An EIGA driven coupled of electromagnetic-thermal field modeling in the induction melting process

Abstract

A crucible-free, an Electrode Induction melting Gas Atomization (EIGA) technique for induction melting of the reactive and refractory metals/alloys is developed. The impedance matching of the superalloy Rene95 in a conical induction has been investigated. An evaluation of the complex electromagnetic and thermal fields on the free surface of the superalloy Rene95 is carried out by both numerical and experimental methods under alternating currents with the output power of 120 kW and operational effective current 2 kA. The two types of coupling induction coils have been devised, tested and compared with the experimental results, revealing the impedance of four-turn induction coil with superalloy Rene95 releasing the electrical energy that causes the most high-temperature distribution in the surface of superalloy Rene95. Induction coil is also known as an “inductor” which is the core component in the melting process of nickel-based superalloy, leading to design a good induction coil to reduce the power consumption and increase the efficiency of the process. The achievements are the melting rate enhancement and a steady-state of continuous liquid metal flow producing the liquid metal streams with diameter of about 5 mm.