Abstract
Crucible induction furnaces are widely used in the aluminum industry, for scrap remelting, metal treatments and casting. The operation principle results in an intense circulation within the furnace, raising a specific question with regard to inclusion dynamics within the melt, reflected by LiMCA measurements at the furnace exit. In an effort to understand the involved phenomena, a hydrodynamic model of an induction furnace was built and complemented by an inclusion module that takes into account the transport of inclusions and the interaction of inclusions with other inclusions (aggregation) or with the crucible walls. A numerical inclusion distribution has been developed that reflects the characteristics of the inclusions present in the melt. The model and results of its application are presented in this paper.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
Preview
Unable to display preview. Download preview PDF.
References
W. Schmitz, D. Trauzedell, “Latest developments in recycling production residues employing coreless induction furnaces”, Casting plant and technology, 4/2013, 12–19.
A. Peel, P.-Y. Menet, “The application of MHD side stirring technology to aluminium melting furnaces for operational efficiency improvement — A case study”, J. Manuf. Sci. Prod. 2015; 15(1): 59–67.
R. Stal, P. Hanley, “Electromagnetic stirring in aluminium ladles”, in Light Metals 2009, Ed. G. Bearne, TMS-AIME, 2009, 627–630.
M.W. Kennedy, J.A. Bakke, R.E. Aune, “Impact of coil geometry on magnetohydrodynamic flow in liquid aluminium and its relevance to inclusion separation by electromagnetophoresys”, J. Manuf. Sci. Prod. 2015; 15(1): 69–78.
D. Shu, J. Wang, B. Sun, “Online electromagnetic filtration of molten aluminium using a multistage separator system”, J. Manuf. Sci. Prod. 2015; 15(1): 89–92.
R. Fritzsch, M.W. Kennedy, S. Akbarnedjad, R.E. Aunes, “Effect of electromagnetic fields on the priming of high grade ceramic foam filters (CFF) with liquid aluminum”, in Light Metals 2015, Ed. M. Hyland, TMS-AIME, 2009, 929–935.
G. Guest, S. Williams, P. Gastaldi, “Development of a new generation electromagnetic metal moving system”, in Light Metals 2012, Ed. C. Suarez., TMS-AIME, 2012, 1013–1018.
A. Bansal, P. Chapelle, Y. Delannoy, E. Waz, P. Le Brun, J.P. Bellot, “Experimental and numeric analysis of the deformation of a liquid aluminum free surface covered by an oxide layer during induction melting”, Metall. Mater. Trans. B, (2015), Vol 46(9), 2096–2109.
A. Bansal, P. Chapelle, E. Waz, Y. Delannoy, P. Le Brun, J.P. Bellot, “Simulation of free surface and molten metal behavior during induction melting of an aluminium alloy”, 8th International Conference on Electromagnetic Processing of Materials, Cannes, France, October 12–16, 2015.
S. Instone, A. Buchholz, G.-U. Gruen, “Inclusion Transport Phenomena in Casting Furnaces”, in Light Metals 2008, Ed. D. De Young, TMS-AIME, 2008, 811–816.
O. Mirgaux, D. Ablitzer, E. Waz, J.P. Bellot, “Mathematical modeling and computer simulation of molten aluminium purification by flotation in stirred reactor”, Met Trans B, Vol. 40B, (2009), 363–375.
P. Gardin, S. Gauthier, M. Simonnet, “Multiphase Model for Predicting the Elimination of Inclusions inside a Liquid-Steel Ladle”, Advanced Engineering Materials, (2011), Vol.13, 538–542.
I.L.A. Daoud, N. Rimbert, A. Jardy, B. Oesterle, S. Hans, J.P. Bellot, “3D modeling of the aggregation of oxides inclusions in a liquid steel ladle: two numerical approaches”, Advanced Engineering Materials, (2011), Vol.13, 543–549.
F. Yamao, K. Sassa, K. Iwai, S. Asai. “Separation of inclusions in liquid metal using fixed alternating magnetic field.” Journal of the Iron and Steel Institute of Japan-Tetsu to Hagane, (1997), Vol. 83(1), 30–35.
S. Wang, L. Zhang, Y. Tian, Y. Li, H. Ling. “Separation of Non-metallic Inclusions from Molten Steel Using High Frequency Electromagnetic Fields.” Metall. Mater. Trans. B, (2014), 45(5), 1915–1935.
V. Bojarevics, K. Pericleous, R. Brooks. “Dynamic model for metal cleanness evaluation by melting in a cold crucible.” Metall. Mater. Trans. B, (2009), Vol. 40(3), 328–336.
M. Ščepanskis, A. Jakovičs, E. Baake, B. Nacke. “Solid inclusions in an electromagnetically induced recirculated turbulent flow: Simulation and experiment.” Int. J. of Multiphase Flow, (2014), Vol 64, 19–27.
S.J. Roach, H. Heinen, “A New Method to Dynamically Measure the Surface Tension, Viscosity and Density of Melts”, Metall. Mater. Trans. B, (2005), Vol. 36(10), 667–675.
C. Garcia-Cordovilla, E. Louis, A. Pamies, “The surface tension of liquid pure aluminium and aluminium-magnesium alloy”, J. of Mat. Sci., 21(1986), 2787–2792.
S. Kumar, D. Ramkrishna, “On the solution of population balance equations by discretization—I. A fixed pivot technique.” Chemical Engineering Science, (1996), Vol. 51(8), 1311–1332.
J. Kumar, M. Peglow, G. Warnecke, S. Heinrich, L. Mörl, “Improved accuracy and convergence of discretized population balance for aggregation: The cell average technique.” Chemical Engineering Science, (2006), Vol. 61(10), 3327–3342.
L. I. Zaichik, O. Simonin, V. M. Alipchenkov. “Turbulent collision rates of arbitrary-density particles.” Int. J. of Heat and Mass Trans., (2010), 53(9), 1613–1620.
S. Instone, M. Badowski, D. Krings, “Sampling Tool for In-Depth Study of Furnace Processes”, in Light Metals 2014, Ed. J. Grandfield, TMS-AIME, 2014, 1003p–1008.
Author information
Authors and Affiliations
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2016 TMS (The Minerals, Metals & Materials Society)
About this chapter
Cite this chapter
Waz, E., Bansal, A., Chapelle, P., Delannoy, Y., Bellot, J.P., Le Brun, P. (2016). Modeling of Inclusion Behavior in an Aluminum Induction Furnace. In: Williams, E. (eds) Light Metals 2016. Springer, Cham. https://doi.org/10.1007/978-3-319-48251-4_144
Download citation
DOI: https://doi.org/10.1007/978-3-319-48251-4_144
Publisher Name: Springer, Cham
Print ISBN: 978-3-319-48615-4
Online ISBN: 978-3-319-48251-4
eBook Packages: Chemistry and Materials ScienceChemistry and Material Science (R0)