Flow pattern in ingot during mould filling and its impact on inclusion removal

A two-dimensional non-steady state computational fluid dynamic model was employed to gain a basic understanding of the flow in the ingot during casting. The surface velocity was found to be affected by the inlet angle and was found to vary with the casting level. The information of surface velocity was related to the probability of the inclusion removal. Water model experiments were also conducted to help the understanding. The model calculation revealed the same trends as the results of water model experiments. Both computational fluid dynamic data and the physical modelling showed that the inlet angle of 5 degrees currently used in the industry was a good alternative regarding inclusion removal. The present work suggests strongly that the melting shop should try to obtain a liquid or semiliquid film at as early stage as possible in ingot casting.