Liquid Metal Flow Under Traveling Magnetic Field—Solidification Simulation and Pulsating Flow Analysis

Shvydkiy, Evgeniy; Baake, Egbert; Köppen, Diana

doi:10.3390/met10040532

Cited by 7 publications

(3 citation statements)

References 43 publications

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“…Owing to its excellent thermal properties, liquid gallium and its alloys have been applied as coolants based on magnetohydrodynamic (MHD) heat transfer mechanisms [18][19][20][21]. To transport heat at smaller scales, liquid gallium outperforms other liquid metals, such as mercury, where higher vaporization temperatures and nontoxic characteristics are required [18].…”

Section: Liquid Gallium As a Heat Transfer Agentmentioning

confidence: 99%

Magnetohydrodynamic-based Internal Cooling System for a Ceramic Cutting Tool: Concept Design, Numerical Study, and Experimental Validation

O’Hara,

Fang

2023

Nanomanuf Metrol

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The effective removal of the heat generated during mechanical cutting processes is crucial to enhancing tool life and producing workpieces with superior surface finish. The internal cooling systems used in cutting inserts employ a liquid water-based solvent as the primary medium to transport the excess thermal energy generated during the cutting process. The limitations of this approach are the low thermal conductivity of water and the need for a mechanical input to circulate the coolant around the inner chamber of the cutting tool. In this context, this paper proposes an alternative method in which liquid gallium is used as the coolant in combination with a magnetohydrodynamic (MHD) pump, which avoids the need for an external power source. Using computational fluid dynamics, we created a numerical model of an internal cooling system and then solved it under conditions in which a magnetic field was applied to the liquid metal. This was followed by a simulation study performed to evaluate the effectiveness of liquid gallium over liquid water. The results of experiments conducted under non-cooling and liquid gallium cooling conditions were analyzed and compared in terms of the tool wear rate. The results showed that after six machining cycles at a cutting speed Vc = 250 m min −1, the corner wear VBc rate was 75 µm with the coolant off and 48 µm with the MHD-based coolant on, representing a decrease of 36% in tool wear. At Vc = 900 m min−1, the corner wear VBc rate was 75 µm with the coolant off and 246 µm with the MHD-based coolant on, representing a decrease of 31% in tool wear. When external cooling using liquid water was added, the results showed at Vc = 250 m min−1, the difference between the tool wear rate reduction with the internal liquid gallium coolant relative to the external coolant was 29%. When the cutting speed was increased to Vc = 900 m min−1, the difference observed between the internal liquid gallium coolant relative to the external coolant was 16%. The study proves the feasibility of using liquid gallium as a coolant to effectively remove thermal energy through internally fabricated cooling channels in cutting inserts.

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Section: Liquid Gallium As a Heat Transfer Agentmentioning

confidence: 99%

Magnetohydrodynamic-based Internal Cooling System for a Ceramic Cutting Tool: Concept Design, Numerical Study, and Experimental Validation

O’Hara,

Fang

2023

Nanomanuf Metrol

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“…5. The detailed inductor parameters cal be found at [40]. Similar experimental setups to study the impact of EM-driven flow on the solidification process by means of TMF are used in several laboratories [12,13,16].…”

Section: Electromagnetic Stirringmentioning

confidence: 99%

Numerical simulation of the EM forced flow during Sn-Pb alloy directional horizontal solidification

Shvydkiy¹,

Smolyanov²,

Baake³

2022

Preprint

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This article presents a study of the influence of electromagnetically (EM) forced convection on segregation formation. As a reference case the solidification of Sn-5 wt pct Pb alloy from the Hebditch and Hunt experiment is taken. Applied forcing of convective flow is determined by the dimensionless electromagnetic forcing parameter F . The study was carried out in the range −3.5 × 10 6 < F < 3.5 × 10 6 . Velocity profiles and flow patterns in the liquid phase are obtained for different applied EM forcing conditions. As a result of parametric analysis, the dependence of the Reynolds number on the electromagnetic forcing parameter was obtained. Electromagnetic forces can significantly affect the flow in the liquid bulk, increasing and slowing down the velocity, as well as changing the circulating flow direction. Solute concentration distribution analysis has shown that EM-forced convection does not affect global solute segregation formation. For the two cases, segregation channels were obtained. However, the analysis of the global segregation index showed that an increase in the Reynolds number provokes a slight decrease in this parameter. The main mechanism of segregation formation is transport of solute rich liquid into the mushy zone. In considered numerical experiment configuration, the penetration into the mushy zone is not large, and even a change in the direction of convection in the liquid bulk does not significantly affect the mushy zone flow. The calculations were made by means of open source code in OpenFOAM and Elmer.

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“…1. In addition, the flow can be controlled by controlling the current and the magnetic field 16,17) . This method is a powerful candidate for enhancing the mass transfer in industrial processes, like the refining process in the metallurgical industry and the electroplating process in the surface treatment industry.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of Effective Diffusion Coefficient under Time-Varying Electromagnetic Force Imposition

Xu,

Iwai

2024

ISIJ Int.

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The mass transfer in the concentration boundary layer is often the rate-determining step for solidliquid chemical reactions. Decreasing the concentration boundary layer thickness is essential to intensify the solid-liquid chemical reaction. Because convection contributes to decreasing the concentration boundary layer thickness, traditional methods excite a macro-scale flow in the bulk region. Since the concentration boundary layer exists in the velocity boundary layer near the solidliquid interface, the traditional methods have limitation in enhancing the mass transfer. Based on this reason, the direct flow excitation near the solid-liquid interface by imposing an electromagnetic force was proposed. The aim of this research is to evaluate the effect of the time-varying electromagnetic force and its frequency on the mass transfer near the solid-liquid interface by evaluating the effective diffusion coefficient. The effective diffusion coefficient was evaluated under the imposition of a static electromagnetic force or a time-varying electromagnetic force with a frequency of 2 Hz or 6 Hz. The results found that by imposing the time-varying electromagnetic force, the mass transfer was enhanced compared to that under the imposition of the static electromagnetic force. The mass transfer was further enhanced by decreasing the time-varying electromagnetic force frequency.

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Liquid Metal Flow Under Traveling Magnetic Field—Solidification Simulation and Pulsating Flow Analysis

Cited by 7 publications

References 43 publications

Magnetohydrodynamic-based Internal Cooling System for a Ceramic Cutting Tool: Concept Design, Numerical Study, and Experimental Validation

Magnetohydrodynamic-based Internal Cooling System for a Ceramic Cutting Tool: Concept Design, Numerical Study, and Experimental Validation

Numerical simulation of the EM forced flow during Sn-Pb alloy directional horizontal solidification

Evaluation of Effective Diffusion Coefficient under Time-Varying Electromagnetic Force Imposition

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