A new method of semi-continuous casting of AZ80 Mg alloy billets by a combination of electromagnetic and ultrasonic fields

The influence of low frequency electromagnetic field and power ultrasonic field on the microstructure of AZ80 Mg alloy billets was studied. The magnetic flux density and time average electromagnetic volume force density were obtained by numerical simulation. The acoustic pressure distribution was also numerically calculated in order to characterize the ultrasonic field propagation. After comparison of the different effects of grain refinement by low frequency electromagnetic casting (LFEC) and ultrasonic casting (UC), a new method (LFEC + UC) was developed by simultaneously applying ultrasonic vibration to the melt during low frequency electromagnetic semi-continuous casting of AZ80 Mg alloy billets. With the application of the compound field under the optimum conditions, the as-cast macrostructure and microstructure were refined and homogeneously distributed. An obvious improvement of mechanical properties was finally obtained. The mechanisms of grain refinement and interaction of low frequency electromagnetic field and power ultrasonic field with the melt were discussed.