EP3622782B1 - Dispositif et procédé de fusion par lévitation au moyen d'unités d'induction disposées de manière inclinée - Google Patents

Dispositif et procédé de fusion par lévitation au moyen d'unités d'induction disposées de manière inclinée Download PDF

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Publication number
EP3622782B1
EP3622782B1 EP19739555.1A EP19739555A EP3622782B1 EP 3622782 B1 EP3622782 B1 EP 3622782B1 EP 19739555 A EP19739555 A EP 19739555A EP 3622782 B1 EP3622782 B1 EP 3622782B1
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EP
European Patent Office
Prior art keywords
induction coils
melting
casting
batch
pair
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EP19739555.1A
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German (de)
English (en)
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EP3622782A1 (fr
Inventor
Sergejs SPITANS
Henrik Franz
Björn SEHRING
Markus Holz
Andreas KRIEGER
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ALD Vacuum Technologies GmbH
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ALD Vacuum Technologies GmbH
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Priority to SI201930009T priority Critical patent/SI3622782T1/sl
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Classifications

    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B6/00—Heating by electric, magnetic or electromagnetic fields
    • H05B6/02—Induction heating
    • H05B6/22—Furnaces without an endless core
    • H05B6/32—Arrangements for simultaneous levitation and heating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D39/00—Equipment for supplying molten metal in rations
    • B22D39/003—Equipment for supplying molten metal in rations using electromagnetic field
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B6/00—Heating by electric, magnetic or electromagnetic fields
    • H05B6/02—Induction heating
    • H05B6/22—Furnaces without an endless core
    • H05B6/24—Crucible furnaces
    • H05B6/26—Crucible furnaces using vacuum or particular gas atmosphere
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B6/00—Heating by electric, magnetic or electromagnetic fields
    • H05B6/02—Induction heating
    • H05B6/36—Coil arrangements
    • H05B6/365—Coil arrangements using supplementary conductive or ferromagnetic pieces
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B6/00—Heating by electric, magnetic or electromagnetic fields
    • H05B6/02—Induction heating
    • H05B6/36—Coil arrangements
    • H05B6/44—Coil arrangements having more than one coil or coil segment

Definitions

  • This invention relates to a levitation melting process and an apparatus for producing castings with tilted induction units.
  • induction units are used in which the respective opposite ferrite poles with the induction coils are not designed to lie in one plane, but rather are tilted at a certain angle to the levitation plane.
  • the tilted arrangement increases the proportion of the induced magnetic field that effectively contributes to the holding force of the field for levitating the melt.
  • U.S. 2,686,864 A also describes a method in which a conductive melt z. B. is suspended in a vacuum under the influence of one or more coils without the use of a crucible.
  • two coaxial coils are used to stabilize the suspended material. After it has melted, the material is dropped or poured into a mold. With the method described there, a 60 g portion of aluminum could be kept in suspension. The molten metal is removed by reducing the field strength, so that the melt escapes downwards through the conical coil. If the field strength is reduced very quickly, the metal falls out of the device in a molten state. It has already been recognized that the "weak spot" of such coil arrangements lies in the center of the coils, so that the amount of material that can be melted in this way is limited.
  • U.S. 4,578,552 A discloses an apparatus and method for levitation melting.
  • the same coil is used both for heating and for holding the melt; the frequency of the alternating current applied is varied to regulate the heating power, while the current strength is kept constant.
  • a device for levitation melting in which at least two opposing horizontally aligned coils, each with a field compressor, are provided in order to achieve a field profile that is more favorable for levitation melting of a sample in a vacuum.
  • levitation melting contamination of the melt by a crucible material or other materials that are in contact with the melt in other processes is avoided.
  • the floating melt is only in contact with the surrounding atmosphere, which is z. B. can be a vacuum or inert gas. Since a chemical reaction with a crucible material is not to be feared, the melt can also be heated to very high temperatures.
  • the Lorentz force of the coil field must compensate for the weight of the charge in order to be able to keep it in suspension. It pushes the batch upwards out of the coil field.
  • the aim is usually to reduce the distance between the opposing ferrite poles. The reduction in the distance makes it possible to generate the same magnetic field with lower voltage that is required to hold a certain melt weight. In this way, the holding efficiency of the system can be improved so that a larger batch can be levitated.
  • the method should allow the use of larger batches through improved efficiency of the coil field.
  • it should enable a high throughput through shortened cycle times, whereby it is ensured that the casting process continues to take place safely without contact of the melt with the coils or their poles.
  • the volume of the molten charge is preferably sufficient to fill the casting mold to an extent sufficient for the production of a cast body (“filling volume”). After the casting mold has been filled, it is allowed to cool down or cooled with coolant so that the material solidifies in the mold. The cast body can then be removed from the mold.
  • a “conductive material” is understood to mean a material which has a suitable conductivity in order to inductively heat the material and to keep it in suspension.
  • a “state of suspension” is understood to mean a state of complete suspension, so that the batch being treated has no contact whatsoever with a crucible or a platform or the like.
  • ferrite pole is used synonymously with the term “core made of a ferromagnetic material”.
  • coil and “induction coil” are also used synonymously alongside one another.
  • the longitudinal axes of the induction coils with their cores in at least one pair are not arranged within a horizontal plane.
  • the induction coils are tilted downwards out of the plane of levitation.
  • the angle ⁇ between the longitudinal axes of the induction coils with their cores and the horizontal plane in at least one pair is preferably 0 ° ⁇ ⁇ 60 °, particularly preferably 10 ° ⁇ 45 °.
  • the magnetic flux in the absence of a charge in the magnetic field above and below the plane is identical.
  • the magnetic flux below the level makes almost no contribution to the holding force of the magnetic field during the levitation of a charge.
  • the ⁇ -shaped arrangement of the coil axes according to the invention makes it possible to increase the holding force of the field, since this increases the magnetic flux above the plane.
  • the induction coils and / or their cores made of a ferromagnetic material have, at least in parts, a frustoconical or conical one Shape on.
  • the special conical shape of the ferrite cores is designed in such a way that the concentration of the magnetic field in the space between the opposing pairs of coils is maximized, but the material still remains far from saturation.
  • a ferromagnetic element (ferrite ring), which is arranged around the cores made of ferromagnetic material and will be described in more detail below, separates the magnetic flux that would otherwise reduce the magnetic field in the space.
  • the induction coils are arranged in pairs that operate at the same frequency and generate a magnetic field in the same direction.
  • they are optimized on the one hand to minimize Joule heat losses in order to achieve an increase in efficiency.
  • they are designed for an optimal distribution of the magnetic field below the melt, which ensures levitation, and the magnetic fields above and to the side of the melt, which counteract the levitation but ensure the dimensional stability of the melt.
  • the induction coils can also be positioned even closer to one another, so that the distance between the opposite poles becomes smaller, which leads to a further increase in the magnetic field induction on the underside of the levitating charge and thus to a more efficient melting process.
  • the induction coils with their cores are movably mounted in at least one pair in a particularly preferred embodiment variant.
  • the coils of a pair move in opposite directions, centrosymmetrically, around the center point of the induction coil arrangement.
  • the coils are pushed together into the melting position. Once the batch has melted and is to be poured into the mold, the coils are not simply switched off, as is customary in the state of the art, or the current intensity is reduced, but instead, according to the invention, moved outwards into a pouring position. This increases the distance between the coils, which on the one hand results in a larger free diameter for the melt on its way into the mold and, on the other hand, the load-bearing capacity of the induced magnetic field is continuously and controlled reduced.
  • the melt is safely kept away from the induction coils and their cores as it passes through the coil plane and only slowly turns into the case because the field is already weakened in the center, but is still strong enough at the coils to generate the Prevent contact. This prevents contamination of the coils and ensures a clean casting in the mold without splashing.
  • the motion vectors of the induction coils in the induction coil pairs are not identical to their longitudinal axes.
  • the coils are not removed from one another along their longitudinal axis, but the tilted coils are shifted within the horizontal plane.
  • the magnetic field level for levitation also remains in the same vertical position when the batch is poured.
  • the current intensity in these induction coils is reduced simultaneously with the movement of the induction coils in the induction coil pairs from the melting position to the casting position. This makes it possible to reduce the required displacement path of the induction coils, since the induced magnetic field is no longer reduced only by the greater distance between the inducing coils. However, it is important to ensure that the reduction in the current strength is coordinated with the movement of the coils so that the field strength is always sufficiently high to be able to keep the melt away from the coils.
  • the distance between the induction coils in the induction coil pairs from the melting position to the casting position is increased by 5-100 mm, preferably 10-50 mm.
  • it must be taken into account for which batch weights the system is to be designed and how large the minimum distance between the coils and the field strength that can be generated with them is.
  • the electrically conductive material used according to the invention has at least one high-melting metal from the following group: titanium, zirconium, vanadium, tantalum, tungsten, hafnium, niobium, rhenium, molybdenum.
  • a metal with a lower melting point such as nickel, iron or aluminum can be used.
  • a mixture or alloy with one or more of the aforementioned metals can also be used as the conductive material.
  • the metal preferably has a proportion of at least 50% by weight, in particular at least 60% by weight or at least 70% by weight, of the conductive material. It has been shown that these metals are particularly advantageous benefit from the present invention.
  • the conductive material is titanium or a titanium alloy, in particular TiAl or TiAlV.
  • metals or alloys can be processed particularly advantageously, since they have a pronounced dependence of the viscosity on the temperature and, moreover, are particularly reactive, in particular with regard to the materials of the casting mold. Since the method according to the invention combines contactless melting in suspension with extremely fast filling of the casting mold, a particular advantage can be realized for such metals in particular. With the method according to the invention, cast bodies can be produced which have a particularly thin or even no oxide layer from the reaction of the melt with the material of the casting mold. And with refractory metals in particular, the improved utilization of the induced eddy current and the exorbitant reduction in heat losses due to thermal contact are noticeable in the cycle times. Furthermore, the load-bearing capacity of the generated magnetic field can be increased so that even heavier batches can be held in suspension.
  • the conductive material is superheated during melting to a temperature which is at least 10 ° C., at least 20 ° C. or at least 30 ° C. above the melting point of the material. Overheating prevents the material from solidifying instantly when it comes into contact with the casting mold, the temperature of which is below the melting temperature. The result is that the charge can be distributed in the mold before the viscosity of the material becomes too high. It is an advantage of levitation melting that there is no need to use a crucible that is in contact with the melt. This avoids the high material loss of the cold crucible process on the crucible wall as well as contamination of the melt by crucible components.
  • melt can be heated to a relatively high level, since operation in a vacuum or under protective gas is possible and there is no contact with reactive materials. However, most materials cannot be overheated at will, since otherwise a violent reaction with the mold is to be feared.
  • the overheating is therefore preferably limited to at most 300 ° C., in particular at most 200 ° C. and particularly preferably at most 100 ° C. above the melting point of the conductive material.
  • At least one ferromagnetic element is arranged horizontally around the area in which the charge is melted.
  • the ferromagnetic element can be arranged in a ring around the melting area, with "ring-shaped" not only being understood to mean circular elements, but also angular, in particular square or polygonal ring elements.
  • the ring elements are accordingly so that the induction coils can be moved according to the invention the number of coils is divided into subsegments, between which the respective induction coils move with their poles in a form-fitting manner.
  • the ferromagnetic element can also have a plurality of rod sections, which in particular protrude horizontally in the direction of the melting area.
  • the ferromagnetic element consists of a ferromagnetic material, preferably with an amplitude permeability ⁇ a > 10, more preferably ⁇ a > 50 and particularly preferably ⁇ a > 100.
  • the amplitude permeability relates in particular to the permeability in a temperature range between 25 ° C and 150 ° C and at a magnetic flux density between 0 and 500 mT.
  • the amplitude permeability is in particular at least one hundredth, in particular at least 10 hundredths or 25 hundredths of the amplitude permeability of soft magnetic ferrite (for example 3C92). Suitable materials are known to those skilled in the art.
  • a device for levitating an electrically conductive material comprising at least one pair of opposite induction coils with a core made of a ferromagnetic material for bringing about the levitation state of a charge by means of electromagnetic alternating fields, the longitudinal axes of the induction coils with their cores in at least one pair not are arranged within a horizontal plane.
  • Figure 1 shows a charge (1) of conductive material that is in the area of influence of alternating electromagnetic fields (melting area) that are generated with the help of the coils (3).
  • Below the batch (1) there is an empty casting mold (2) that is held by a holder (5) is kept in the fill area.
  • the casting mold (2) has a funnel-shaped filling section (6).
  • the holder (5) is suitable for lifting the casting mold (2) from a feed position into a casting position, which is symbolized by the arrow shown.
  • a ferromagnetic material (4) is arranged in the core of the coils (3).
  • the axes of the coil pair shown in dotted lines in the drawing are tilted downwards and aligned with the horizontal plane of levitation, with two opposing coils (3) forming a pair.
  • Figure 2 shows a side sectional view analogous to FIG Figure 1 of tilted coils (3) with their cores made of the ferromagnetic material (4).
  • the horizontal plane is drawn in dashed lines and the angles ⁇ are marked, by which the longitudinal axes of the coils (3) shown in dotted lines have tilted out of the horizontal plane.
  • Figure 3 shows a side sectional view of an embodiment variant with frustoconical coils and poles shown in black.
  • the cutting plane runs centrally through the longitudinal axis of a coil pair.
  • the induction coils (3) and their cores made of a ferromagnetic material (4) are each shaped like a truncated cone and are entirely surrounded by a ferrite ring.
  • the induction coils (3) are designed as waveguides, which also offers the option of internal cooling using a cooling fluid.
  • the longitudinal axes of the poles and coils tilted towards the levitation plane are clearly visible.
  • Figure 4 and Figure 5 show the coil arrangement of Figure 3 in plan or side perspective view.
  • the arrangement consists of two pairs of coils, which are oriented at a 90 ° angle to each other.
  • the induction coils (3) with their cores made of a ferromagnetic material (4) are positively movably mounted between four ferrite ring segments so that together an octagonal ferromagnetic element is created and they can be moved between a closely spaced melting position and a widely spaced casting position.
  • the Figures 4 and 5 both show the melting position of the coils. Especially in Figure 5 the displacement of the coils between the inside and outside of the ring can be clearly seen.

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  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Induction Heating (AREA)
  • Continuous Casting (AREA)
  • Crucibles And Fluidized-Bed Furnaces (AREA)

Claims (13)

  1. Procédé de production de pièces moulées à partir d'un matériau électriquement conducteur utilisant un procédé de fusion en lévitation, dans lequel des champs électromagnétiques alternatifs, générés par au moins une paire de bobines d'induction (3) opposées et munies respectivement d'un noyau constitué d'un matériau ferromagnétique (4), sont utilisés pour induire l'état de lévitation d'un lot (1), comprenant les étapes ci-dessous consistant à :
    - introduire un lot (1) d'une matière de départ dans la zone d'influence d'au moins un champ électromagnétique alternatif, de sorte que le lot (1) est maintenu en état de lévitation,
    - faire fondre le lot (1),
    - positionner un moule de coulée (2) dans une zone de remplissage située en-dessous du lot (1) en lévitation,
    - verser l'ensemble du lot (1) dans le moule de coulée (2),
    - retirer la pièce moulée solidifiée du moule de coulée (2),
    caractérisé en ce que les axes longitudinaux des bobines d'induction (3) avec leurs noyaux (4) ne sont pas agencés dans un plan horizontal au sein d'au moins une paire.
  2. Procédé selon la revendication 1, caractérisé en ce qu'un angle β entre les axes longitudinaux des bobines d'induction (3) munies de leurs noyaux et le plan horizontal satisfait respectivement 0° < β ≤ 60°, de préférence 10°≤ β ≤ 45° au sein d'au moins une paire.
  3. Procédé selon la revendication 1 ou 2, caractérisé en ce que les bobines d'induction (3) et/ou leurs noyaux constitués d'un matériau ferromagnétique (4) présentent au moins partiellement une forme tronconique ou conique.
  4. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que les bobines d'induction munies de leurs noyaux sont agencées mobiles l'une par rapport à l'autre au sein de chaque paire et se déplacent entre une position de fusion présentant un espacement faible et une position de coulée présentant un espacement important, le procédé comprend en tant que première étape supplémentaire un décalage des paires de bobines d'induction dans la position de fusion présentant un espacement faible, et la coulée de l'ensemble du lot (1) dans le moule de coulée (2) intervient grâce à un déplacement des bobines d'induction (3) de la position de fusion présentant un espacement faible jusqu'à la position de coulée présentant un espacement important au sein d'au moins une paire.
  5. Procédé selon la revendication 4, caractérisé en ce que, lors de la coulée du lot (1) l'intensité du courant dans ces bobines d'induction (3) est réduite en même temps que le déplacement des bobines d'induction (3) au sein des paires de bobines d'induction de la position de fusion jusqu'à la position de coulée.
  6. Procédé selon la revendication 4 ou 5, caractérisé en ce que l'espacement des bobines d'induction (3) au sein des paires de bobines d'induction entre la position de fusion et la position de coulée est augmenté de 5 à 100 mm, de préférence de 10 à 50 mm.
  7. Procédé selon l'une quelconque des revendications 4 à 6, caractérisé en ce que les vecteurs de déplacement des bobines d'induction (3) au sein des paires de bobines d'induction ne se confondent pas avec leurs axes longitudinaux.
  8. Dispositif de fusion en lévitation d'un matériau électriquement conducteur, comprenant au moins une paire de bobines d'induction (3) opposées et munies respectivement d'un noyau constitué d'un matériau ferromagnétique (4) afin d'induire l'état de lévitation d'un lot (1) au moyen de champs électromagnétiques alternatifs,
    caractérisé en ce que les axes longitudinaux des bobines d'induction (3) munies de leurs noyaux ne sont pas agencés dans un plan horizontal au sein d'au moins une paire.
  9. Dispositif selon la revendication 8, caractérisé en ce que l'angle β entre les axes longitudinaux des bobines d'induction (3) munies de leurs noyaux et le plan horizontal satisfait respectivement 0° < β ≤ 60°, de préférence 10°≤ β ≤ 45° au sein d'au moins une paire.
  10. Dispositif selon la revendication 8 ou 9, caractérisé en ce que les bobines d'induction (3) et/ou leurs noyaux constitués d'un matériau ferromagnétique (4) présentent au moins partiellement une forme tronconique ou conique.
  11. Dispositif selon l'une quelconque des revendications 8 à 10, caractérisé en ce que les bobines d'induction (3) munies de leurs noyaux sont agencées mobiles l'une par rapport à l'autre au sein de chaque paire et se déplacent entre une position de fusion présentant un espacement faible et une position de coulée présentant un espacement important.
  12. Dispositif selon la revendication 11, caractérisé en ce que l'espacement des bobines d'induction (3) au sein des paires de bobines d'induction entre la position de fusion et la position de coulée est augmenté de 5 à 100 mm, de préférence de 10 à 50 mm.
  13. Dispositif selon la revendication 11 ou 12, caractérisé en ce que les vecteurs de déplacement des bobines d'induction (3) au sein des paires de bobines d'induction ne se confondent pas avec leurs axes longitudinaux.
EP19739555.1A 2018-07-17 2019-07-09 Dispositif et procédé de fusion par lévitation au moyen d'unités d'induction disposées de manière inclinée Active EP3622782B1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
SI201930009T SI3622782T1 (sl) 2018-07-17 2019-07-09 Naprava in postopek za lebdilno taljenje z nagnjeno razmeščenimi indukcijskimi enotami

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102018117304.0A DE102018117304A1 (de) 2018-07-17 2018-07-17 Vorrichtung und Verfahren zum Schwebeschmelzen mit gekippt angeordneten Induktionseinheiten
PCT/EP2019/068432 WO2020016063A1 (fr) 2018-07-17 2019-07-09 Dispositif et procédé de fusion par lévitation au moyen d'unités d'induction disposées de manière inclinée

Publications (2)

Publication Number Publication Date
EP3622782A1 EP3622782A1 (fr) 2020-03-18
EP3622782B1 true EP3622782B1 (fr) 2020-09-16

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US (1) US11102850B1 (fr)
EP (1) EP3622782B1 (fr)
JP (1) JP6931748B1 (fr)
KR (1) KR102237272B1 (fr)
CN (1) CN111742616B (fr)
DE (1) DE102018117304A1 (fr)
ES (1) ES2825948T3 (fr)
PT (1) PT3622782T (fr)
RU (1) RU2737067C1 (fr)
SI (1) SI3622782T1 (fr)
TW (1) TWI736936B (fr)
WO (1) WO2020016063A1 (fr)

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WO2023122336A1 (fr) * 2021-12-24 2023-06-29 Build Beyond, Llc Système et procédé de génération d'un flux magnétique contrôlé

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TWI736936B (zh) 2021-08-21
TW202007223A (zh) 2020-02-01
US20210251055A1 (en) 2021-08-12
KR102237272B1 (ko) 2021-04-07
EP3622782A1 (fr) 2020-03-18
RU2737067C1 (ru) 2020-11-24
CN111742616B (zh) 2021-06-18
SI3622782T1 (sl) 2020-11-30
US11102850B1 (en) 2021-08-24
CN111742616A (zh) 2020-10-02
JP6931748B1 (ja) 2021-09-08
PT3622782T (pt) 2020-10-19
KR20200116159A (ko) 2020-10-08
JP2021526300A (ja) 2021-09-30
DE102018117304A1 (de) 2020-01-23
ES2825948T3 (es) 2021-05-17
WO2020016063A1 (fr) 2020-01-23

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