Numerical Investigation of In‐Mold Electromagnetic Stirring Effects on Flow Dynamics, Solidification Kinetics, and Inclusion Control

ABSTRACT A three‐dimensional, time‐dependent model was established to investigate billet continuous casting under electromagnetic stirring (EMS) conditions. The simulation framework combined a dynamic electromagnetic field (EMF) with fluid flow, solidification processes, and inclusion migration. The study examined how EMS influences solidification characteristics of molten steel by applying the k‐ε turbulence model in combination with the enthalpy‐porosity method. Moreover, the inclusion migration analysis was performed using a stochastic tracking model. It is observed that the presence of EMS follows to the disruption of formation of a solidified layer in the initial stage of casting in a mold wall, and consequently, the liquid core turns into a mushy interface at the centerline of the strand. Based on the comparison of peak velocities, it is observed that the inclusion velocity along the centerline of the stirrer decreases from 1.13227 m/s in the absence of EMS to 0.57128 m/s when EMS was applied. The process of stirring produces a uniform temperature distribution across the entire domain due to swirl flow production. A further experiment was carried out to determine the effects of inclusion size and density on removal behavior performance. From the results, it is clear that in‐mold EMS considerably influences removal performance and solidification.