Internal electromagnetic stirring is an advanced melt treatment method, which can be used in direct chill casting to prepare large-scale Al alloy billets. Intercooling intensity is a primary parameter of internal electromagnetic stirring; its effects on temperature fields and microstructures have been investigated via numerical simulations and industrial experiments, respectively. The simulated results show an increase in the intercooling affected area and a decrease in sump depth with an increase in the intercooling heat transfer coefficient. The heat transfer coefficient should not exceed 500 W/(m² °C) because the solid fraction of the intercooling end bottom may exceed 50%. The experiment’s results demonstrate that the average grain sizes in the edge, 1/2 radius, and center are 151 ± 13 μm, 159 ± 14 μm, and 149 ± 16 μm, respectively, under a liquid nitrogen flow rate of 160 L/min, which is much finer than that of 80 L/min and more homogeneous than that of 240 L/min. Furthermore, an experimental liquid nitrogen flow rate of 80 L/min, 160 L/min, and 240 L/min approximately correspond to the simulated heat transfer coefficient of 200 W/(m² °C), 300 W/(m² °C), and 400 W/(m² °C), respectively.