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Numerical simulation studies of jet rapid solidification technology for magnetic materials: a review

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Abstract

Jet rapid solidification (JRS) is a key process to obtain the ribbon of magnetic materials. Numerical simulation is an effective method to analyze real-time distribution of status parameters during the JRS process and optimize the process. In this paper, the numerical simulation research in two JRS processes, namely, planar flow casting (PFC) and melt spinning (MS), is reviewed. First, based on the principle of rapid solidification, the working principles of PFC and MS processes are summarized and distinguished. The theoretical models, analytical models, and research methods of PFC and MS processes are further introduced and compared in three main research aspects, denoted as melt puddle, cooling roller, and inclusions in the tundish. Regarding the melt puddle, the influence of the melt puddle on the thickness of rapidly solidified ribbons is analyzed. The flow behavior and heat transfer analysis of melt puddle are discussed. In terms of the cooling roller, numerical analyses of the cooling roller structure optimization, parameter optimization, and “fluid–solid-thermal” coupling are summarized. Moreover, the simulation of the movement of inclusions in the PFC tundish is compared. Lastly, the current challenges and future opportunities are also addressed. The development of high-quality JRS ribbons has significant theoretical, social, and economic significance because its quality and stability determine the final characteristics of magnets. Therefore, the application of numerical simulation technology in the JRS process is beneficial for optimizing process routes and system structures, achieving the visual tracking of process, and objectively guiding the development of new JRS equipment.

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Abbreviations

Hc:

Coercivity of magnetic materials (Oe or A/m)

Br:

Remanence of magnetic materials (T or Gs)

BH:

Magnetic energy product of magnetic materials (GOe or J/m3)

V :

Solidification velocity of molten alloy (ms)

B :

Breadth of the nozzle slot (mm)

G :

Gap between the nozzle face and the surface of chill wheel (mm)

T :

Ribbon thickness (mm)

U :

Linear velocity of wheel surface (m/s)

L :

Puddle length (mm)

∆P :

Over pressure at the outlet of nozzle slot (KPa)

USM:

Upstream meniscus

DSM:

Downstream meniscus

t d :

Dwell time of ribbon (s)

T j :

Jetting temperature of molten alloy (K or ℃)

D :

Diameter of casting wheel (mm)

Th :

Thickness of casting wheel (mm)

μ m :

Viscosity of the molten alloy (Pa·s)

h ω :

Average heat transfer coefficient between cooling roller and water (W/(m2 ·K))

h a :

Average heat transfer coefficient between cooling roller and ambient air (W/(m2 ·K))

We :

Weber number

λ ω :

Thermal conductivity of cooling water (W/(m·K))

ρ ω :

Density of cooling water (kg/m)

μ ω :

Viscosity density of cooling water (Pa·s)

u ω :

Velocity of cooling water (m/s)

C ω :

Specific heat capacity of cooling water (J/(kg·K))

d :

Cooling channel equivalent diameter (m)

g :

Gravity acceleration (m/s2)

Fe :

Electromagnetic force (N)

S T :

Source term of energy equation

Prt :

Prandtl number of the turbulent

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Funding

This research work was financially supported by the National Key Research and Development Plan of China (No. 2022YFB3504600).

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Authors and Affiliations

  1. School of Mechanical Engineering, Dalian University of Technology, Dalian, 116024, China

    Haorui Zhai, **aodong Li, Wuwei Zhu & Shuzhou Yu

  2. School of Materials Science and Engineering, Dalian University of Technology, Dalian, 116024, China

    Ying Chang

  3. Division of Functional Materials, Central Iron & Steel Research Institute Group (CISRI), Bei**g, 100081, China

    Yikun Fang

  4. Fujian Changting Golden Dragon Rare Earth Co., Ltd., Changting, Longyan, 366399, China

    Qingfang Huang

  5. Advanced Technology & Materials Co., Ltd., Central Iron & Steel Research Institute Group (CISRI), Bei**g, 100081, China

    **aojun Yu

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  1. Haorui Zhai
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Contributions

HZ: conceptualization, methodology, investigation, data curation, and writing—original draft; YC: conceptualization, methodology, supervision, and funding acquisition; XL: data curation and writing—review and editing; WZ: investigation and data curation; YF: methodology; SY: data curation and writing—review and editing; QH: investigation and funding acquisition; XY: supervision and project administration.

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Zhai, H., Chang, Y., Li, X. et al. Numerical simulation studies of jet rapid solidification technology for magnetic materials: a review. Int J Adv Manuf Technol 130, 2065–2083 (2024). https://doi.org/10.1007/s00170-023-12787-y

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