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Fabrication and Simulation of a Two‐Stage Mold with Low Magnetic Shielding for Soft‐Contact Electromagnetic Continuous Casting

A new low magnetic shielding (LMS) copper alloy (Cu–40Mn–2Al) connected with copper through tungsten inert gas (TIG) welding to form a new two‐stage mold for soft‐contact electromagnetic continuous casting is described. Experimental and numerical simulation methods are used to study the LMS effect, the cooling performance, and the strength of the two‐stage mold. With the solid solution of a large proportion of the Mn and a little of Al elements in the copper, the electrical resistivity of the copper alloy increases significantly. Furthermore, the thickness of the skin layer is about 1.5 times larger than that of the base alloy (Cu–10Mn–5Si–3Al–1.2P–1Ti), which greatly reduces the LMS effect. Numerical simulation results agree well with the experimental results on the LMS effect of the copper alloy. The electromagnetic force reaches the maximum value at the meniscus and gradually attenuates from the surface to the center of the billet. Critically, the electromagnetic force exceeds the critical value required for pushing the molten steel away the wall of the mold. Thus, the developed copper alloy achieves the requirements for two‐stage mold with the properties of the LMS effect, the well cooling effect, the high strength.