Sven Eckert

Velocity Measurement Techniques for Liquid Metal Flows

Analysis and control of fluid flows, often subsidiary to industrial design issues,require measurements of the flow field. For classical transparent fluids such aswater or gas a variety of well-developed techniques (laser Doppler and parti-cle image velocimetry, Schlieren optics, interferometric techniques, etc.) havebeen established. In contrast, the situation regardingopaque liquids still lacksalmost any commercial availability. Metallic and semiconductor melts oftenpose additional problems of high temperature and chemical aggressiveness,rendering any reliable determination of the flow field a challenging task. Thisreview intends to summarise different approaches suitable for velocity mea-surements in liquid metal flows and to discuss perspectives, particularly inview of some recent developments (ultrasound, magnetic tomography).Focus-ing mainly on local velocity measurements, it is subsequently distinguishedbetween invasive and non-invasive methods, leaving entirely aside the acqui-sition of temperature, pressure, and concentration, for which [1] may serve asa comprehensive reference.

The flow structure of a bubble-driven liquid-metal jet in a horizontal magnetic field

Static magnetic fields are known to be suitable for damping mean flow and turbulent motion in an electrically conducting liquid. In this paper, an experimental study is presented considering the influence of a horizontal magnetic field on a bubble-driven flow of a liquid metal. The investigation is focused on the liquid circulation inside a liquid metal column driven by a central jet produced by gas injection. The fluid vessel has a circular cross-section and electrically insulating walls. Low gas flow rates were applied, resulting in a plume of separated bubbles rising inside a spot around the cylinder axis. This axisymmetric configuration is exposed to a horizontal magnetic field. We present detailed experimental data describing the spatial as well as the temporal structure of the velocity field. Measurements of the vertical and the radial velocity component, respectively, were performed using the ultrasound Doppler velocimetry (UDV), allowing for the first time a complete mapping of the liquid velocity distribution for a bubble-driven liquid metal flow. The magnetic field considerably modified the global and local properties of the flow field compared to an ordinary bubble plume. In the parameter range considered here we did not find a prior flow suppression, but, in fact, a restructuring of the convective motion. The original axisymmetric flow field became anisotropic with respect to the direction of the magnetic field lines. An upwards flow dominated in a plane parallel to the magnetic field, whereas the recirculating motion was enforced in the orthogonal plane. Contrary to usual expectations, the application of a moderate magnetic field (100 < Ha < 400,1 ≤ N ≤ 10) destabilizes the global flow and gives rise to transient, oscillating flow patterns with predominant frequencies.

Effect of an Electromagnetic Brake on the Turbulent Melt Flow in a Continuous-Casting Mold

This article presents numerical and experimental investigations with respect to the fluid flow in the continuous-casting process under the influence of an external direct current (DC) magnetic field. Numerical calculations were performed by means of the software package CFX (Ansys, Inc., Canonsburg, PA) with an implemented Reynolds-averaged Navier–Stokes (RANS)-SST turbulence model. The nonisotropic nature of the magnetohydrodynamic (MHD) turbulence was taken into account by specific modifications of the turbulence model. The numerical results were validated by flow measurements carried out in a small-scale mockup using the eutectic alloy GaInSn. The jet flow discharging from the submerged entry nozzle was exposed to a level magnetic field spanning across the entire wide side of the mold. The comparison between our numerical calculations and the experimental results displays a good agreement; in particular, we reconstructed the peculiar phenomenon of an excitation of nonsteady, nonisotropic, large-scale flow perturbations caused by the application of the DC magnetic field. Another important result of our study is the feature that the electrical boundary conditions, namely the wall conductivity ratio, have a serious influence on the mold flow while it is exposed to an external magnetic field.

Experimental observation of swirl accumulation in a magnetically driven flow

Independent poloidal and azimuthal body forces are induced in a liquid metal cylinder by travelling and rotating magnetic fields of different frequencies, respectively. The bulk axial and azimuthal velocities are measured by the ultrasound Doppler method. Particle image velocimetry is used to observe the upper free surface velocity distribution. The transition from the poloidal to the azimuthal body force governed regime occurs at a fixed ratio of the respective force magnitude of around 100. This transition is marked by the formation of a concentrated vortex revealing several similarities to intense atmospheric vortices. The vortex structure is controlled by a relatively weak azimuthal force while the maximum speed of the swirl is mainly governed by the poloidal one. Under a certain force ratio the average axial velocity changes its direction in the vortex core, resembling the subsidence in an eye of a tropical cyclone or a large tornado. Multiple moving vortices encircle the vortex core in this regime.

Chimney Formation in Solidifying Ga-25wt pct In Alloys Under the Influence of Thermosolutal Melt Convection

The directional solidification of Ga-25wt pct In alloys within a Hele-Shaw cell under the influence of thermosolutal convection was observed by means of X-ray radioscopy. The unstable density stratification at the solidification front causes the formation of rising plumes containing solute-rich liquids. The development of the chimneys and the probability of their surviving depend sensitively on the spatial and temporal properties of the flow field. Variations of the vertical temperature gradient along the solidification cell lead to the observation of different mechanisms for chimney formation. Perturbations of the dendritic structure are the origin of development of segregation freckles in case of low temperature gradients. The long-term stabilities of these segregation channels are strongly influenced by the transient nature of the melt convection. The situation at higher temperature gradients is characterized by two dominating convection rolls in the liquid phase which are driven by a lateral temperature gradient and the convex shape of the solidification front. The penetration of this flow pattern into the mushy zone results in continuous accumulation of solute in the central part of the mushy zone followed by a remelting of the solid fraction and the occurrence of a stable chimney.

Liquid metal experiments with swirling flow submerged entry nozzle

Abstract The influence of a swirling flow inside the submerged entry nozzle on the structure and the stability of a liquid metal flow in a physical model of a slab casting mould are investigated. For visualisation of the flow, contactless inductive flow tomography (CIFT) is applied. As expected and desired, the swirling flow leads to a stronger upward fluid motion along the walls. At the same time, however, the oscillatory character of the flow becomes stronger. These flow features obtained with CIFT are shown to be in reasonable agreement with independent measurements using ultrasonic Doppler velocimetry. Preliminary results of numerical simulations also show a similar behaviour.

Visualization of Liquid Metal Two-phase Flows in a Physical Model of the Continuous Casting Process of Steel

We present an experimental study concerned with investigations of the two-phase flow in a mock-up of the continuous casting process of steel. A specific experimental facility was designed and constructed at HZDR for visualizing liquid metal two-phase flows in the mold and the submerged entry nozzle (SEN) by means of X-ray radioscopy. This setup operates with the low melting, eutectic alloy GaInSn as model liquid. The argon gas is injected through the tip of the stopper rod into the liquid metal flow. The system operates continuously under isothermal conditions. First results will be presented here revealing complex flow structures in the SEN widely differing from a homogeneously dispersed bubbly flow. The patterns are mainly dominated by large bubbles and large-area detachments of the liquid metal flow from the inner nozzle wall. Various flow regimes can be distinguished depending on the ratio between the liquid and the gas flow rate. Smaller gas bubbles are produced by strong shear flows near the nozzle ports. The small bubbles are entrained by the submerged jet and mainly entrapped by the lower circulation roll in the mold. Larger bubbles develop by coalescence and ascend toward the free surface.

Two-dimensional ultrasound Doppler velocimeter for flow mapping of unsteady liquid metal flows.

We present a novel pulsed-wave ultrasound Doppler system for fluid flow investigations being able to determine two-dimensional vector fields of flow velocities. Electromagnetically-driven liquid metal flows appear as an attractive application field for such a measurement system. Two linear ultrasound transducer arrays each equipped with 25 transducer elements are used to measure the flow field in a square plane of 67×67 mm(2). The application of advanced processing methods as a multi-beam operation, an interlaced echo signal acquisition and a segmental array technique enable high data acquisition rates and concurrently a high spatial resolution, which have not been obtained so far for flow measurements in liquid metals. The extended pulsing strategy and essential operation principles such as the multiplexing electronic concept will be presented within this paper. The capabilities of the measuring system make it suitable for investigations of non-transparent, turbulent flows. Here, we present measurements of liquid metal flows driven by a rotating magnetic field for demonstration purposes. The measuring setup realized here reveals details of the swirling fluid motion in a horizontal section of a cube. Frame acquisition rates up to 30 fps were achieved for a complete two-dimensional flow mapping.

Simulation of Channel Segregation During Directional Solidification of In—75 wt pct Ga. Qualitative Comparison with In Situ Observations

Freckles are common defects in industrial casting. They result from thermosolutal convection due to buoyancy forces generated from density variations in the liquid. The present paper proposes a numerical analysis for the formation of channel segregation using the three-dimensional (3D) cellular automaton (CA)—finite element (FE) model. The model integrates kinetics laws for the nucleation and growth of a microstructure with the solution of the conservation equations for the casting, while introducing an intermediate modeling scale for a direct representation of the envelope of the dendritic grains. Directional solidification of a cuboid cell is studied. Its geometry, the alloy chosen as well as the process parameters are inspired from experimental observations recently reported in the literature. Snapshots of the convective pattern, the solute distribution, and the morphology of the growth front are qualitatively compared. Similitudes are found when considering the coupled 3D CAFE simulations. Limitations of the model to reach direct simulation of the experiments are discussed.

Dual-plane ultrasound flow measurements in liquid metals

An ultrasound measurement system for dual-plane, two-component flow velocity measurements especially in opaque liquids is presented. Present-day techniques for measuring local flow structures in opaque liquids disclose considerable drawbacks concerning line-wise measurement of single ultrasound probes. For studying time-varying flow patterns, conventional ultrasound techniques are either limited by time-consuming mechanical traversing or by the sequential operation of single probes. The measurement system presented within this paper employs four transducer arrays with a total of 100 single elements which allows for flow mapping without mechanical traversing. A high frame rate of several 10 Hz has been achieved due to an efficient parallelization scheme using time-division multiplexing realized by a microcontroller-based electronic switching matrix. The functionality and capability of the measurement system are demonstrated on a liquid metal flow at room temperature inside a cube driven by a rotating magnetic field (RMF). For the first time, the primary and the secondary flow have been studied in detail and simultaneously using a configuration with two crossed measurement planes. The experimental data confirm predictions made by numeric simulation. After a sudden switching on of the RMF, inertial oscillations of the secondary flow were observed by means of a time-resolved measurement with a frame rate of 3.4 Hz. The experiments demonstrate that the presented measurement system is able to investigate complex and transient flow structures in opaque liquids. Due to its ability to study the temporal evolution of local flow structures, the measurement system could provide considerable progress for fluid dynamics research, in particular for applications in the food industry or liquid metal technologies.