Table Of ContentElectromagnetic Processing of Materials
FLUID MECHANICS AND ITS APPLICATIONS
Volume99
SeriesEditor: R.MOREAU
MADYLAM
EcoleNationaleSupe´rieured’HydrauliquedeGrenoble
BoˆıtePostale95
38402SaintMartind’He´resCedex,France
AimsandScopeoftheSeries
Thepurposeofthisseriesistofocusonsubjectsinwhichfluidmechanicsplaysa
fundamentalrole.
As well as the more traditional applications of aeronautics, hydraulics, heat and
masstransferetc.,bookswillbepublisheddealingwithtopicswhicharecurrently
in a state of rapid development, such as turbulence, suspensions and multiphase
fluids,superandhypersonicflowsandnumericalmodelingtechniques.
It is a widely held view that it is the interdisciplinary subjects that will receive
intensescientificattention,bringingthemtotheforefrontoftechnologicaladvance-
ment. Fluids have the ability to transport matter and its properties as well as to
transmit force, therefore fluid mechanics is a subject that is particularly open to
crossfertilizationwithothersciencesanddisciplinesofengineering.Thesubjectof
fluidmechanicswillbehighlyrelevantindomainssuchaschemical,metallurgical,
biologicalandecologicalengineering.Thisseriesisparticularlyopentosuchnew
multidisciplinarydomains.
The medianlevelof presentationis the first year graduatestudent. Some textsare
monographsdefiningthecurrentstate ofafield;othersareaccessibleto finalyear
undergraduates;butessentiallytheemphasisisonreadabilityandclarity.
Forfurthervolumes:
http://www.springer.com/series/5980
Shigeo Asai
Electromagnetic Processing
of Materials
Materials Processing by Using Electric
and Magnetic Functions
123
ShigeoAsai
JapanScienceandTechnologyAgency
Ahara-cho23-1
457-0063Nagoya
Minami-ku
Japan
[email protected]
ThisworkispartlybasedonanupdatedtranslationfromtheoriginalJapaneseworkentitled:
“ZairyouDenziPurossesingu”,byShigeoAsai,2000,UchidaRokakuho,Japan.
ISSN0926-5112
ISBN978-94-007-2644-4 e-ISBN978-94-007-2645-1
DOI10.1007/978-94-007-2645-1
SpringerDordrechtHeidelbergLondonNewYork
LibraryofCongressControlNumber:2011945107
©SpringerScience+BusinessMediaB.V.2012
Nopartofthisworkmaybereproduced,storedinaretrievalsystem,ortransmittedinanyformorby
anymeans,electronic,mechanical,photocopying,microfilming,recordingorotherwise,withoutwritten
permissionfromthePublisher,withtheexceptionofanymaterialsuppliedspecificallyforthepurpose
ofbeingenteredandexecutedonacomputersystem,forexclusiveusebythepurchaserofthework.
Printedonacid-freepaper
SpringerispartofSpringerScience+BusinessMedia(www.springer.com)
Preface
Most people who choose to read this book are likely to begin with the question
“WhatisElectromagneticProcessingofMaterials?”Thisquestionisareasonable
one since Electromagnetic Processing of Materials, so called EPM, will find
its future development in concert with Materials Science and Engineering, a
conjoiningofareasofresearchthathasnotyetbeenfullyconsummated.
Inthemetalsindustry,utilizationoftheLorentzforcestartedinveryearlytimes;
for example, machines to effect electromagnetic levitation and electromagnetic
mixingwereinventedin1923and1932,respectively,butwithlittleunderstanding
of the science behind them. To bridge the gap between technology and sci-
ence, the term Magnetohydrodynamics, which had been established by Alfve´n in
1942, was first introduced at the IUTAM (InternationalUnion of Theoretical and
Applied Mechanics) symposium entitled “Metallurgical Applications of Magne-
tohydrodynamics”, held in 1982 in Cambridge, England. Thus, we can say that
Electromagnetic Processing of Materials started from this symposium where the
twochannelsofMetallurgyandMagnetohydrodynamicswerecombined.Theterm
ElectromagneticProcessingofMaterialsfirstappearedatTheSixthInternational
IronandSteelCongressheldin1990inNagoya,JapanandthenthefirstSymposium
ofEPM washeld in1994,also in Nagoya.Thatis, EPM startedin the1980sand
grewinthe1990sasanintimatecollaborationbetweenFranceandJapan.Thefirst
fruits of EPM progress were found in utilization of the Lorentz force, mainly for
developmentofsteelmakingprocesses,especiallyofcontinuouscastingprocesses.
By the2000stheactivityof EPM hadspreadinto theutilizationofmagnetization
force,enabledbythefortuitousfactthatahighmagneticfield,uptoaround15Tesla,
becameeasilyavailablethroughthedevelopmentofsuper-conductingtechnologies.
Briefly speaking, EPM is now located in one branch of Materials Science and
Engineering andaimstocreatenew materialsand/ortodesignefficientprocesses
bymakinguseofvariousfunctionswhichappearwhenelectricandmagneticfields
areappliedtoknownmaterials.
ThisbookcontainsnotonlyanEnglishtranslationofmy bookonElectromag-
netic Processingof Materialsfirst publishedin 2000by UchidaRokakuho,Japan,
thecontentofwhichisbasedonthelecturesgivenforadvancedundergraduateand
v
vi Preface
graduatestudentsintheDepartmentofMaterialsScienceandEngineering,Nagoya
Universityovertwodecades,butalsotheintroductionoftransportphenomena.Fur-
thermore,tablesandappendixareaddedforhelpingthedesignofelectromagnetic
processes, and better understanding of the contents of the book. In Chap. 1, the
birth, characteristics and prospects of EPM are described to give readers a brief
summary of what EPM is. In Chap. 2, the concept of Transport Phenomena,
which is indispensable in materials processing, is given a concise introduction in
order to establish that the transportphenomenaof mass, heat and momentumcan
all be described by the same diffusion type equation. In Chap. 3, I describe the
essentialsofMagnetohydrodynamicsthatarerequiredforunderstandingEPMand
I show that the governing equation of a magnetic field can also be expressed by
thesamediffusiontypeequationasintroducedinChap.2.Thatis,itisunderstood
that the concept of transport phenomena holds not only in relation to heat, mass
andmomentum,butalsoinmagneticfields.Thoughmanymathematicalequations
appearin this chapter,for the sake of developinga stricter analysis, I recommend
that the beginner in EPM read until Chap. 5 by skipping derivation of equations.
Afterthat,readersshouldagainreadtheskippedChapters.InChap.4,thevarious
functions that appear when applying electric and magnetic fields to materials are
enumeratedandtheirutilizationinmaterialsprocessingis explored.Recently,due
toadvancesinsuperconductingmagnets,ahighmagneticfieldhasbecomereadily
available and is being applied in various fields of science. In this trend many
interestingphenomenarelatingtohighmagneticfieldshavebeenfoundandanew
academicareacalledMagneto-Sciencehasbeguntoopenagatetofurtherresearch.
Inordertoconnecttheseedssproutingfromthenewacademicfieldwiththeneeds
of Materials Science and Engineering, a new branch of EPM is growing. Thus,
in Chap. 5, materials science and engineering utilizing a high magnetic field is
introduced and the functions that appear when applying a high magnetic field to
materialsprocessingareexplained.
EPM has only recently been recognized as a cutting edge technology. If
publication of this textbook leads to opening a new academic field in Materials
Science and Engineering, and becomes universally known as Electromagnetic
Processing of Materials, it will deepen my great pleasure as one of the persons
who have participated in this field from the beginning. Especially, I would like
to dedicate this book to the late Dr. Marcel Garnier of the EPM-MADYRAM in
Grenoble,France,whofirstinitiatedanddevelopedthisfieldtogetherwithme.
I am indebted to many people for help of one kind or another in the making
of this book.I am especially gratefulto the late Professor Iwao Muchiat Nagoya
UniversityandthelateProfessorJulianSzekelyatMIT,whotaughtmethebasisof
MetallurgicalReactionEngineeringandMagnetohydrodynamics,respectively.
Thoseacademicbackgroundspromptedmeto writethisbook.ProfessorEmeritus
Tsuyoshi Masumoto of Tohoku University, Japan always has encouraged us in
developingthisfield bynominatingthe EPM subjecttoa placein the science and
technology program in The Ministry of Education, Culture, Sports, Science and
Technology,Japan.ProfessorEmeritusRene´ MoreauofSIMAP/EPMinGrenoble,
notonlygaveusefulacademicadviceregardingtheproblemsofMagnetohydrody-
Preface vii
namics,butalsokindlyarrangedacontactwithSpringertopublishthisbook.The
ProfessorYvesFautrelleofSIMAP/EPMinGrenobleandProfessorShojiTaniguchi
ofTohokuUniversityhavedevotedalotofeffortfordevelopingEPMwithmefora
longtime.Aboveall,theauthorwouldliketothankProfessorKen-ichiMiyazawa
ofNagoyaUniversitywhopainstakinglyreadeachdraft,queryingeveryambiguity
andexposingthemanyinconsistenciesintheoriginalmanuscript.Carefulreviews
ofthefinalmanuscriptscontributedcrucialdescriptionsoftheacademicviewpoints
of Profs.NoboruYoshikawaand KazuyukiUenoof TohokoUniversity,Kazuhiko
IwaiofNagoyaUniversityandHideyukiYasudaofOsakaUniversity.Inthissense
Iamnottheonlyauthorofthisbook,butsharethatrolewithallofmycolleagues
inworldEPMcommunity.
Despite this help, errors and obscurities undoubtedlyremain. I would be most
gratefultoanyonewhobringsthemtomyattentionatoneoftheaddressesbelow.
Postaladdress:Yakushiyama112,Narumi-cho,
Midori-ku,Nagoya,458-0846,Japan
e-mailaddress:[email protected]
[email protected]
Japan ShigeoAsai
Contents
1 DevelopmentofElectromagneticProcessingofMaterials............... 1
1 TheBirthofElectromagneticProcessingofMaterials.................. 1
2 TheComparisonofVariousEnergies.................................... 2
3 IndustrialBackgroundandEngineeringAspects........................ 4
3.1 IncreaseofElectricEnergyConsumption........................ 4
3.2 DevelopmentofRelatedTechnologies........................... 4
3.3 High Density, Cleanliness and Controllability
ofElectricEnergy ................................................. 4
3.4 EffectiveUseofElectricEnergy.................................. 5
3.5 ApplicationofMagnetohydrodynamicstoMaterialsProcessing 5
4 TreeofElectromagneticProcessingofMaterials........................ 6
References..................................................................... 7
2 TransportPhenomenainMaterialsProcessing........................... 9
1 Formulation................................................................ 9
1.1 Flux ................................................................ 9
1.2 ConservationLaw ................................................. 11
1.3 MathematicalFormulationandSolution ......................... 11
2 DerivationofGoverningEquations ...................................... 12
2.1 TheEquationofContinuity....................................... 13
2.2 EnergyEquationforaFluidwithConstantDensity............. 15
2.3 TheEquationofMotion........................................... 17
3 DimensionlessNumbersAppearinginTransportPhenomena.......... 21
4 TheProcedureforSolvingProblemsbyUseofGoverningEquations. 23
4.1 The Mass Diffusion Model in the Infinite
One-DimensionalField............................................ 23
4.2 TheDiffusionModelintheFiniteOne-DimensionalField ..... 27
4.3 TheLaminarFlowinaCylindricalTube......................... 32
4.4 TheLaminarFlowBetweenParallelWalls ...................... 34
4.5 AnalysisofSurfaceWaveMotion................................ 35
ix
x Contents
AppendixesA–E .............................................................. 36
AppendixA:MethodsforSolvingEq.2.37............................. 36
AppendixB:DerivationofEq.2.54...................................... 39
AppendixC:DerivationofEq.2.57...................................... 41
AppendixD:DerivationofEq.2.65 ..................................... 43
AppendixE:DerivationofEq.2.72...................................... 45
References..................................................................... 47
3 MagnetohydrodynamicsinMaterialsProcessing ........................ 49
1 FundamentalEquation.................................................... 50
1.1 TransportEquationofVorticity................................... 50
1.2 TheEquationofEnergy........................................... 52
1.3 TheDiffusionEquationoftheMagneticField................... 52
2 ElectromagneticForceandMaxwellStressTensor ..................... 54
3 TheEffectofaStaticMagneticField(DirectMagnetic
Field)onaFlow........................................................... 55
4 DiffusionofaMagneticField ............................................ 62
4.1 SimplifiedModel.................................................. 62
4.2 Diffusion Model of a Magnetic Field in
One-DimensionalSemi-infiniteSpace ........................... 63
4.3 MagneticPressureandJouleHeat................................ 64
4.4 DiffusionModelofaMagneticFieldinLimited
One-Dimension.................................................... 67
4.5 TravelingMagneticField ......................................... 70
5 BoundaryConditions ..................................................... 74
6 DimensionlessNumbersRelatingtoMagnetohydrodynamics.......... 77
7 SolutionsofProblems3.1–3.12.......................................... 80
References..................................................................... 86
4 ElectromagneticProcessingofMaterials.................................. 87
1 FunctionsofElectricandMagneticFieldsPerforming
onElectricallyConductiveFluids........................................ 87
1.1 ShapeControllingFunction....................................... 87
1.2 FlowSuppressingFunction....................................... 90
1.3 WaveSuppressingFunction....................................... 91
1.4 SeparatingandAgglomeratingFunctions........................ 91
1.5 Driving(Mixing)Function........................................ 92
1.6 Oscillating(Vibrating)Function.................................. 94
1.7 SplashingFunction................................................ 94
1.8 Levitating(GravityChanging)Function ......................... 94
1.9 TemperatureRaisingFunction.................................... 95
1.10 FlowVelocityDetectingFunction................................ 95
1.11 CompoundFunction............................................... 96
2 ProcessesUsingElectromagneticForce ................................. 96
2.1 ShapeControllingFunction....................................... 96
2.2 FlowSuppressingFunction....................................... 101
