Numerical simulation studies of jet rapid solidification technology for magnetic materials: a review

Jet rapid solidification (JRS) is a key process to obtain the ribbon of magnetic materials. Numerical simulation is an effective method to analyze real-time distribution of status parameters during the JRS process and optimize the process. In this paper, the numerical simulation research in two JRS processes, namely, planar flow casting (PFC) and melt spinning (MS), is reviewed. First, based on the principle of rapid solidification, the working principles of PFC and MS processes are summarized and distinguished. The theoretical models, analytical models, and research methods of PFC and MS processes are further introduced and compared in three main research aspects, denoted as melt puddle, cooling roller, and inclusions in the tundish. Regarding the melt puddle, the influence of the melt puddle on the thickness of rapidly solidified ribbons is analyzed. The flow behavior and heat transfer analysis of melt puddle are discussed. In terms of the cooling roller, numerical analyses of the cooling roller structure optimization, parameter optimization, and “fluid–solid-thermal” coupling are summarized. Moreover, the simulation of the movement of inclusions in the PFC tundish is compared. Lastly, the current challenges and future opportunities are also addressed. The development of high-quality JRS ribbons has significant theoretical, social, and economic significance because its quality and stability determine the final characteristics of magnets. Therefore, the application of numerical simulation technology in the JRS process is beneficial for optimizing process routes and system structures, achieving the visual tracking of process, and objectively guiding the development of new JRS equipment.