dynamics (CFD), we analyze flow fields across varying rotor speeds, diameters, blade counts, stator configurations, and electromagnetic field strengths. The results demonstrate that increasing rotor speed and diameter significantly enhances melt flow velocity and vortex intensity. Conversely, a greater number of rotor blades results in reduced flow velocity due to higher resistance. Moreover, the shape and diameter of the stator opening impact flow patterns, with circular openings producing higher velocities. The interaction of electromagnetic fields and intensive shearing generates three distinct vortices, achieving the highest overall flow velocity and a uniform distribution. Additionally, adjustments in excitation coil current and rotor speed enable further control of melt flow, offering valuable insights for optimizing casting processes and enhancing ingot quality.