Effect of Electromagnetic Stirring Position on Uniform Direct Chill Casting of Large-Sized 7005 Alloy Billet

A numerical simulation is carried out to investigate the effect of the stirring position on large-sized 7005 alloy billet prepared by direct chill casting imposed with A-EMS and intercooling named uniform direct chill (UDC) casting. Moreover, the effect of the stirring position on the Lorentz force, fluid flow, heat transfer, and solidification occurring in UDC casting is investigated. It is found that when the stirring position moves upwards, the Lorentz force imparts the forced flow to the melt more effectively. Moreover, when the stirring position increases from 0 mm to 100 mm with respect to the graphite ring level, the maximum convection velocity of the melt increases from 150 mm/s to 210 mm/s. Furthermore, the temperature field of the melt in the sump becomes more homogeneous as the stirring position elevates. The microstructure of the 7005 billets becomes finer and uniform when the stirring position moves up to 50 mm.