Use of time-modulated AC magnetic fields for melt flow control during unidirectional solidification

The rotary stirring during solidification has been proved to be a striking method for achieving a purposeful alteration of the microstructure of casting ingots, such as grain refinement or the promotion of a transition from a columnar to an equiaxed dendritic growth (CET). However, the imposition of a rotating magnetic field (RMF) also causes problems like the occurrence of typical segregation pattern or a deflection of the upper free surface leading to surface defects or the entrainment of gas. A permanent radial inward flow along the solidification front is responsible for the transport of solute to the axis of the ingot resulting in typical freckle segregation pattern in form of vertical channels filled with alloy of eutectic composition. We present a new innovative method of electromagnetic stirring using a modulated RMF which offers a considerable potential for a well-aimed modification of casting properties. This paper considers the directional solidification of Al-Si alloys from a water cooled copper chill. Modulated AC magnetic fields were applied for melt agitation. The comparison between numerical simulations and solidification experiments delivered a good agreement. Our results demonstrate that the modulated magnetic field enables an effective control of the flow field and the structure of the solidified samples.