Structural optimization of single-strand crucible for planar flow casting: Simulation and application study

Amorphous ribbon materials are evolving to meet social development trends and commercial demands, focusing on high efficiency and stability. However, the flow of molten metal and the behavior of inclusions in the crucible during the ribbon production process significantly affect both the mechanical properties and surface quality of the ribbons. A well-designed flow control structure is crucial for optimizing molten metal flow and improving cleanliness. This study, based on computational fluid dynamics, develops a two-phase flow model and a unidirectional Discrete phase model, combined with physical simulations, to investigate the effects of different retaining wall structures on molten metal flow and inclusion removal in a single-strand crucible. The results indicate that case D, which reduces the bottom hole area and positions it 50 mm from the centerline, with 20° horizontal inclination for both upper and bottom diversion holes, and a 20° vertical inclination for the upper diversion hole, is the optimal retaining wall structure. Compared to the prototype structure, this case reduced the dead zone proportion by 18.6%, extended the mean residence time to 54 s and increased the inclusion removal rate by 20.7%. Industrial application data showed that after structural optimization, the inclusion content in the molten metal decreased by 12%, the ribbon lamination factor remained above 89.5%, and the average thickness range was reduced by 0.6. This demonstrates that numerical simulations can guide industrial optimization, enhancing the metallurgical effect of the single-strand crucible in continuous casting and improving the quality and performance of the final product.