The University of Alabama

Inductotherm Corp.

Sandvik Limited

Nagy H El-Kaddah

Thomas S Piwonka

John T Berry

The solid metal to be melted is placed on a support, within an induction coil which is adapted to provide a greater electromagnetic force towards the lower portion of the quantity of metal. When energy is provided to the coil, the metal melts from the top downward, but the concentration of electromagnetic force towards the bottom of the metal causes the liquid metal to retain a cylindrical shape. When most of the metal is melted, the liquid metal passes through an opening in the support. In a preferred embodiment, the coil is movable relative to the quantity of metal, and at the beginning of the melting process only the top portion of the quantity of metal is disposed within the coil. As the quantity of metal melts, the coil is moved downward. The method may also be used for removing impurities from the quantity of metal.

Induction melting of metals without a crucible

The solid metal to be melted is placed within an induction coil which is adapted to provide a greater electomagnetic force towards the lower portion of the quantity of metal. The solid metal rests on a support, having an opening therethrough, which is kept at a low temperature relative to the metal as it melts. When energy is provided to the coil, the metal melts from the top downward, but the concentration of electromagnetic force towards the bottom of the metal causes the liquid metal to retain a cylindrical shape. When most of the metal is melted, the liquid metal passes through the opening in the support into a casting mold.

A system which provides an improved design capable of removing liquid phase inclusions by combining a filter and an electromagnetic separation device through the addition of baffles to a chamber where molten metal is flowing under the influence of an applied electromagnetic field. The placement and the shape of the baffles reduces vorticity effects of the magnetic field in each of the baffled compartments and eliminates the convective flow resulting from the electromagnetic force in order to trap inclusions against the walls of the baffles.

Growing community of inventors

Tuscaloosa, AL, United States of America

Nagy H El-Kaddah