Effect of entrance nozzle design on the fluid flow in an ingot mold during filling

Earlier studies have shown that the mold powder reacts with Steel during filling of the mold during ingot casting of ball-bearing and tool steels, which results in formation of inclusions. Since all inclusions are bad for the material properties for these grades, this is a phenomenon that needs to be avoided. In this study, fundamental mathematical modeling of the filling of an ingot has been used to predict the fluid flow characteristics. A special effort has been made to model the effect of a modified inlet allowing for a larger volume flow. Predictions made by the presently used numerical model, indicates that a successive increase in the opening angle of the inlet nozzle leads to a gradual decrease in the disturbance of the free surface, during mold filling. Furthermore, the horizontal velocities are lower, which results in lower values of the Weber number which is an indication of less chances for mold powder entrapment into steel. It is concluded that both these improvements leads to decreased possibilities for the creation of inclusions in the steel due to interaction with the mold powder.