Numerical model of electrode induction melting for gas atomization

Purpose - The purpose of this paper is to create a numerical model of electrode induction melting process for the gas atomization (EIGA) and process and investigate the complex interaction of the electromagnetic and thermal fields on the fluid flow with free surface. Design/methodology/approach - The modelling approach is based on the free surface code SPHINX which includes time dependent electromagnetic, thermal and fluid flow with free surface modelling and the commercial software COMSOL for investigating 3D electromagnetic effects. Findings - The melting dynamics, liquid film formation and the outflow free surface behavior are predicted by SPHNIX using an optimized geometry. Quasi-stationary AC electromagnetic solutions with COMSOL predict some 3D effects of the coil, including frequency dependent estimates of voltage, electric current and power. Originality/value - The importance of magnetic forces controlling the free surface jet formation, partial semi-levitation and the outflow superheat is uncovered by numerical modelling tools. An optimized geometry is presented for the EIGA process.