Multi-physics modeling in the electromagnetic levitation and melting of reactive metals

The aim of this article is to demonstrate the capability of the software for predicting free-surface motion, internal fluid flow and temperature in an electromagnetically levitated sample of liquid metal. Multi-physics solutions which demonstrate the usefulness of Comsol as a powerful MHD simulation tool have been generated to two industrial problems using the ALE moving-mesh module in combination with the Navier-Stokes, Maxwell and General Heat transfer modules. The first problem, which has relevance to continuous casting of metal ingots in a cold crucible, considers the transient free-surface motion of a semi-levitated volume of metal when its shape is confined by the field of a solenoid. The ability to establish the steadystate profile of the melt is an important factor in determining power requirements and thermal losses. This can then be fed into a 3D model (with static geometry) to include the effects of joule heating and the influence of the finger segments. The second problem is concerned with the thermo-physical property measurement of reactive molten materials using a novel technique reported in [9]. Comsol is used to predict the surface motion, centre of mass oscillations and temperature fluctuation in a metal droplet suspended in the AC field of a solenoid