A three-dimensional numerical model combining electromagnetic field, fluid flow, heat transfer, and solidification has been established to study the effect of nozzle injection mode and mold electromagnetic stirring (M-EMS) on the internal quality of a continuously cast bloom. The model is validated by measured data of the magnetic flux density along the stirrer center line. According to the simulation and experimental results, M-EMS can introduce a horizontal swirling flow ahead of the solidification front, promoting the superheat dissipation of molten steel and columnar to equiaxed transition (CET). As the stirring current increases from 0 to 800 A, the superheat at the mold exit in the bloom center decreases by 1.9 K for the single-port nozzle case and 3.8 K for the five-port nozzle case. The resulting increase in the equiaxed crystal ratio is about 5.65% and 4.06%, respectively. In comparison, the injection mode shows a more significant influence on the heat transfer and solidification structure in the bloom under the present casting conditions. The superheat at the mold exit in the bloom center decreases by 5.1–7.7 K as the injection mode changes from a single-port nozzle to a five-port nozzle, and the increase in the equiaxed crystal ratio ranges between 14.8% and 17%. It is found that the flow velocity of the molten steel in front of the solidification interface for the five-port nozzle is higher than that for the single-port nozzle regardless of the M-EMS power. The washing effect here reinforces both the heat exchange through the solidification interface and the dendrite re-melting or fragmenting, stimulating the formation of an equiaxed crystal at the bloom center. In addition, it is observed that both the central shrinkage and carbon segregation have decreased with the five-port nozzle plus M-EMS. This suggests that the combined application of a five-port nozzle and M-EMS can effectively improve the internal quality of large bloom castings.

Based on the Maxwell’s equations, a finite element model is established to study the characteristics of electromagnetic field in the mold of billet and bloom continuous casting with electromagnetic stirring (M-EMS). A novel integral method for calculating electromagnetic torque is proposed to evaluate the stirring intensity of stirrer. In order to verify the accuracy of the model, a well-designed electromagnetic torque detecting device is fabricated. The predicted value of electromagnetic torque and magnetic flux density are consistent with the measured data. The optimum frequency is determined by the maximal electromagnetic torque of the strand. The effect of stirring current intensity and different stirrer positions along the length of mold on the electromagnetic field has been studied numerically. The results show that the optimum frequency is smaller when the copper tube of the mold is thicker and the section size is bigger. Besides, the electromagnetic torque of the strand is a quadratic function of the running current intensity. Moreover, the installation position of stirrer strongly affects the prediction of electromagnetic field distribution, further influencing the optimum frequency and the electromagnetic torque of strand.