Simulation of Direct Chill Casting in the Presence of Low Frequency Magnetic ‎Field to Produce 7075 Aluminum Alloy Billets

Direct Chill casting is a suitable method for the production of high diameter aluminum sheets. In this method, molten aluminum is poured into a mold and the mold is cooled by hydrogen. Despite the improvements made in the casting process, unwanted defects still appear during the production of the product. To deal with these problems, improved methods of direct refrigeration (DC) process are used, including direct refrigeration casting using hot top and casting in the presence of low frequency magnetic field (LFEC). Due to the advantages of direct refrigeration casting in the presence of a magnetic field, simulation of this process is important in order to better investigate the effect of the magnetic field on the molten pool, so that before any experimental work a numerical approximation of the magnetic field effect is obtained. Be. In this report, the direct refrigeration casting process is simulated in the presence of a magnetic field using ANSYS Fluent 19.2 software. The simulation output includes temperature distribution profiles, liquid volume fraction, velocity and steady-state flow lines for DC and LFEC casting for 70- and 14-inch diameter aluminum alloy billets and associated molds.