Numerical simulation and industrial application of nozzle clogging in bilateral-port nozzle

Abstract In this study, an inclusion deposition model was used to simulate the nozzle clogging process in industrial casting. The concepts of inclusion parcel and inclusion magnification factor were introduced in the model, which could be applied to an industrial-scale nozzle clogging simulation. The simulation results were verified using the results from the industry study. The results show that nozzle clogs were formed with Al-O and Al-O-Ce inclusions of diameter 5–10 μm. The nozzle clog formed initially at the nozzle bottom and was deposited on the nozzle wall during the casting process. The volume fraction of the nozzle clog in the nozzle was 52.26% at the end of the casting process. The velocity magnitude in the nozzle increased during casting. The 5 μm Al-O and Al-O-Ce inclusions cause more deposition. The number of the deposited Al-O and Al-O-Ce inclusions were similar.