materials

Article
Numerical and Experimental Study on Carbon Segregation in
Shaped Billet of Medium Carbon Steel with Combined
Electromagnetic Stirring
Pengchao Li 1,2 , Guifang Zhang 1,3, *, Peng Yan 1, *, Nan Tian 1 and Zhenhua Feng 1

1 Faculty of Metallurgical and Energy Engineering, Kunming University of Science and Technology,
Kunming 650093, China; 13696392999@163.com (P.L.); tian1852558@163.com (N.T.);
fengzhenhua666@126.com (Z.F.)
2 Linyi Iron and Steel Investment Group Special Steel Co., Ltd., Linyi 276000, China
3 Key Laboratory of Clean Metallurgy for Complex Iron Resources in Colleges and Universities of Yunnan
Province, Kunming University of Science and Technology, Kunming 650093, China
* Correspondence: guifangzhang65@163.com (G.Z.); yanp_km@163.com (P.Y.)

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 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
Citation: Li, P.; Zhang, G.; Yan, P.;
significantly improved.
Tian, N.; Feng, Z. Numerical and
Experimental Study on Carbon
Keywords: continuous casting; shaped billet; combined electromagnetic stirring; multi-physical field
Segregation in Shaped Billet of
Medium Carbon Steel with
model; carbon segregation
Combined Electromagnetic Stirring.
Materials 2023, 16, 7464. https://
doi.org/10.3390/ma16237464
1. Introduction
Academic Editor: Rodrigo Moreno
Carbon segregation is one of the key indicators of continuous casting billet quality
Received: 30 October 2023 standards [1,2]. This defect will adversely affect the drawing stability during continuous
Revised: 21 November 2023 casting, harming the uniformity of the properties of rolled and finished products [3,4].
Accepted: 27 November 2023 Then, the control of carbon segregation is one of the key constraints on the development
Published: 30 November 2023
and application of high-quality steel [5]. In the rolling and subsequent heat treatment
process, carbon segregation defects can only be reduced but cannot be eliminated [6,7].
Therefore, it is particularly important to improve the macro-segregation of continuous
Copyright: © 2023 by the authors.
casting billet during the continuous casting stage. At present, most of the research on
Licensee MDPI, Basel, Switzerland. carbon segregation in continuous casting billet is focused on central segregation [8–10].
This article is an open access article For continuous casting billet, a large part is used to replace steel ingots to produce large
distributed under the terms and forgings, which have higher requirements for the performance uniformity of the entire
conditions of the Creative Commons section. Therefore, the control of the carbon segregation of continuous casting billet should
Attribution (CC BY) license (https:// focus on the fluctuation of carbon elements in the entire section.
creativecommons.org/licenses/by/ With the maturity of electromagnetic stirring (EMS) technology, EMS technology has
4.0/). been widely used in the control of solidification structure and segregation behavior of

Materials 2023, 16, 7464. https://doi.org/10.3390/ma16237464 https://www.mdpi.com/journal/materials

Materials 2023, 16, 7464 2 of 14

continuous casting billet [11]. Luo et al. [12] conducted an industrial test on the function
of final electromagnetic stirring (F-EMS) on the center segregation of the billet, and the
results showed that the excellent billet quality was achieved when the current of F-EMS
was 360–380 A. Sun et al. [13] adopted alternating F-EMS to make the internal organization
of continuous casting billets more uniform and the carbon segregation index closer to 1 and
more stable. Jiang et al. [14] studied the direction of EMS. When the EMS always moves in
one direction, the improvement in the central segregation is better than that of the positive
and negative alternating agitation. Du et al. [15] designed three combinations of EMS to
investigate its influence on the quality of casting billet, using mold electromagnetic stirring
(M-EMS) alone, M-EMS + F-EMS, and M-EMS + alternating F-EMS. Li et al. [16] used the
same method to compare the effects of M-EMS alone and M-EMS + F-EMS on the internal
quality of continuous casting billets and obtained the result that the combined EMS is
much better than that of M-EMS alone. Ayata et al. [17] compared the low cross-section
structure and the segregation of continuous casting billets without EMS, using M-EMS
alone, strand electromagnetic stirring (S-EMS) alone, and M-EMS + F-EMS combined.
For the application of EMS to the liquid steel in the continuous casting process, it is
necessary to study the parameters in depth to improve the carbon segregation, which has
a positive role in improving the mechanical properties and service performance. Dong
et al. [18] obtained a typical macro-segregation mode, including the peak value of positive
segregation on the center line and the minimum value of negative segregation on both
sides through the proposed three-dimensional macro segregation model. The simulation
results are in good agreement with the experimental results. Sun et al. [19] investigated the
negative segregation behavior of the subsurface layer, and the effect on the compositional
homogeneity of cast billets with a cross-section size of 320 mm × 425 mm was simulated.
In this paper, based on the continuous casting production of special-shaped medium
carbon steel (300 mm × 340 mm), a coupled numerical model, encompassing electro-
magnetism, heat, and solute transport, was developed to investigate carbon segregation
behaviors under different stirring parameters of combined electromagnetic stirring (M-
EMS + F-EMS). Subsequently, combined with on-site industrialization tests, the operating
parameters were optimized for the production of medium-carbon steel continuous casting
in a steel plant, China.

2. Model Descriptions
2.1. Assumptions
In the present research, a number of hypotheses are proposed to simplify the complex-
ity and enhance computational efficiency.
(1) The molten steel in the billet is regarded as an incompressible Newtonian fluid.
(2) The transport phenomena occurring during the continuous casting process, i.e., the
casting speed, the casting temperature, etc., are treated as steady states and remain
unchanged [20].
(3) Vibration, mold taper, bulging [21], and solidification shrinkage deformation influence
on the flow field is ignored, and the meniscus was assumed for the adiabatic plane.
(4) The solidification process in the liquid–solid interface is considered to occur in the
local thermodynamic equilibrium state.
(5) The thermal effect of F-EMS on the casting billet was ignored.

2.2. Governing Equations

Continuous casting electromagnetic stirring is a process in which a magnetic field is
generated inside liquid steel. Then, the electromagnetic force is generated by the movement
of the liquid steel to promote liquid steel movement [22]. Proper forced flow can effectively
control the vertical growth of columnar crystal structure and does not cause obvious
segregation [23]. Micro-segregation refers to the uneven distribution of solute elements
between dendrites, which is caused by the different solubility of elements in the solid–liquid
phase in the solidification process.
Materials 2023, 16, 7464 3 of 14

(1) Electromagnetic Model

The electromagnetic force for electromagnetic stirring can be obtained by calculating
Maxwell’s equations, namely (1), (2), (3), and (4):

∇×H = J (1)

∂B
∇×E = − (2)
∂t

∇·B = 0 (3)

J = σ ·E (4)
In Equations (1)–(4), H represents the magnetic field strength, A/m; J represents the
current intensity, A/m2 ; t denotes time, s; E denotes the electric field intensity, V/m; B
denotes the magnetic flux density, T; and σ denotes the electric conductivity, S/m.
Then, the electromagnetic force expression [24] is shown as follows:

1
Fm = Re(J × B∗ ) (5)
2
where Fm denotes the time-average electromagnetic volume force, Re denotes the real part
of the complex quantity, and B∗ is the complex conjugate of B.
(2) Fluid Flow Model
The process is considered to be steady; therefore, the partial time derivatives of the
velocity are zero and can be deleted from the equations of continuity and momentum
conservation. Then, the melt flow pattern is described via the continuity and momentum
equations as follows:
Equation of continuity:
∇ · (ρu) = 0 (6)
In Equation (6), ρ is the fluid density (kg/m3 ) and u is the fluid velocity, m/s.
Momentum conservation [25] equation:

∇·ρ(uu) = ∇·(µeff ∇·u) − ∇ P + ρg + Sp + Fm +FB (7)

In Equation (7), P is the static pressure, N/m2 ; µeff is the effective viscosity coefficient,
Pa·s; g denotes the acceleration of gravity, m/s2 ; FB denotes the thermal buoyancy source
term; and Sp represents the Darcy source term, which can be calculated using the following
equation.
(1 − f l )2
Sp = 3 Amush (u − us ) (8)
f l + 0.01
where us is the casting speed, m/s, and f l is the liquid fraction. In order to better describe
the solute transport process, the low Reynolds number equation k − ε is used in this paper.
  
µT
∇·(ρuk) == ∇ · µ + ∇k + G − ρε + Sk (9)
σk

ε2
  
µT ε
∇·(ρuε) = ∇ · µ+ ∇ε + Cε1 G − Cε2 ρ + Sε (10)
σε k k

k2
µ T = ρCµ (11)
ε
Materials 2023, 16, 7464 4 of 14

Sk and Sε are source terms, which are adopted to take the effects of the porous material
into consideration. The values of constants in the model are: Cµ = 0.09, Cε1 = 1.44,
Cε2 = 1.92, σk = 1.0, and σε = 1.3 [26].
(1) Heat Transfer Model
Heat transfer energy conservation equation:

∂
(ρH ) + ∇ · (ρuH ) = ∇ · (Keff ∇ T ) (12)
∂t
In Equation (12), H denotes the total enthalpy, J/kg, and Keff denotes the effective ther-
mal conductivity, W/(m·K). H and Keff can be obtained by solving the following equation.
Z T
H = href + c p dT + f l L (13)
Tref

T ≤ Ts

 KT,s
Ke f f = KT,s f s + KT,l f l Ts < T < Tl (14)
µ
KT,l + PrTt T > Tl


In Equation (13), hre f is the reference enthalpy, J/kg; c p denotes the specific heat
capacity of steel, J/(kg·K); and L is the latent heat of steel, J/kg. In Equation (14), Pr t
denotes the turbulent Prandtl number and f l denotes the liquid phase fraction, which can
be obtained by solving the following formula:

 0
 T ≤ Ts
T − Ts
fl = T − Ts Ts < T < Tl (15)
 1l

T > Tl

(2) Solute Transfer Model

Solute conservation equation:
  
µturb
∇ · (ρuc) = ∇ · ρDl + ∇c + Ss (16)
SCt

In Equation (16), c is the concentration of solute element, wt.%, and Dl is diffusion

coefficient of solute in the liquid phase. SCt is turbulent Schmidt number, and a value of
1.0. Ss is usually the source term in the solute conservation equation, which includes the
molecular diffusion term Sdif and the convection–diffusion Scon calculated via Equation (17)
with Equation (18), respectively.

Sdif = ∇ · [ρ f s Ds ∇ · (cs − c)] + ∇ · [ρ f l Dl ∇ · (cl − c)] (17)

Scon = ∇ · [ρ(u − us )(cl − c)] (18)

2.3. Model Parameter and Numerical Solution

The schematic diagram of the EMS used in this paper is shown in Figure 1. The
numerical model was obtained using the finite element software COMSOL Multiphysics
v6.0. The model is composed of an electromagnetic agitator, a toroidal core, and 12 coil
packages, the whole process model of continuous casting is divided into three sections: the
first section ends at the secondary cooling zone; the second section is the second, third,
and fourth section of the second cooling zone and the air cooling section before F-EMS
(about Z = −9 m); the third section is the F-EMS mixing section until the casting billet
is completely solidified, and the F-EMS installation position is Z = −9.34 m. The whole
geometry model of the electromagnetic field was taken to be surrounded by an air sphere
in which most of the magnetic flux lines are closed. Both the exit and the entrance of the
Materials 2023, 16, x FOR PEER REVIEW 5 of 15

Materials 2023, 16, 7464 5 of 14

which most of the magnetic flux lines are closed. Both the exit and the entrance of the
model are velocity boundary conditions. The velocity at the exit is set to the drawing
speed,
modeland
arethe velocity
velocity at theconditions.
boundary entrance isThe to 𝒖𝒊𝒏 ; at
setvelocity it can be calculated
the exit according
is set to the drawing to Equa-
speed,
tion (19).
and the velocity at the entrance is set to uin ; it can be calculated according to Equation (19).

𝒖𝒊𝒏 4L
=2 𝒖𝒔 (19)
uin = us (19)
πd2

Figure
Figure 1. 1. Schematicdiagram
Schematic diagram of
of the
the combined
combinedEMS
EMS(mm): (a)(a)
(mm): M-EMS; (b) F-EMS.
M-EMS; (b) F-EMS.

In Equation (19), L2 is the cross-sectional area of the casting billet, m2 ; d is the nozzle
In Equation (19), 𝐿 is the cross-sectional area of the casting billet, m2; 𝑑 is the nozzle
diameter, m. Set the meniscus to adiabatic. The wall surface of the outer surface of the
diameter, m. Set the meniscus to adiabatic. The wall surface of the outer surface of the
billet is set as the slip boundary condition in the flow field calculation. When calculating
billet
the is settransfer
heat as the slip
in theboundary
part of thecondition in the flow
mold, the surface fieldis calculation.
heat flux When
set to q, and its calculating
magnitude
thecan
heat transfer in the part of the mold,
be calculated via Equations (20)–(22). the surface heat flux is set to 𝑞, and its magnitude
can be calculated via Equations (20)–(22). p
q = 2,680,000 − b L/us (20)
𝑞 = 2,680,000 − 𝑏 𝐿⁄𝒖𝐬 (20)

1.5 × (2,680,000
. ×( , , − q) )
b= 𝑏=√ ⁄
(21) (21)
Lm /us 𝒖𝒔
cw Qm ∆T ∆
q=𝑞= (22) (22)
Seff

In In
Equations (20)–(22), 𝐿L is
Equations(20)–(22), is the
the distance
distancetotothe meniscus,
the meniscus, m; L m is
m; 𝐿 the
is distance from from
the distance
the meniscus to the exit of the mold, m; cw is the specific heat capacity of cooling water,
the meniscus to the exit of the mold, 3m; 𝑐 is the specific heat capacity of cooling water,
J/(kg·K); Qm is cooling water flow, m /s; ∆T is the temperature difference between the
J/(kg·K); 𝑄 is cooling water flow, m3/s; ∆𝑇 is the temperature difference between the inlet
inlet water temperature and the return water temperature of the cooling water, K; and Seff
water temperature
is the contact area and the return
between water
the billet and temperature
the mold, m2 . of thesurface
The coolingof water, the 𝑆 is
K;inand
the billet
thesecondary
contact area between the billet and the mold, m 2. The surface of the billet in the sec-
cooling zone is set as convective heat transfer, and the heat transfer coefficient
ondary cooling zone
is determined is set as
by Equation convective
(23). heat
The surface of transfer,
the billet and
in thethe
airheat transfer
cooling zone iscoefficient
set as is
surface radiation
determined to the environment,
by Equation whichof
(23). The surface is the
determined
billet invia
theEquation (24).zone is set as sur-
air cooling
face radiation to the environment, which is determined
0.851
via Equation (24).
hs = 116 + 10.44w (23)
.
h = 116 + 10.44𝑤 (23)
 
qs = εσ Tb4 − Ta4 (24)
𝑞 = 𝜀𝜎(𝑇 − 𝑇 ) (24)
The macro-segregation model was solved in the computational domain using a finite
segmentation calculation method. Table 1 lists the relevant parameters of the continuous
Materials 2023, 16, x FOR PEER REVIEW 6 of 15

casting and molten steel. Considering the multiple streams on site, the casting speed is set
Materials 2023, 16, 7464 6 of 14
to 0.65 m/min.

Table 1. Relevant parameter for continuous casting and molten steel [4,27,28].
The macro-segregation model was solved in the computational domain using a finite
Parameter
segmentation calculation Value
method. Table 1 lists the relevant parameters of the continuous
casting and molten steel. Considering
Density/kg ·m−3 the multiple streams on site, the casting speed is set
7000
to 0.65 m/min. Casting speed/m·min−1 0.65
Table 1. Relevant Casting
parametertemperature/K
for continuous casting and molten steel [4,27,28]. 1793
Liquid thermal conductivity/W·(m·K) −1 35
Parameter Value
Solid phase thermal conductivity/W·(m·K)−1 38
−3
Heat capacity at constant·m
Density/kg pressure/J·(kg·K) −1 7000 800
Casting speed/m·min−1 0.65
DynamicCasting
viscosity of liquid steel/Pa·s
temperature/K 17930.006
Carbon solute concentration/wt.%
Liquid thermal conductivity/W·(m·K)−1 35 0.45
Solid phase thermal
Latent heat conductivity/W (m·K)−1
of fusion/J·kg·−1 38 250
−1
Heat capacity at constant pressure/J·(kg·K) 800 , .
Carbon diffusion coefficient
Dynamic viscosity in solid
of liquid phase/cm
steel/Pa ·s
2·s−1 0.0761exp(
0.006 )
. ∙
Carbon solute concentration/wt.% 0.45 ,
Carbon diffusion coefficient in liquid−1 phase/cm ·s
2 −1 0.0052exp( )
Latent heat of fusion/J·kg 250 . ∙
Currentcoefficient
Carbon diffusion range ofinM-EMS/A
solid phase/cm2 ·s−1 0, 150, −200, 250,
134,557.44
0.0761exp( 8.314·T ) 300
CarbonFrequency range in
diffusion coefficient ofliquid phase/cm2 ·s−1
M-EMS/Hz 0.0052exp( − 11,700
2.0
8.314 ·T )
Current range of M-EMS/A 0, 150, 200, 250, 300
Current range of F-EMS/A 160, 180, 200, 220, 250
Frequency range of M-EMS/Hz 2.0
Frequency
Current range
range ofof F-EMS/Hz
F-EMS/A 8.0 250
160, 180, 200, 220,
Frequency range of F-EMS/Hz 8.0
3. Experimental Implementation
3. Experimental
The samplingImplementation
diagram for carbon segregation analysis is shown in Figure 2. A 5 mm
heighThe sampling
sample withdiagram
diameter for5carbon
mm was segregation
removedanalysis
from the is shown in Figurefor
billet section 2. analysis,
A 5 mm and a
heigh sample with diameter 5 mm was removed from the billet section
total of nine samples were taken from the bloom (the length of the bloom is Y for analysis, and a mm,
= 300
total of nine samples were taken from the bloom (the length of the bloom is Y = 300 mm,
and the width of the blank X = 340 mm. Five points are the central points, two points are
and the width of the blank X = 340 mm. Five points are the central points, two points are
the
theY1/8
Y1/8points, threepoints
points, three pointsareare
thethe Y1/4
Y1/4 points,
points, fourfour points
points are theareY3/8
the points,
Y3/8 points, six points
six points
are the X1/8 points, seven points are the X1/4 points, eight points are the
are the X1/8 points, seven points are the X1/4 points, eight points are the X3/8 points, and X3/8 points, and
one
oneand
and nine pointsare
nine points arethe
the1010mm
mm subcutaneous
subcutaneous edges).
edges). CarbonCarbon concentration
concentration is analyzed
is analyzed
using
using a carbon–sulfur analyzer (EMIA Pro, Horiba Inc., Kyoto, Japan). Medium carbon carbon
a carbon–sulfur analyzer (EMIA Pro, Horiba Inc., Kyoto, Japan). Medium
steelwas
steel was used
used in
inthis
thisresearch,
research, and
andthethe
chemical analysis
chemical results
analysis are presented
results in Tablein2.Table 2.
are presented

Figure 2.
Figure Diagram of
2. Diagram ofsampling
samplingpoint
pointforfor
carbon content
carbon analysis.
content analysis.
Materials 2023, 16, 7464 7 of 14
Materials 2023, 16, x FOR PEER REVIEW 7 of 15

Table 2. The main chemical components of medium carbon steel used in this study (wt.%).
Table 2. The main chemical components of medium carbon steel used in this study (wt.%).
Element C Cr Mn Ni P Si Fe
Element
Content C
0.45 Cr
0.25 Mn
0.58 Ni
0.28 P
0.013 Si
0.22 Fe
Bal.
Content 0.45 0.25 0.58 0.28 0.013 0.22 Bal.

In order to clearly express the variation of carbon concentration, the segregation index
In order to clearly express the variation of carbon concentration, the segregation in-
was used to quantify the macroscopic segregation inside the continuous casting billet. The
dex was used to quantify the macroscopic segregation inside the continuous casting billet.
carbon segregation index is presented via Equation (26) [29]:
The carbon segregation index is presented via Equation (26) [29]:
C
a=𝑎 =i (25)
Cl
where 𝑎 denotes the carbon segregation index; 𝐶 denotes the carbon concentration at the
where a denotes the carbon segregation index; Ci denotes the carbon concentration at the
sampling
sampling point
point i; and 𝐶
i; and Cl denotes
denotes the
the carbon
carbon concentration
concentration of
of molten
molten steel
steel in
in the
the tundish.
tundish.

4.
4. Results
Results and
and Discussion
Discussion
4.1. Model
Model Validation
Validation
To verify the reliability of the macro-segregation
macro-segregation of the multi-physical
multi-physical model
model estab-
estab-
model, the carbon
lished by this model, carbon solute distribution
distribution results of the billet under the condition
condition
casting at 1788 K and casting speed of 0.65 m/min
of continuous casting without EMS
m/min without EMS are
are pre-
pre-
sented in Figure 3a. The carbon segregation results were compared with the billet under
same continuous
the same continuouscasting
castingconditions,
conditions,asasshown
shownininFigure
Figure3b.3b.
AsAs
cancan be seen
be seen in the
in the re-
results
sults ofof casting
casting billetand
billet andsimulation
simulationshown
shownininFigure
Figure3,3,negative
negativesegregation
segregation and
and positive
positive
segregation appear
appear in the same position
position despite
despite some
some deviation
deviation ofof carbon
carbon concentration.
concentration.
In addition, the deviations at 0.2–0.4 m under the skin of the square billet
In addition, the deviations at 0.2–0.4 m under the skin of the square billet may be may be related
related
to the
to the fluctuation
fluctuation ofof influencing factors in
influencing factors in the
the production
production process. Then, the
process. Then, the comparison
comparison
results indicate
results indicate that
that the
the prediction
prediction of
of carbon
carbon distribution using the
distribution using the multi-physical model
multi-physical model
has good reliability.
has good reliability.

Figure
Figure 3.3. Verification
Verification of carbon segregation
of carbon segregation in
in casting
casting billet:
billet: (a) simulation results;
(a) simulation results; (b) verification
(b) verification
results.
results.

4.2. Lorentz
Lorentz Force
Force of
of Casting
Casting Billet
Billet with Electromagnetic Stirring
Lorentz force
Lorentz forceisisthe
themain
maindriving
driving force
force of of electromagnetic
electromagnetic stirring,
stirring, which
which drives
drives the
the liquid steel to rotate. Electromagnetic stirring functions under different
liquid steel to rotate. Electromagnetic stirring functions under different currents and fre-currents and
frequencies
quencies andand does
does notnotaffect
affectthe
thedirection
directionand
and distribution trend
trendofofLorentz
Lorentzforce.
force.Figure
Figure4
4presents
presentsthe
theLorentz
Lorentzforce distribution
force distributioninin
the billet
the with
billet the
with action
the actionof of
F-EMS
F-EMS under
under250
250A
Aand 8 Hz.
and 8 Hz.
Materials
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Figure
Figure4.4.Lorentz
Lorentzforce
Lorentz forcedistribution
force distributionin
distribution inthe
in thearea
the areaof
ofF-EMS:
F-EMS:(a)
(a)longitudinal
longitudinalsection;
section;(b)
(b)transverse
transverse
cross-section.
cross-section.
cross-section.

As
Asshown
shownin inFigure
Figure4a, 4a, the
theF-EMS
the F-EMSis
F-EMS isinstalled
is installedat
installed atZ
at ZZ===−9.5
−−9.59.5m, m,andandthe theLorentz
Lorentzforce
force
distribution
distributionisissymmetrically
symmetricallydistributed
distributedalong
distributed alongboth
along bothsides
both sidesof
sides ofthethecasting
castingbillet.
billet.The
TheLorentz
Lorentz
force
forceatat the
thecenter
the centeris
center the
isisthe largest,
thelargest,
largest,andand
andthe the surface
surface
the surface isisis9700
9700
9700 N/m
N/mN/m 3 .3.3ItItcan
. Itcancanbebe seen
seen
be from
from
seen from Figure
Figure
Figure4b
4b
4b that
thatthat the
thethe reverse
reverse
reverse of Lorentz
of Lorentz
of Lorentz force
force is clockwise
is clockwise
force is clockwise rotation,
rotation,
rotation, the
the maximum maximum
the maximum Lorentz
Lorentz force
forceforce
Lorentz on
on this
on
this
this section
section is atisis
section atatthe
the thecorner
corner of the
corner of the
thesquare,
ofsquare, and and
square, the the
theLorentz
andLorentz forceforce
Lorentz decreases
force decreasesas the
decreases as the
thedistance
asdistance from
distance
from
from the
thefinal
the final electromagnetic
electromagnetic
final electromagnetic stirring
stirring
stirring center
center gets
center gets closer.
closer.
gets closer. This
This
This isisisclosely
closely related
relatedto
closelyrelated tothe
the“skin
the “skin
effect”
effect”of
effect” ofelectromagnetic
electromagneticfields. fields.In Inorder
orderto toinvestigate
investigatethe theeffect
effectof
effect ofF-EMS
F-EMSwith withdifferent
different
different
current
currentand
current andfrequency
and frequencyon
frequency onthe
on theinternal
the internalflow
internal flowfield
flow fieldof
field ofthe
of thecasting
the castingbillet,
casting billet,the
billet, theX-axis
the X-axisLorentz
X-axis Lorentz
Lorentz
force
force distribution
distribution at
at the
the casting
casting blank
blank center
center
force distribution at the casting blank center is shown in Figure 5.is
is shown
shown in
in Figure
Figure 5.
5.

Figure
Figure5.5.
Figure 5.Lorentz
Lorentz
Lorentz force
force
force distribution
distributionin
distribution the
inin area
the
the of
ofF-EMS:
area
area of (a)
(a)different
F-EMS:
F-EMS: (a) current
different
different with
current
current frequency
with
with of
of8.0
frequency
frequency of
8.0
Hz;
8.0 (b)
Hz; different
(b) frequencies
different with
frequencies current
with of
current180
Hz; (b) different frequencies with current of 180 A.of A.
180 A.

Asshown
As
As shownin
shown inFigure
in Figure5,5,
Figure 5,the
theLorentz
the Lorentzforce
Lorentz forceincreases
force increaseslinearly
increases linearlywith
linearly withthe
with thedistance
the distanceincreasing
distance increasing
increasing
from
from the bloom center to the edge and approaches zero at the
from the bloom center to the edge and approaches zero at the center. The Lorentzforce
the bloom center to the edge and approaches zero at the center.
center. The
The Lorentz
Lorentz force
force
increases
increases with
with the
the increase
increase inin current,
current, which
which agrees
agrees with
with Ampere’s
Ampere s
increases with the increase in current, which agrees with Ampere s law. In the continuous law.
law. In
In the
the continuous
continuous
castingbloom,
casting
casting bloom,the
bloom, themost
the mostobvious
most obviousarea
obvious areaof
area ofelectromagnetic
of electromagneticstirring
electromagnetic stirringeffect
stirring effectisis
effect isthe
theliquid
the liquidphase
liquid phase
phase
region
region
regionofof bloom.
ofbloom.
bloom.As As
Ascan can
canbe be
beseen seen
seenin in Figure
inFigure
Figure5a, 5a, the
5a,the maximum
themaximum
maximumLorentz Lorentz
Lorentzforceforce
forcein in the
inthe liquid
theliquid
liquid
phase
phase section
section is
is 3300
3300 N/m
N/m 3 33
at ata a current
current ofof 250
250 A.
A. Then,
Then, the
the maximum
maximum Lorentz
Lorentz force
force ininthe
the
phase section is 3300 N/m at a current of 250 A. Then, the maximum Lorentz force in the
liquid
liquid phase
phase section
section shown
shown in
in Figure
Figure 5b
5b is
is 1480
1480 N/m
N/m 3 33
atat the
the frequency
frequency of
of 8.0
8.0 Hz.
Hz. Therefore,
Therefore,
liquid phase section shown in Figure 5b is 1480 N/m at the frequency of 8.0 Hz. Therefore,
thestirring
the
the stirringcurrent
stirring currentisisismore
current more
more effective
effective
effective inin
in improving
improving
improving thethe
the internal
internal
internal flow
flowflow
of of bloom
ofthe
the the bloom
bloom thanthan
than the
the
Materials 2023, 16, x FOR PEER REVIEW 9 of 15
Materials 2023, 16, 7464 9 of 14

frequency.
the ThisThis
frequency. could guideguide
could the adjustment of EMS
the adjustment of parameters to obtain
EMS parameters excellent
to obtain bloom
excellent
quality.
bloom quality.

4.3. C Solute Distribution in Casting Billet

The results of of carbon
carbon solute
solute distribution
distribution in the the mold
mold are
are shown
shown in in Figure
Figure 6.6. In the
the
solute is enriched
mold area, the solute enriched below the meniscus partly due to the influence of eddy
solute buoyancy.
currents and hot solute buoyancy. The concentration
concentration of carbon in the liquid phase in the the
center of
center of the
the crystallizer
crystallizerhas
hasnot
notchanged,
changed,and andthetheconcentration
concentration ofof carbon
carbon onon
thethe surface
surface is
is the
the same
same as as
thethe concentration
concentration of liquid
of liquid steel.
steel. At At
thethe lower
lower endend of the
of the model,
model, as the
as the posi-
position
moves inward,
tion moves the positive
inward, segregation
the positive gradually
segregation changeschanges
gradually to negative segregation,
to negative which is
segregation,
caused
which is bycaused
the “washing effect” of the
by the “washing liquid
effect” steelliquid
of the on the solidification
steel front and the
on the solidification strong
front and
cooling condition of the mold.
the strong cooling condition of the mold.

Figure 6.
Figure 6. Carbon
Carbon solute
solutedistribution
distributionininthe
thecentral
centralsection
sectionofof F-EMS:
F-EMS: (a)(a) carbon
carbon solute
solute distribution
distribution in
in the
the central
central axial
axial section;
section; (b)(b) distribution
distribution of carbon
of carbon solutes
solutes at different
at different locations.
locations.

The distribution of of solute

solutecarbon
carbonelements
elementsatatdifferent
differentpositions
positionsfrom
fromthe
themeniscus
meniscus is
shown
is shownin in
Figure 7. With
Figure 7. With thethe
solidification process,
solidification process,the the
liquid phase
liquid phasecavity gradually
cavity graduallyde-
decreases,
creases, andand carbon
carbon doesnot
does notsimply
simplyaccumulate
accumulateininthe theliquid
liquidphase
phasecavity
cavity on
on the
the cross-
cross-
section. Due to the convection caused by gravity and hot solute solute buoyancy
buoyancy in the natural
natural
convection zone, the solute distribution in the the liquid
liquid phase
phase cavity
cavity is
is uneven.
uneven. The
The liquid
liquid
steel in the liquid phase cavity forms two symmetrical circulations on
the liquid phase cavity forms two symmetrical circulations on the cross-section the cross-section
due to the action of buoyancy and the influence of gravity, which leads to more complex
macroscopic segregation behavior. As As shown
shown in in Figure 7, under the dual action of the the
“solute
“solute scour”
scour” effect
effect of
of circulation
circulation and
and gravity,
gravity, the
the concentration
concentration of of solute
solute elements
elements is is
gradually
gradually less
less than
than the
the outer
outer arc
arc side,
side, while
while the
the solute
solute elements
elements gradually
gradually accumulate
accumulate andand
increase
increase on
on the
the outer
outer arc
arc side.
side.
Materials 2023, 16, x FOR PEER REVIEW 10 of 1
Materials 2023, 16, 7464 10 of 14

Figure 7. Distribution
Figure 7. Distributionof carbon solutes
of carbon at at
solutes different
differentdistances
distances from
from meniscus: −1m;
meniscus: (a) Z == −1 m;(b) Z = −
(b) Z = − 2 m; (c) Z = − 4 m; (d) Z = − 6 m; (e) Z = −
m; (c) Z = −4 m; (d) Z = −6 m; (e) Z = −8 m; (f) Z = −10 m.8 m; (f) Z = − 10 m.

When the appropriate parameters of M-EMS are identified as a current of 250 A and
When the appropriate parameters of M-EMS are identified as a current of 250 A and
a frequency of 2.0 Hz, 8 Hz is set as the electromagnetic stirring frequency at the end
a frequency of 2.0 Hz,
of solidification. Then,8 Hz
the is set as are
currents theconsidered
electromagnetic stirring
180 A, 200 A, and frequency
250 A, and atthe
the end o
solidification.
distribution Then, thesolute
of carbon currents
in theare considered
billet 180 A,solidifying
after completely 200 A, and 250 A,inand
is shown the8.distribu
Figure
As shown in Figure 8a–c, the distribution of carbon in the casting billet changes
tion of carbon solute in the billet after completely solidifying is shown in Figure 8. A significantly
under
shown inthe action8a–c,
Figure of electromagnetic
the distributionforceofgenerated
carbon in using
theF-EMS.
castingThe concentration
billet area
changes significantly
of central carbon shifts from the center to the left with the clockwise rotation of the flow
under the action of electromagnetic force generated using F-EMS. The concentration area
field, and the area of the concentration area is larger than that without F-EMS.
of centralThecarbon shifts
effects of fromcurrents
different the center to the
on carbon left withare
segregation theshown
clockwise rotation
in Figure of the flow
8d, which
field, and the area of the concentration area is larger than that without F-EMS.
the sampling position is shown in black line. Because the frequency has a slight influence
on the distribution of the flow field and electromagnetic force, the carbon concentration
distributions on the center line are compared under the currents of 0 A, 180 A, 200 A,
and 250 A. As shown in Figure 8d, the carbon solute concentration increases significantly
in the center without EMS, resulting in a serious center segregation problem. With the
enhancement of the current in F-EMS, the carbon center segregation problem was signif-
icantly improved. This is mainly attributed to the stirring action of F-EMS on the liquid
phase hole near the installation position and the distribution of carbon becoming more
uniform. However, the improvement of carbon solute segregation with different currents is
not obvious, which is because the tangential velocity generated in the liquid phase hole
does not significantly augment with the current increase.
Materials 2023, 16, x FOR PEER REVIEW 11 of 15
Materials 2023, 16, 7464 11 of 14

Figure 8. Distribution
Figure of carbon
8. Distribution solutes
of carbon soluteswith
withF-EMS
F-EMSat
atdifferent currents:(a)
different currents: (a)180
180A;
A;(b)
(b)200
200A;A; (c) 250
A; (d)
(c)line chart
250 A; of carbon
(d) line chart ofdistribution.
carbon distribution.

4.4. Experimental Study on the Structure and Macro-Segregation in the Casting Billet
The effects of different currents on carbon segregation are shown in Figure 8d, which
The solidification structure of the casting billets with M-EMS and combined EMS are
the sampling
presented inposition
Figures 9isand
shown in black line.
10, respectively. Because
The overall the frequency
quality of the generoushasbillet
a slight influence
is very
on the
poordistribution
without M-EMS, of the flow field
as shown and 9a.
in Figure electromagnetic force,obvious
Then, there are some the carbon
cornerconcentration
cracks
distributions on the center
in the subcutaneous tissue,line
andare
thesecompared under
small corner cracksthecould
currents
not beof 0 A, 180 during
eliminated A, 200 A, and
250 subsequent
A. As shown bar in
rolling.
Figure They
8d,expand easily,solute
the carbon resulting in elongated cracks
concentration in thesignificantly
increases rolling in
billet. As can be seen in Figure 9b, the thick columnar crystals grow
the center without EMS, resulting in a serious center segregation problem. With the en- vertically upward
along the bottom surface of each side, and it is easy to bridge the columnar crystals in
hancement of the current in F-EMS, the carbon center segregation problem was signifi-
the central part due to the central loose side and central shrinkage hole. In Figure 9a–c, a
cantly improved.
light This isinmainly
pattern is formed attributed
the equiaxed crystaltoarea
theinstirring action
the central area.of F-EMS
This on the
is called the liquid
phase
“white band”, which is generally caused by negative segregation. With the continuous more
hole near the installation position and the distribution of carbon becoming
uniform.
increaseHowever,
in M-EMSthe improvement
current intensity, the of carbon
white band solute segregation
in the casting with
billet also differentIncurrents
disappeared.
particular, as marked in Figure 9d, the overall carbon segregation
is not obvious, which is because the tangential velocity generated in the liquid fluctuates the least under
phase hole
the parameter configuration of the 250 A current
does not significantly augment with the current increase. and 2 Hz frequency, and the segregation
index is maintained at 1.06–1.18.

4.4. Experimental Study on the Structure and Macro-Segregation in the Casting Billet
The solidification structure of the casting billets with M-EMS and combined EMS are
presented in Figures 9 and 10, respectively. The overall quality of the generous billet is
very poor without M-EMS, as shown in Figure 9a. Then, there are some obvious corner
cracks in the subcutaneous tissue, and these small corner cracks could not be eliminated
during subsequent bar rolling. They expand easily, resulting in elongated cracks in the
rolling billet. As can be seen in Figure 9b, the thick columnar crystals grow vertically up-
 “white band”, which is generally caused by negative segregation. With the continuous
increase in M-EMS current intensity, the white band in the casting billet also disappeared.
In particular, as marked in Figure 9d, the overall carbon segregation fluctuates the least
Materials 2023, 16, 7464 under the parameter configuration of the 250 A current and 2 Hz frequency, and12the seg-
of 14
regation index is maintained at 1.06–1.18.

Figure
Figure9.9.Effect
Materials 2023, 16, x FOR PEER REVIEW EffectofofM-EMS
M-EMScurrent
current on the
the solidification
solidificationstructure
structureofofcasting
casting billet:
billet: (a)(a) 0 A;
0 A; (b)
(b)13 of150
150 A; A;
15
(c)(c)200
200A;A;(d)
(d)250
250A;
A;(e)
(e)300
300 A;
A; (f)
(f) carbon segregation
segregationindex.
index.

In order to further optimize the combined EMS parameters and study the influence
of F-EMS on carbon segregation, an optimization test on F-EMS was carried out with the
parameters of mold electromagnetic stirring at a current of 250 A and a frequency of 2.0
Hz, and the result is shown in Figure 10.

Figure 10. Effect of F-EMS current on the solidification structure of casting billet: (a) 160 A; (b) 180
Figure 10. Effect of F-EMS current on the solidification structure of casting billet: (a) 160 A; (b) 180 A;
A; (c) 200 A; (d) 220 A; (e) 250 A; (f) carbon segregation index.
(c) 200 A; (d) 220 A; (e) 250 A; (f) carbon segregation index.
In Figure 10a,f, positive segregation appears at the center of the billet, and other
points appear alternatively as positive and negative segregation, of which negative segre-
gation forms more easily. In Figure 10b,f, when the final electromagnetic stirring current
is 180 A, the carbon segregation index is controlled to remain within the limits of 0.96 to
Materials 2023, 16, 7464 13 of 14

In order to further optimize the combined EMS parameters and study the influence
of F-EMS on carbon segregation, an optimization test on F-EMS was carried out with the
parameters of mold electromagnetic stirring at a current of 250 A and a frequency of 2.0 Hz,
and the result is shown in Figure 10.
In Figure 10a,f, positive segregation appears at the center of the billet, and other points
appear alternatively as positive and negative segregation, of which negative segregation
forms more easily. In Figure 10b,f, when the final electromagnetic stirring current is 180 A,
the carbon segregation index is controlled to remain within the limits of 0.96 to 1.05,
accompanied by a narrower fluctuation, and the trend increases from the subcutaneous to
the solidifying center. When the current increases to 200 A, the carbon segregation index is
between 1.07–1.20, which gradually increases from subcutaneous to the solidifying center,
where the carbon segregation is more serious. When the F-EMS increases from 220 A to
250 A, the carbon segregation index is controlled at between 1.04 and 1.3. Meanwhile, the
trend of carbon segregation increases from the subcutaneous area to the solidifying center,
resulting in serious carbon segregation at the billet center. According to the comprehensive
analysis of Figure 10, under the combined electromagnetic stirring optimization parameters,
the mold electromagnetic stirring current is 250 A with a frequency of 2.0 Hz, and the final
electromagnetic stirring current is 180 A with a frequency of 8.0 Hz. Under this parameter,
the probability of negative segregation can be significantly reduced.

5. Conclusions
(1) The simulation results of combined electromagnetic stirring reveal that a symmetric
circulation pattern emerges on the transverse section of the casting square billet due
to the effect of thermal and solute buoyancy in the natural convection zone. Under
the influence of electromagnetic stirring at the end of square billet solidification, the
variation in tangential velocity generated via electromagnetic stirring in the liquid
phase pockets of the casting is minimal at different current levels, resulting in relatively
minor differences in the distribution of carbon solute within the cross-section of
square billet.
(2) The 300 mm × 340 mm special-shaped billet industrial test samples for carbon segre-
gation show that the appropriate current and frequency parameters for M-EMS are
250 A and 2.0 Hz, while the suitable current and frequency parameters for F-EMS are
180 A and 8.0 Hz. Under these conditions, the carbon segregation index is controlled
in order to remain within the limits of 0.96 to 1.05.

Author Contributions: Conceptualization, P.L. and G.Z.; experimental setup design, P.L., G.Z. and
P.Y.; validation, P.L., N.T. and Z.F.; analysis, G.Z. and P.Y.; writing, P.L., G.Z. and P.Y.; project
administration, P.L. and G.Z.; funding acquisition, G.Z. All authors have read and agreed to the
published version of the manuscript.
Funding: The work was supported by the National Natural Science Foundation of China (NSFC),
grant number “52074140”.
Data Availability Statement: The data presented in this study are available on request from the
corresponding author.
Conflicts of Interest: Author Pengchao Li was employed by the Linyi Iron and Steel Investment
Group Special Steel Co., Ltd. The remaining authors declare that the research was conducted in the
absence of any commercial or financial relationships that could be construed as a potential conflict
of interest.

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