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1Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
New possibilities for velocity New possibilities for velocity measurements in metallic meltsmeasurements in metallic melts
S. Eckert, G. Gerbeth, F. Stefani
Department Magnetohydrodynamics, Forschungszentrum Rossendorf P.O. Box 510119, D-01314 Dresden, Germany, http://www.fz-rossendorf.de/FWS/FWSH
E-mail: [email protected]
Sino-German Workshopon Electromagnetic Processing of Materials
Oct. 11-13, Shanghai, China
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2Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
Knowledge about the flow field and the transport
properties of the flow
Why do we need flow measurements in metallic melts ?Why do we need flow measurements in metallic melts ?
Optimisation of products, technologies and facilities
• better understanding of the process• validation of CFD models• on-line control and monitoring
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3Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
Commercial measuring techniques Commercial measuring techniques for liquid metal flows are almost for liquid metal flows are almost not available !not available !
Reasons– properties of the fluid (opaqueness, heat conductivity,..)
– high temperatures
– chemical reactivity
– interfacial effects
– external electromagnetic fields
Current situationCurrent situation
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4Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
GoalsGoals
• to develop measuring techniques for liquid metal flows at moderate temperatures
model experiments (T 300°C)
• to extend the range of application towards higher temperatures
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5Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
Data of interestData of interest
• flow rate
• local velocity
• fluctuations, turbulence level
• flow pattern (velocity profiles, 3D-structure)
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6Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
• Local probes (invasive)
• Electric Potential Probe (EPP, Vives Probe)
• Mechano-Optical Probe (MOP)
• Ultrasonic methods (non-invasive, but need contact)
• Ultrasound Doppler Velocimetry (UDV)
• Inductive methods (contact-less)
• Inductive Flowmeter (IFM)
• Contactless Inductive Flow Tomography (CIFT)
• X-ray radioscopy
• Local probes (invasive)
• Electric Potential Probe (EPP, Vives Probe)
• Mechano-Optical Probe (MOP)
• Ultrasonic methods (non-invasive, but need contact)
• Ultrasound Doppler Velocimetry (UDV)
• Inductive methods (contact-less)
• Inductive Flowmeter (IFM)
• Contactless Inductive Flow Tomography (CIFT)
• X-ray radioscopy
List of measuring techniquesList of measuring techniques
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7Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
Ultrasound Doppler Velocimetry (UDV)Ultrasound Doppler Velocimetry (UDV)
• Takeda (1987, 1991)
• Commercial instrument
• standard transducers
(Tmax = 150°C)
• Measurement of instantaneous velocity profiles
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9Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
UDV in liquid metals – problemsUDV in liquid metals – problems
• High temperature
• Acoustic coupling
• Transmission of ultrasonic energy through
interfaces (channel walls)
• Wetting conditions
• Availability of reflecting particles
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10Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
Concept of an integrated probe IConcept of an integrated probe I
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11Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
Concept of an integrated probe IIConcept of an integrated probe II
• Collaboration with the University Nishni-Novgorod (Russia)• Piezoelectric transducer coupled on an acoustic wave guide
made of stainless steel• Stainless steel foil (0.1 mm) wrapped axially around a capillary
tube: length 200 mm, outer diameter 7.5 mm
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14Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
UDV – Flows driven by RMF/TMFUDV – Flows driven by RMF/TMF
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15Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
Vertical velocity Streamfunction
UDV – Flow driven by RMFUDV – Flow driven by RMF
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16Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
Vertical velocity Streamfunction
UDV – Flow driven by TMFUDV – Flow driven by TMF
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17Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
UDV – Flow driven by RMF/TMFUDV – Flow driven by RMF/TMF
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18Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
• Rectangular alumina crucible (130 80 mm2)
• melt depth 40 mm
• inductive heater
• melt temperature:
620°C (CuSn), 750°C (Al)
• installation of the integrated sensor at the free surface of the melt
• Doppler angle 35°
UDV in CuSn/Al – Experimental Set-upUDV in CuSn/Al – Experimental Set-up
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19Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
UDV in CuSn/Al – ResultsUDV in CuSn/Al – Results
Profiles obtained at two positions: • different signs• similarity of shape and
amplitude
Velocity signal obtained in liquid
aluminium by up-and-down moving
of the sensor by hand
10.0 12.5 15.0 17.5 20.0 22.5 25.0-60
-40
-20
0
20
40
60
velo
city
[mm
/s]
time [s]
70 75 80 85 90 95 100-200
-100
0
100
200
position 1 position 2
velo
city
[m
m/s
]
measuring depth [mm]
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20Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
• An existing flow field will modify an applied magnetic field:
B=B0+b, b~Rm B0 (Rm=µLv)
e.g. the magnetic field measured outside the melt contains information about the flow field
• Rm ~ 10-3 b ~ O(T)Example: crystal growth configuration
(Czochralski method)
Contactless Inductive Flow Tomography (CIFT)
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21Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
SV sr
srSdsdV
rr
rBrurotrB 3
00
'
'')'(
4'
)'()'(
4)(
SV ss
ssSdsdV
rs
rBrudivs 3
'
'')'(
2
1
'
)'()'(
2
1)(
• Bio-Savart‘s law
• inverse method to reconstruct the velocity field • additional requirements:
– mass conservation (div u = 0)– Tichonov regularization (keeps the mean quadratic
curvature of the velocity field finite)
CIFT - Basics
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22Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
CIFT - ExperimentCIFT - Experiment
• Cylinder filled with InGaSn
(D = 180 mm , H = 180 mm)
• Magnetic field: two pairs of Helmholtz coils 10mT
• 48 Hall sensors
(KSY44-Infineon, resolution 1 T)
• Mechanical stirrer (2000rpm)
max. velocity ~ 1 m/s
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23Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
Lid with stirrer and motor
Vessel, electronic equipment
CIFT - ExperimentCIFT - Experiment
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24Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
CIFT - ResultsCIFT - Results
Induced magnetic fieldfor transverse primaryfield
Induced magnetic fieldfor axial primary field
Reconstructed velocity field
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25Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
CIFT - ResultsCIFT - Results
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26Sino-German-Workshop, Oct. 11-13 2004, Shanghai, China
ConclusionsConclusions
• Several measuring techniques exist to determine the velocity field in metallic melts
• Successful investigations are under progress to extend the application range towards higher temperatures
• Promising new developments:– Ultrasound Doppler Velocimetry (UDV)– Contactless Inductive Flow Tomography (CIFT)