The aim of the article is to demonstrate the capability of the software COMSOL for predicting free surface motion, internal fluid flow and temperature in an electromagnetically levitated sample of liquid metal. Multiphysics solutions which demonstrate the usefulness of Comsol as a powerful MHD simulation tool have been generated to two industrial problems using the ALE moving mesh module in combination with the Navier Stokes, Maxwell and General heat transfer modules. The first problem, which has relevance to continuous casting of metal ingots, considers the transient free-surface motion of a semi-levitated volume of metal when its shape is confined by the field of a solenoid. The ability to establish the steady-state profile of the melt is an important factor in determining power requirements and thermal losses. This can then be fed into a 3D model (with static geometry) to include the effects of joule heating and the influence of the finger segments. The second problem is concerned with the thermo-physical property measurement of reactive molten materials using a novel technique reported in [9]. Comsol is used to predict the surface motion, centre of mass oscillations and temperature fluctuation in a metal droplet suspended in the AC field of a solenoid.
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