Three-Dimensional Molten Pool Simulation in Amorphous Alloy Ribbon Preparation via Planar Flow Casting

A coupled air-melt two-phase flow three-dimensional (3D) volume of fluid (VOF) model was established to simulate the molten pool formation process during planar flow casting (PFC) of amorphous alloy ribbons, based on the continuity equation, momentum equation, and energy equation. The evolution of the 3D molten pool behavior was studied. The results indicate that the heat exchange characteristics and flow behaviour of the molten pool exhibit distinct 3D distribution features, the continuous changes of the tri-junction point (J*) during the PFC process can lead to the formation of fish-scale patterns, under the influence of the airflow, air pockets will be drawn into the peripheral molten pool, resulting in burrs and wrinkles along the casting direction at the edge of the ribbon.