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NASA NTRS2016

A Study of Heat Transfer and Flow Characteristics of Rising Taylor Bubbles

Practical application of flow boiling to ground- and space-based thermal management systems hinges on the ability to predict the systems heat removal capabilities under expected operating conditions. Research in this field has shown that the heat transfer coefficient within two-phase heat exchangers can be largely dependent on the experienced flow regime. This finding has inspired an effort to develop mechanistic heat transfer models for each flow pattern which are likely to outperform traditional empirical correlations. As a contribution to the effort, this work aimed to identify the heat transfer mechanisms for the slug flow regime through analysis of individual Taylor bubbles.An experimental apparatus was developed to inject single vapor Taylor bubbles into co-currently flowing liquid HFE 7100. The heat transfer was measured as the bubble rose through a 6 mm inner diameter heated tube using an infrared thermography technique. High-speed flow visualization was obtained and the bubble film thickness measured in an adiabatic section. Experiments were conducted at various liquid mass fluxes (43-200 kgm2s) and gravity levels (0.01g-1.8g) to characterize the effect of bubble drift velocityon the heat transfer mechanisms. Variable gravity testing was conducted during a NASA parabolic flight campaign.Results from the experiments showed that the drift velocity strongly affects the hydrodynamics and heat transfer of single elongated bubbles. At low gravity levels, bubbles exhibited shapes characteristic of capillary flows and the heat transfer enhancement due to the bubble was dominated by conduction through the thin film. At moderate to high gravity, traditional Taylor bubbles provided small values of enhancement within the film, but large peaks in the wake heat transfer occurred due to turbulent vortices induced by the film plunging into the trailing liquid slug. Characteristics of the wake heat transfer profiles were analyzed and related to the predicted velocity field. Results were compared and shown to agree with numerical simulations of colleagues from EPFL, Switzerland.In addition, a preliminary study was completed on the effect of a Taylor bubble passing through nucleate flow boiling, showing that the thinning thermal boundary layer within the film suppressed nucleation, thereby decreasing the heat transfer coefficient.

capillary flow↗

NASA NTRS2022

Experimental Heat Transfer Results and Flow Visualization of Vertical Upflow Boiling in Earth Gravity with Subcooled Inlet Conditions – In Preparation for Experiments Onboard the International Space Station

Since 2012, researchers at the Purdue University Boiling and Two-Phase Flow Laboratory (PU-BTPFL) and NASA Glenn Research Center have been collaborating on a long-term effort to study flow boiling and condensation in microgravity. The ultimate goal has been to develop the Flow Boiling and Condensation Experiment (FBCE) for the International Space Station (ISS). Based on the findings from prior flow boiling experiments both at different orientations in Earth gravity and onboard parabolic flights simulating short durations of microgravity, a final refined experiment design, construction, and operating procedure have been arrived at for long-duration microgravity flow boiling experiments onboard the ISS. This study investigates flow boiling of n-Perfluorohexane with subcooled inlet in a rectangular channel of dimensions 114.6 mm heated length, 2.5 mm width, and 5 mm height. These pre-launch experiments (Mission Sequence Testing) were conducted in vertical upflow orientation in Earth gravity using the same experimental rig that was launched to the ISS in August 2021. The various operating parameters varied are heating configuration (single- and double-sided), mass velocity (180 – 3200 kg/m2s), inlet subcooling (+0 – 32°C, encompassing both highly subcooled and near-saturated inlet conditions), and inlet pressure (119 – 191 kPa). High-speed video flow visualization images are presented to explain the two-phase interfacial physics within the channel’s heated section. Heat transfer results in terms of flow boiling curves, streamwise profiles of wall temperature and heat transfer coefficient, and averaged heat transfer coefficients are analyzed and parametric effects elucidated. Severe temporal thermodynamic equilibrium is observed for near-saturated inlet at very low velocities. Nucleate boiling degradation starts at larger heat fluxes for single-sided heating than double sided at low mass velocities with highly subcooled inlet, and conversely at high mass velocities with near-saturated inlet. Nucleate boiling degradation can be delayed to higher heat fluxes by highly subcooling the inlet and increasing mass velocity. The entire local heat transfer coefficient profiles are degraded at higher heat fluxes for near-saturated inlet, but only the downstream part for highly subcooled inlet. This study also confirmed reliability of the upcoming ISS experimental data for subcooled inlet conditions and the collected Earth-gravity data will be used for comparison against the ISS data.

flow boiling↗

NASA NTRSDate not supplied

Flow Boiling and Condensation Experiment (FBCE): Latest Findings from the Summary ISS Experiments

Since 2011, researchers from Purdue University and NASA Glenn Research Center (GRC) have been collaborating to investigate the effects of gravity on several aspects of flow boiling and flow condensation. This massive research endeavor, termed the Flow Boiling and Condensation Experiment (FBCE), has culminated in development of NASA’s largest and most complex facility for investigation of two-phase fluid physics onboard the ISS. FBCE consists of two separate studies: flow boiling, using the Flow Boiling Module (FBM), and flow condensation, using the Condensation Module for Heat Transfer Measurements (CM-HT); the FBM experiments have already been completed while the condensation experiments began in 2024. This presentation will summarize mostly new results from the flow boiling experiments, with a focus on analysis of pressure drop and two-phase flow instabilities in microgravity using both experimental data and video records from the ISS experiments, as well as development of machine learning models. These new predictive tools are part of the arsenal of predictive methods developed by the Purdue-Glenn team for design of future space systems.

Microgravity↗

NASA NTRS2025

Direct Numerical Simulation of Flow Past a Gaussian Bump at a High Reynolds Number

We present the results from a direct numerical simulation of a spanwise-periodic turbulent flow past a Gaussian bump. The problem setup is designed to investigate the interaction of an incoming turbulent boundary layer with the strong favorable and adverse pressure gradients generated by the Gaussian bump as the flow passes over it at a Reynolds number of 340000 based on the bump height, or 4 million based on the bump length. The statistical results from the present simulation are compared against our earlier results at a Reynolds number of 2 million. An internal layer, which forms beneath the strongly accelerated boundary layer over the windward side of the bump, is found to generate its near-wall turbulence stress peaks in closer proximity of the wall in the higher Reynolds-number case. Furthermore, the logarithmic layer of the higher Reynolds-number boundary layer appears more resistant to changes induced by strong acceleration and surface curvature effects over the same region. Despite a nearly identical flow separation point in the two flows, the detached shear layer grows at a faster rate and subsequently reattaches at an earlier point in the higher Reynolds-number flow. The surface pressure and skin-friction distributions over the attached flow region compare well against the corresponding experimental data for both flows. However, some differences appear in the separated flow region, which are attributed to the three-dimensionality of the experimental model setup that is not included in the simulation owing to the spanwise periodic assumption. Comparisons with the stereoscopic particle image velocimetry measurements on the central plane of the experimental model over the windward side of the bump show reasonable overall agreement in the mean velocity components, but the turbulence stress components do not agree well at some streamwise locations. Comparisons over the leeward side of the bump show that the mean separated shear layer in the simulation is tilted significantly more toward the wall than the experimental shear layer on the central plane. This mismatch in the mean shear layer orientation is due to the experimental model three-dimensionality and tunnel end-wall effects, which are not modeled in the present spanwise-periodic simulation.

Favorable and Adverse Pressure Gradients↗

DOE OSTI2017

An immersed boundary method for fluid–structure interaction with compressible multiphase flows

This paper presents a two-dimensional immersed boundary method for fluid–structure interaction with compressible multiphase flows involving large structure deformations. This method involves three important parts: flow solver, structure solver and fluid–structure interaction coupling. In the flow solver, the compressible multiphase Navier–Stokes equations for ideal gases are solved by a finite difference method based on a staggered Cartesian mesh, where a fifth-order accuracy Weighted Essentially Non-Oscillation (WENO) scheme is used to handle spatial discretization of the convective term, a fourth-order central difference scheme is employed to discretize the viscous term, the third-order TVD Runge–Kutta scheme is used to discretize the temporal term, and the level-set method is adopted to capture the multi-material interface. In this work, the structure considered is a geometrically non-linear beam which is solved by using a finite element method based on the absolute nodal coordinate formulation (ANCF). The fluid dynamics and the structure motion are coupled in a partitioned iterative manner with a feedback penalty immersed boundary method where the flow dynamics is defined on a fixed Lagrangian grid and the structure dynamics is described on a global coordinate. We perform several validation cases (including fluid over a cylinder, structure dynamics, flow induced vibration of a flexible plate, deformation of a flexible panel induced by shock waves in a shock tube, an inclined flexible plate in a hypersonic flow, and shock-induced collapse of a cylindrical helium cavity in the air), and compare the results with experimental and other numerical data. The present results agree well with the published data and the current experiment. Finally, we further demonstrate the versatility of the present method by applying it to a flexible plate interacting with multiphase flows.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2019

Scaling ability of the counter-current flow limitation (CCFL) correlations for application to reactor thermal hydraulics

The limitation of gas-liquid counter-current flow is important for getting coolant to the core preventing heat-up. To illustrate the scaling dependence of counter-current flow in the downcomer, the upper core tie plate and the hot leg, some results are presented. Based on a derivation of the counter-current flow equations for vertical and horizontal flows, the scaling ability of existing correlations is shown for homogeneous vertical counter-current flow (Kutateladze-type equation) and separated horizontal flow in the hot leg during reflux-condenser conditions (Wallis equation). The large reactor scale heterogeneous counter-current flow in the downcomer and at the upper core tie-plate needed an extension of the Kutateladze-type equation. Finally, Bankoff suggested that for CCFL in perforated plates such as upper tie plate, a parameter that is a combination of actual length scale (Wallis parameter) and Laplace constant (Kutateladze parameter) will be required.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Numerical study of multi-component flow and mixing in a scaled fission product venting system

Numerical simulation of isothermal multi-component gas flow was conducted to study fluid flow and mixing in a scaled low-pressure, low-temperature test facility for the fission product venting system (FPVS) of a gas cooled fast reactor (GFR). The geometry of FPVS test facility was an open loop including gradual expansion coupling and two 90°pipe elbows. First, the validation of large eddy simulation (LES) wall-adapting local eddy-viscosity (WALE) turbulent model was performed for transitional flow in a circular pipe with gradual expansion. The reactingFOAM solver in OpenFOAM v8 was employed. By introducing appropriate turbulence disturbance at the flow inlet, such as turbulence intensity, the numerical results showed good agreement in (1) the velocity profile downstream of the pipe expansion measured by particle image velocimetry (PIV) in this study, and (2) the reattachment length reported in the literature. Using this validated model, the numerical simulation of flow and component mixing was performed for the FPVS with an inlet flowrate corresponding to a Reynolds number of 2,400 to investigate the flow behavior and component mixing. Standard deviation of the mass fraction of component, referred to as absolute mixing index (AMI), was calculated to quantify the mixing of components, showing that the component mixing length determined by AMI is related to the reattachment length downstream of the expansion. Additionally, this study was able to identify the best location in the FPVS test facility to measure the velocity and concentration profies where multicomponent flow is well mixed.

15 GEOTHERMAL ENERGY↗

DOE OSTI2016

Study on dynamics of the influence exerted by plasma on gas flow field in non-thermal atmospheric pressure plasma jet

In this paper, first, steady state of the plasma jet at different operating conditions is investigated through Schlieren photography with and without applying shielding gas. Second, the dynamic process for the plasma impacting on the gas flow field is studied. When the discharge is ignited, reduction in laminar flow occurs. However, when the gas flow rate is too low or too high, this phenomenon is not obvious. What is more, both frequency and voltage have significant impact on the effect of plasma on the gas flow, but the former is more significant. Shielding gas provides a curtain for plasma to propagate further. High speed camera along with Schlieren photography is utilized to study the impact of plasma on the gas flow when plasma is switched on and off. The transition of the gas flow from laminar to turbulent or vice versa happens right after the turbulent front. It is concluded that appearance and propagation of turbulence front is responsible for the transition of the flow state.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Lagrangian conditional statistics and flow topology in edge plasma turbulence

Lagrangian statistics and particle transport in edge plasma turbulence are investigated using the Hasegawa–Wakatani model and its modified version. The latter shows the emergence of pronounced zonal flows. Different values of the adiabaticity parameter are considered. The main goal is to characterize the role of coherent structures, i.e., vortices and zonal flows, and their impact on the Lagrangian statistics of particles. Computationally intensive long time simulations following ensembles of test particles over hundreds of eddy turnover times are considered in statistically stationary turbulent flows. The flow topology is characterized using the Lagrangian Okubo–Weiss criterion in order to split the flow into topologically different domains. In elliptic and hyperbolic regions, the probability density functions (PDFs) of the residence time have self-similar algebraic decaying tails. However, in the intermediate regions, the PDFs exhibit exponentially decaying tails. Topologically conditioned PDFs of the Lagrangian velocity, and acceleration and density fluctuations are likewise computed. The differences between the classical Hasegawa–Wakatani system and its modified version are assessed, and the role of zonal flows is highlighted. Here, the density flux spectrum, which characterizes the contributions of different length scales, is studied, and its inertial scaling is found to be in agreement with predictions based on dimensional arguments. Analyzing the angular change of particle tracers at different time scales, corresponding to coarse grained curvature, completes the study, and these multiscale geometric statistics quantify the directional properties of the particle motion in different flow regimes.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2015

Inflow/outflow boundary conditions for particle-based blood flow simulations: Application to arterial bifurcations and trees

When blood flows through a bifurcation, red blood cells (RBCs) travel into side branches at different hematocrit levels, and it is even possible that all RBCs enter into one branch only, leading to a complete separation of plasma and R- BCs. To quantify this phenomenon via particle-based mesoscopic simulations, we developed a general framework for open boundary conditions in multiphase flows that is effective even for high hematocrit levels. The inflow at the inlet is duplicated from a fully developed flow generated in a pilot simulation with periodic boundary conditions. The outflow is controlled by adaptive forces to maintain the flow rate and velocity gradient at fixed values, while the particles leaving the arteriole at the outlet are removed from the system. Upon valida- tion of this approach, we performed systematic 3D simulations to study plasma skimming in arterioles of diameters 20 to 32 microns. For a flow rate ratio 6:1 at the branches, we observed the \all-or-nothing" phenomenon with plasma only entering the low flow rate branch. We then simulated blood-plasma separation in arteriolar bifurcations with different bifurcation angles and same diameter of the daughter branches. Our simulations predict a significant increase in RBC flux through the main daughter branch as the bifurcation angle is increased. Lastly, we demonstrated the new methodology for simulating blood flow in ves- sels with multiple inlets and outlets, constructed using an angiogenesis model.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS1945

On two-dimensional flows of compressible fluids

This report is devoted to the study of two-dimensional steady motion of a compressible fluid. It is shown that the complete flow pattern around a closed obstacle cannot be obtained by the method of Chaplygin. In order to overcome this difficulty, a formula for the stream-function of a two-dimensional subsonic flow is derived. The formula involves an arbitrary function of a complex variable and yields all possible subsonic flow patterns of certain types. Conditions are given so that the flow pattern in the physical plane will represent a flow around a closed curve. The formula obtained can be employed for the approximate determination of a subsonic flow around an obstacle. The method can be extended to partially supersonic flows.

HODOGRAPHY METHOD↗

DOE OSTI2021

Increasing temperature and flow management alter mercury dynamics in East Fork Poplar Creek

East Fork Poplar Creek (EFPC) is a mercury (Hg) contaminated creek in east Tennessee, USA. Stream restoration activities included the initiation of a flow management programme in 1996 in which water from a nearby lake was pumped to the head of the creek. We conducted regular water sampling for 2 years along the length of EFPC during active flow management and for 5 years after flow management stopped. Total Hg and total monomethylmercury (MMHg) concentration and flux decreased in the uppermost reaches of EFPC that were closest to the point of water addition. Most water quality parameters, including DOC concentration, remained unchanged after flow management termination. Nevertheless, SUVA 254 , a measure of dissolved organic matter (DOM) composition, increased and coincided with increased dissolved Hg (Hg D ) concentration and flux and decreased Hg solid-water partitioning coefficients throughout EFPC. Higher SUVA 254 and Hg D concentration have potential implications for bioavailability and MMHg production. Total and dissolved MMHg concentrations increased in lower reaches of EFPC after the end of flow management and these increases were most pronounced during spring and early summer when biota are more susceptible to exposure and uptake. A general warming trend in the creek after active flow management ended likely acted in concert with higher Hg D concentration to promote higher MMHg concentration. Total and dissolved MMHg concentrations were positively correlated with water temperature above a threshold value of 10°C. Concentration changes for Hg and MMHg could not be accounted for by changes in creek discharge that accompanied the cessation of flow management. In addition to the changing DOM composition in-stream, other watershed-scale factors likely contributed to the observed patterns, as these changes occurred over months rather than instantaneously after flow management stopped. Nevertheless, similar changes in MMHg have not been observed in a tributary to EFPC.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Identifying preferential flow from soil moisture time series: Review of methodologies

Abstract Identifying and quantifying preferential flow (PF) through soil—the rapid movement of water through spatially distinct pathways in the subsurface—is vital to understanding how the hydrologic cycle responds to climate, land cover, and anthropogenic changes. In recent decades, methods have been developed that use measured soil moisture time series to identify PF. Because they allow for continuous monitoring and are relatively easy to implement, these methods have become an important tool for recognizing when, where, and under what conditions PF occurs. The methods seek to identify a pattern or quantification that indicates the occurrence of PF. Most commonly, the chosen signature is either (1) a nonsequential response to infiltrated water, in which soil moisture responses do not occur in order of shallowest to deepest, or (2) a velocity criterion, in which newly infiltrated water is detected at depth earlier than is possible by nonpreferential flow processes. Alternative signatures have also been developed that have certain advantages but are less commonly utilized. Choosing among these possible signatures requires attention to their pertinent characteristics, including susceptibility to errors, possible bias toward false negatives or false positives, reliance on subjective judgments, and possible requirements for additional types of data. We review 77 studies that have applied such methods to highlight important information for readers who want to identify PF from soil moisture data and to inform those who aim to develop new methods or improve existing ones. Core Ideas Soil moisture data can be used to identify the occurrence of preferential flow (PF) and its initiating conditions. Various data‐analysis methods to identify PF differ in susceptibility to error, bias, and subjectivity. These methods can utilize vast amounts of data from soil moisture monitoring networks to develop understanding of when, where, and under what conditions PF occurs. Newly developed methods may lead to better accuracy and reliability, and reduce the need for subjective judgments. Plain Language Summary Preferential flow through soil occurs when a large amount of water is suddenly available, as during an intense storm. This type of flow moves rapidly through the soil in distinct narrow pathways rather than moving evenly throughout the body of soil, with major consequences for groundwater resources, ecosystems, spreading of contaminants, and other vital concerns. Methods of detecting preferential flow have been developed that utilize measurements of soil water content made by sensors installed at various depths. This measurement technology has been widely implemented, many locations now having datasets years in length, and various methods have been developed for using these to identify preferential flow. The various methods are based on different features in the soil moisture records and vary in their advantages and shortcomings. In this review, we explain and evaluate these methods, highlighting important information for their implementation to identify preferential flow from soil moisture data and for efforts to develop new methods or improve existing ones.

Nimmo, John R↗

DOE OSTI2024

Partial spectral flow in the D1D5 CFT

The two-dimensional 𝒩 = 4 superconformal algebra has a free field realization with four bosons and four fermions. There is an automorphism of the algebra called spectral flow. Under spectral flow, the four fermions are transformed together. In this paper, we study partial spectral flow where only two of the four fermions are transformed. Partial spectral flow is applied to the D1D5 CFT where a marginal deformation moves the CFT away from the free point. The partial spectral flow is broken by the deformation. We show that this effect can be studied due to a transformation of the deformation which is well-defined under partial spectral flow. As a result in the spectrum, we demonstrate how to compute the second-order energy lift of a D1D5P state through its partial spectral flowed state. We find that D1D5P states related by partial spectral flow do not have the same lift in general.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2026

MRV Challenge 3: velocity and passive scalar comparison in a 3D turbulent flow

The third iteration of a magnetic resonance velocimetry (MRV) challenge comparison activity consisting of 3D flow measurements for a turbulent flow in a water channel moving past centrally positioned cubic obstacles is reported. In this challenge iteration, MRV measurements are coupled with either temperature or concentration measurements to extend the diagnostic utility. Five research teams from around the world conducted the measurements on a single shared apparatus. The water channel included partial elements along the channel sidewalls that varied in height and precluded easy optical accessibility. In addition to a turbulent mainstream flow, a secondary flow entered the channel between the second and third cubic elements from a square injector hole at the channel bottom wall. The injector jet interacts with the mainstream flow and mixes turbulently as it advects downstream. For the selected flow regime and water solutions used as working fluids, the mixing of the higher temperature or concentration through the secondary flow with the mainstream flow satisfies the same dynamics so that both temperature and concentration fields behave as passive scalars and can be directly compared. The measurements are explained in detail by each participating team, and the results are interpolated onto a common grid and compared using line profiles, contour plots, and isosurfaces.

Benson, Mike [ORNL] (ORCID:000000023210116X)↗

DOE OSTI2019

A Stochastic Study of Flow Anisotropy and Channelling in Open Rough Fractures

The quantification of fluid flow in rough fractures is of high interest for reservoir engineering, especially for deep geothermal applications. Herein, rough self-affine fractures are stochastically generated with incremental shear displacement and geometrically described by two aperture definitions, the vertical aperture a vert and the effective aperture a eff . In order to compare their effect on fracture flow, such as anisotropy and channelling, Local Cubic Law (LCL) model-based 2D fluid flow is simulated. The particularity of this approach is the combination of a stochastic generation of self-affine fractures with a statistical analysis (560 individual realizations) of the impact of the LCL’s aperture constraint on fracture flow. The results show that aperture definition affects the quantitative interpretation of flow anisotropy and channeling as well as the aperture distribution of the fractures with shearing. Higher values of mean aperture for a given fracture are found using a vert , whereas the aperture standard deviation is larger with a eff . In addition, flow anisotropy is significantly sensitive to aperture definition for small shear displacements and shows a relative higher dispersion with a eff . Thus, LCL prediction models based on a vert are expected to lead to higher dispersion of anisotropy results with a higher uncertainty (factor ~ 2). Realizations based on avert lead to an enhanced clustering of high flow rates for higher shearing displacements. This channeling development results in higher total flow rates for these simulations. Finally, these findings support the direct calibration of pre-existing LCL anisotropy simulations based on avert towards more representative results using a eff .

58 GEOSCIENCES↗

DOE OSTI2020

Free-Surface Liquid Lithium Flow Modeling and Stability Analysis for Fusion Applications

Liquid metal plasma facing components are considered an attractive design choice for fusion devices including pilot plants. Virtual prototyping of such devices includes modeling of free-surface flow of the electrically conductive liquid, which requires computational fluid dynamics (CFD) and magnetohydrodynamics (MHD) simulations. Numerical tools capable of simulating flows and heat transfer in the free-surface MHD flow were developed at PPPL based on the customized ANSYS CFX. Here, MHD is introduced using a magnetic vector potential approach. Free-surface flow capabilities are available in the code and were tested. Special stabilization procedures were derived and applied to improve convergence of the momentum equations with the source terms due to the Lorentz force and surface tension. Important characteristics of the fusion-relevant liquid metal flow is free surface smoothness and stability. Heat flux from the plasma impacts the liquid surface at a very acute angle, so any change of the free surface from axisymmetry can dramatically increase the local heat flux density and thus create excessive evaporation of liquid lithium into the plasma, which is detrimental to operations. Stability analysis of the liquid metal film flow was performed to determine applicable flow regimes. Thin film flow along horizontal wall is considered. Effects of gravity, magnetic field, and surface tension are included in the analysis.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2018

Numerical Simulation of the Effects of Horizontal and Vertical EMBr on Jet Flow and Mold Level Fluctuation in Continuous Casting

In this article, a new type of electromagnetic braking (EMBr), named vertical EMBr (V-EMBr) was introduced in the continuous casting process. In order to investigate its capability and applicability, the impacts of horizontal and vertical EMBrs on the flow pattern in a continuous casting mold were simulated by means of an implemented Reynolds-averaged Navier–Stokes (RANS) SST k–ω turbulence model. The characteristics of electromagnetic field and flow field inside a 1450 mm × 230 mm mold with Ruler-EMBr and V-EMBr have been compared. The numerical simulation results indicate that the static magnetic field generated by Ruler-EMBr can cover the main part of the discharging jet flow, which has a better control of the flow pattern in lower part of the mold. The static magnetic field generated by V-EMBr can cover both the vicinity of the mold narrow faces and the impingement region of the jet flow, which can effectively control the liquid steel flow in the upper recirculation zone. The parametric study also shows that the large vortices beneath the jet flow can be almost completely eliminated at an optimized magnetic flux density with Ruler-EMBr. In addition, the surface velocity and steel/slag interface fluctuation can be suppressed with the application of V-EMBr to acceptable values even with a wide variation of SEN port angles. It is estimated that to reach the same level of braking effect on the upper recirculation flow, a magnetic flux density of 0.1 T is sufficient for V-EMBr, while 0.2 T is needed for Ruler-EMBr. Based on the results, a second-generation V-EMBr has been developed, which combines both of the merits of Ruler-EMBr and V-EMBr.

36 MATERIALS SCIENCE↗