Numerical simulation of the internal stress of Fe–Si–B amorphous alloy ribbons prepared by planar flow casting

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Abstract Internal stress generated during the rapid cooling and solidification of the melt is one of the key factors that deteriorate the magnetic properties of amorphous ribbons produced by planar flow casting (PFC). In this study, a two-dimensional thermo-mechanical coupling model was developed for the PFC process of Fe 78 Si 9 B 13 amorphous ribbons using ANSYS Fluent and industrial casting parameters. The volume of fluid method was employed to capture the evolution of the melt-pool free surface, while an equivalent slicing strategy was introduced to obtain the solidified layer for subsequent stress analysis. The thermal stress distribution was then calculated in ANSYS Workbench. The results show that the melt pool reaches a quasi-steady state after approximately 5 ms. The predicted stable thickness of the solidified ribbon is about 26 μ m, which is consistent with practical production observations. Once the casting process becomes stable, the temperature field exhibits a relatively steady isothermal pattern, whereas both temperature and stress show clear gradient characteristics along the ribbon thickness direction. The equivalent stress in the solidified layer varies only slightly overall, with an average value of approximately 170 MPa. Increasing the casting temperature or the cooling-wheel speed leads to a higher initial internal stress. However, as the ribbon extends along the casting direction, the stress gradually decreases and eventually tends to stabilize. The proposed model and the revealed stress-evolution characteristics provide a theoretical basis and numerical reference for optimizing the PFC process, regulating internal stress, and improving the magnetic performance of amorphous ribbons.

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