Abstract:
In the cause of pulsed electromagnetic casting, the inductance effect of the coil (Lenz's law) causes distortion and deformation of the pulse waveform, and the electromagnetic effect induced by the actual waveform is crucial for the solidification field of aluminum alloys. In this study, a finite element mathematical model of the electromagnetic field is established in combination with the experimental research to investigate the effects of pulse intensity, frequency, and duty cycle on the filed density and the spatial and temporal distribution characteristics of magnetic flux density and electromagnetic force. Furthermore, the influence of those factors on the melt surface fluctuations and solidification structures are analyzed. Results show that when the peak current is 100 A, the frequency is 20 Hz, and the duty cycle is 20%, the coil's effective pulse loading current and the magnetic flux density are at their maximums, and the magnetic field is evenly distributed. At this point, the magnetic pressure caused by the radial electromagnetic force plays a dominant role in driving and controlling the melt surface fluctuations, leading to clear waves on the liquid surface. The α-Al phase in the ZL114A alloy is refined, and the fine and dispersed secondary phase is formed. As the frequency increases to 80 Hz, the amplitude of surface fluctuations decreases, and the primary Si phase becomes coarser and segregated. When the duty cycle increases to 80%, the amplitude of the surface fluctuations increases significantly, the violent melt oscillation is unfavorable for the refinement of the solidified structure.