An advanced mathematical model for the fluid flow coupled with heat transfer confined by a free surface and a solidification front in a cold crucible was developed. Validity of the model was confirmed through measurements of a solidification front, surface velocity of the melt and surface temperatures.
Effects of operation parameters, such as coil current, dome height and casting velocity, on the fields of velocity and temperature were investigated.
Generally, two kinds of recirculation flow are expected to appear in the melt. They make a collision slightly above the contact point between the melt and the crucible wall. An appropriate geometrical configuration of the dome height and the position of a coil exists to promote melting of scraps fed onto dome.
A titanium ingot consisting of completely melted scraps was continuously cast aided by the proposed operation obtained through the numerical calculation.