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Electromagnetic Metallurgy: Metallurgical Process, Materials Processing and Resource Utilization
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Electromagnetic Metallurgy: Metallurgical Process, Materials Processing and Resource Utilization

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Metals and Alloys".

Deadline for manuscript submissions: 20 July 2025 | Viewed by 5035

Special Issue Editors

Prof. Dr. Guifang Zhang

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Guest Editor
Department of Metallurgical Engineering, Kunming University of Science and Technology, Kunming, China
Interests: electromagnetic metallurgy; numerical simulation; resource utilization
Prof. Dr. Kongzhai Li

E-Mail Website
Guest Editor
Department of Metallurgical Engineering, Kunming University of Science and Technology, Kunming, China
Interests: energy utilization during metallurgical process; high-value utilization of hydrocarbon resources
Dr. Peng Yan

E-Mail
Guest Editor Assistant
Department of Metallurgical Engineering, Kunming University of Science and Technology, Kunming, China
Interests: electromagnetic metallurgy; numerical simulation; resource utilization

Special Issue Information

Dear Colleagues,

Electromagnetic metallurgy technology utilizes the force and thermal effects of electromagnetic fields to achieve energy transfer, fluid motion, and shape control in metallurgical processes, ultimately aiming to optimize metallurgical processes, enhance production efficiency, and improve product quality and performance. In recent years, with the increasing awareness of low-carbon and environmental protection, electromagnetic metallurgy technology has garnered growing attention and emphasis in the metallurgy and materials preparation fields due to its advantages such as high efficiency, environmental friendliness, and excellent controllability. It exhibits the following development trends: (1) Automation and process advancement in the field of steel metallurgy. (2) Continuous expansion of its applications in various areas, including the entire process of steel continuous casting, non-ferrous metal smelting and casting, and the preparation of non-metallic and new materials. (3) The emergence of new technologies such as suspension metallurgy, strong magnetic fields, and static magnetic fields. The metallurgical and materials preparation process involves the coupling of multiple physical fields, including energy transfer and conversion, momentum and mass transfer, and structural evolution. In electromagnetic metallurgy processes, the electromagnetic-fluid phenomena resulting from the coupling of electromagnetic fields, flow fields, and temperature fields are a key focus of research and attention. This topic focuses on the research progress and development trend of electromagnetic technologies used in the field of Metallurgy and Materials, aiming to provide a platform to seek the new functionality of Electromagnetic metallurgy technologies, broadening their application fields in the future.

Prof. Dr. Kongzhai Li
Prof. Dr. Guifang Zhang
Dr. Dong Tian
Guest Editors

Dr. Peng Yan
Guest Editor Assistant

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Keywords

  • electromagnetic metallurgy
  • numerical modeling
  • electromagnetic stirring
  • electromagnetic levitation
  • electromagnetic elimination
  • electromagnetic induction heating
  • electromagnetic processing of materials
  • electromagnetic separation

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Published Papers (4 papers)

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Research

24 pages, 8540 KiB  
Article
Numerical Simulation of Free Surface Deformation and Melt Stirring in Induction Melting Using ALE and Level Set Methods
by Pablo Garcia-Michelena, Emilio Ruiz-Reina, Olaia Gordo-Burgoa, Nuria Herrero-Dorca and Xabier Chamorro
Materials 2025, 18(1), 199; https://doi.org/10.3390/ma18010199 - 5 Jan 2025
Viewed by 645
Abstract
This study investigates fixed and moving mesh methodologies for modeling liquid metal–free surface deformation during the induction melting process. The numerical method employs robust coupling of magnetic fields with the hydrodynamics of the turbulent stirring of liquid metal. Free surface tracking is implemented [...] Read more.
This study investigates fixed and moving mesh methodologies for modeling liquid metal–free surface deformation during the induction melting process. The numerical method employs robust coupling of magnetic fields with the hydrodynamics of the turbulent stirring of liquid metal. Free surface tracking is implemented using the fixed mesh level set (LS) and the moving mesh arbitrary Lagrangian–Eulerian (ALE) formulation. The model’s geometry and operating parameters are designed to replicate a semi-industrial induction melting furnace. Six case studies are analyzed under varying melt masses and coil power levels, with validation performed by comparing experimentally measured free surface profiles and magnetic field distributions. The melt’s stirring velocity and recirculation patterns are also examined. The comparative analysis determines an improved performance of the ALE method, convergence, and computational efficiency. Experimental validation confirms that the ALE method reproduces the free surface shape more precisely, avoiding unrealistic topological changes observed in LS simulations. The ALE method faces numerical convergence difficulties for high-power and low-mass filling cases due to mesh element distortion. The proposed ALE-based simulation procedure is a potential numerical optimization tool for enhancing induction melting processes, offering scalable and robust solutions for industrial applications. Full article
(This article belongs to the Special Issue Electromagnetic Metallurgy: Metallurgical Process, Materials Processing and Resource Utilization)
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12 pages, 14472 KiB  
Article
Research on the Relative Placement Angle of the Induction Heater and the Channel in a Four-Channel Induction-Heating Tundish
by Xiqing Chen, Pu Wang, Hong Xiao, Siyan Lei, Haiyan Tang and Jiaquan Zhang
Materials 2024, 17(12), 3011; https://doi.org/10.3390/ma17123011 - 19 Jun 2024
Cited by 2 | Viewed by 825
Abstract
In order to optimize the application effect of induction heating (IH) tundishes, a four-channel IH tundish is taken as the research object. Based on numerical simulation methods, the influence of different relative placement angles of induction heaters and channels on the electromagnetic field, [...] Read more.
In order to optimize the application effect of induction heating (IH) tundishes, a four-channel IH tundish is taken as the research object. Based on numerical simulation methods, the influence of different relative placement angles of induction heaters and channels on the electromagnetic field, flow field and temperature field of the tundish is investigated. We focus on comparing the magnetic flux density (B) and electromagnetic force (EMF) distribution of the channel. The results show that regardless of the relative placement angle between the heater and the channel, the distribution of B in the central circular cross-section of the channel is eccentric. When the heater rotates around channel 1 towards the bottom of the tundish, the distribution of B in the central circular cross-section of the channel changes from a horizontal eccentricity to a vertical one. Through the analysis of the B contour in the longitudinal section of the channel, the difference in effective magnetic flux density area (ΔAB) between the upper and lower parts of the channel can be obtained, thereby quantitatively analyzing the distribution of B in this section. The distribution pattern of ΔAB is consistent with the distribution pattern of the electromagnetic force in the vertical direction (FZ) of the channel centerline. The ΔAB and FZ of channel 1 gradually increase as the heater rotates downwards, while those of channel 2 reach their maximum value at a rotation angle of 60°. Compared to the conventional placement, when the heater rotation angle is 60°, the outlet flow velocities at channel 1 and channel 2 decrease by 15% and 12%, respectively. However, the outlet temperature at channel 2 increases by 1.96 K, and the molten steel flow at the outlet of channel 1 and channel 2 no longer exhibits significant downward flow. This shows that when the heater rotation angle is 60°, it has a dual advantage. On the one hand, it is helpful to reduce the erosion of the molten steel on the channel and the bottom of the discharging chamber, and on the other hand, it can more effectively exert the heating effect of the induction heater on the molten steel in the channel. This presents a new approach to enhance the application effectiveness of IH tundish. Full article
(This article belongs to the Special Issue Electromagnetic Metallurgy: Metallurgical Process, Materials Processing and Resource Utilization)
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15 pages, 6242 KiB  
Article
Simulation Study on the Influence of Different Molten Steel Temperatures on Inclusion Distribution under Dual-Channel Induction-Heating Conditions
by Bing Yi, Guifang Zhang, Qi Jiang, Peng Yan, Zhenhua Feng and Nan Tian
Materials 2023, 16(24), 7556; https://doi.org/10.3390/ma16247556 - 8 Dec 2023
Cited by 1 | Viewed by 1316
Abstract
Impurity elimination in tundishes is an essential metallurgical function in continuous casting. If inclusions in a tundish cannot be effectively removed, their presence will have a serious impact on the quality of the bloom. As a result, this research investigates the locations of [...] Read more.
Impurity elimination in tundishes is an essential metallurgical function in continuous casting. If inclusions in a tundish cannot be effectively removed, their presence will have a serious impact on the quality of the bloom. As a result, this research investigates the locations of inclusion particles in a six-strand induction-heating tundish in depth, combining the flow, temperature, and inclusion trajectories of molten steel under electromagnetic fields. The results show that a pinch effect occurred in the induction-heating tundish, and a rotating magnetic field formed in the channel, with a maximum value of 0.158 T. The electromagnetic force was directed toward the center of the axis, and its numerical distribution corresponds to the magnetic flux density distribution, with a maximum value of 2.11 × 105 N/m3. The inclusion particles’ movement speed accelerated as the molten steel’s temperature rose, and their distribution in the channel was identical to the rotating flow field distribution. When the steel’s temperature rose from 1750 K to 1850 K, the removal percentage of inclusion particles in the discharge chamber rose by 9.20%, the removal rate at the outlet decreased from 8.00% to 3.00%, and the adhesion percentage of inclusion particles in the channel decreased from 48.40% to 44.40%. Full article
(This article belongs to the Special Issue Electromagnetic Metallurgy: Metallurgical Process, Materials Processing and Resource Utilization)
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14 pages, 5473 KiB  
Article
Numerical and Experimental Study on Carbon Segregation in Shaped Billet of Medium Carbon Steel with Combined Electromagnetic Stirring
by Pengchao Li, Guifang Zhang, Peng Yan, Nan Tian and Zhenhua Feng
Materials 2023, 16(23), 7464; https://doi.org/10.3390/ma16237464 - 30 Nov 2023
Cited by 5 | Viewed by 1318
Abstract
Carbon segregation is the major and classical internal defect in the continuous casting process of carbon steel. Based on the combined electromagnetic stirring equipment for new billet in a steel plant, China, the influence of combined electromagnetic stirring (M-EMS + F-EMS) on the [...] Read more.
Carbon segregation is the major and classical internal defect in the continuous casting process of carbon steel. Based on the combined electromagnetic stirring equipment for new billet in a steel plant, China, the influence of combined electromagnetic stirring (M-EMS + F-EMS) on the carbon segregation of 300 mm × 340 mm special-shaped billet was studied via numerical simulation and on-site industrialization tests. The Lorentz force and carbon solute distribution were simulated under different EMS parameters. The formation mechanism of the carbon segregation of medium carbon steel with different combined electromagnetic stirring processes was analyzed. The results show that: (1) with the combined action of “solute flushing” effect and gravity, the carbon concentration in the loose side of the medium carbon steel casting billet is gradually lower than the fixed side, while the carbon concentration on the fixed side gradually accumulates more; and (2) under the action of combined electromagnetic stirring, the segregation index of casting billet could be controlled to remain between 0.96–1.05 and shows an increasing change in solidification from the skin to the center. When the current and frequency of M-EMS are 250 A and 2.0 Hz and the F-EMS are 180 A and 8.0 Hz, the carbon segregation defects in the special-shaped (300 mm × 340 mm) casting billet can be significantly improved. Full article
(This article belongs to the Special Issue Electromagnetic Metallurgy: Metallurgical Process, Materials Processing and Resource Utilization)
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