A Numerical Study on Molten Pool Behavior and Ribbon Thickness Under Varying Casting Parameters in Planar Flow Casting

Despite the widespread use of planar flow casting (PFC) for amorphous alloy ribbons, previous two-dimensional (2D) numerical studies have primarily focused on isolated flow or thermal behaviors, lacking a systematic quantification of how key casting parameters collectively influence melt puddle geometry and ribbon thickness. To fill this gap, this work establishes a coupled air–melt two-phase 2D Volume of Fluid (VOF) model based on the continuity, momentum, and energy equations. An analysis was conducted on how various parameters affect the melt puddle behavior and ribbon thickness. The results indicate that, as the roller speed (U) increases from 21 m/s to 30 m/s, the detachment length (Ln) decreases by 31%. Over the same interval, the puddle length (L) decreases by 30%. When the ejection speed (V) increases from 1.4 m/s to 2.0 m/s, the ejection temperature (Te) increases from 1433 K to 1733 K, and the slit width (W) increases from 0.4 mm to 0.6 mm, Ln rises by roughly 39.7–133%, while L increases by approximately 32.3–112%. To produce thinner amorphous ribbons for loss reduction, high roller speed, low ejection speed, and small nozzle slit are crucial parameters.