EP3626028B1 - Procédé de fusion par lévitation au moyen d'unités d'induction mobiles - Google Patents

Procédé de fusion par lévitation au moyen d'unités d'induction mobiles Download PDF

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Publication number
EP3626028B1
EP3626028B1 EP19739553.6A EP19739553A EP3626028B1 EP 3626028 B1 EP3626028 B1 EP 3626028B1 EP 19739553 A EP19739553 A EP 19739553A EP 3626028 B1 EP3626028 B1 EP 3626028B1
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EP
European Patent Office
Prior art keywords
melting
induction coils
batch
casting
coils
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Application number
EP19739553.6A
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German (de)
English (en)
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EP3626028A1 (fr
Inventor
Sergejs SPITANS
Henrik Franz
Björn SEHRING
Egon Bauer
Andreas KRIEGER
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
ALD Vacuum Technologies GmbH
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ALD Vacuum Technologies GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by ALD Vacuum Technologies GmbH filed Critical ALD Vacuum Technologies GmbH
Priority to SI201930003T priority Critical patent/SI3626028T1/sl
Priority to PL19739553T priority patent/PL3626028T3/pl
Publication of EP3626028A1 publication Critical patent/EP3626028A1/fr
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Publication of EP3626028B1 publication Critical patent/EP3626028B1/fr
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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
    • H05B6/36—Coil arrangements
    • H05B6/44—Coil arrangements having more than one coil or coil segment
    • 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
    • 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
    • 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
    • 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

Definitions

  • This invention relates to a levitation melting method and a device for producing castings with movable induction units.
  • the method uses induction units in which the respective opposite ferrite poles are designed to be movable with the induction coils and move in opposite directions.
  • the induction units for melting the batches can be arranged close to one another in order to achieve an increase in efficiency of the induced magnetic field.
  • the induced magnetic field is reduced by increasing the distance between the ferrite poles and the induction coils and thus avoiding contact with the melt with the ferrite poles or the induction coils.
  • US 2,686,864 A also describes a method in which a conductive melting material 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 material in suspension. After melting, the material is dropped into a mold or poured off. 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 tapered coil. If the field strength is reduced very quickly, the metal falls out of the device in the molten state. It has already been recognized that the "weak spot" of such coil arrangements lies in the middle of the coils, so that the amount of material that can be melted in this way is limited.
  • US 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 being varied to regulate the heating power, while the current strength is kept constant.
  • suspension melting is avoided.
  • the reaction of a reactive melt, for example of titanium alloys, with the crucible material is excluded, which would otherwise force ceramic crucibles to escape onto copper crucibles operated using the cold crucible method.
  • the floating melt is only in contact with the surrounding atmosphere, which is e.g. B. can be vacuum or protective gas. Since there is no fear of a chemical reaction with a crucible material, the melt can also be heated to very high temperatures.
  • the Lorentz force of the coil field must compensate for the weight of the batch in order to be able to keep it in suspension. It pushes the batch upwards out of the coil field.
  • the aim is to reduce the distance between the opposite ferrite poles. The reduction in distance allows the same magnetic field that is required to hold a specific melt weight to be generated with a lower voltage. In this way, the holding efficiency of the system can be improved so that a larger batch can be levitated.
  • the heating efficiency is also increased, since the losses in the induction coils are reduced.
  • a device for levitation melting with rigidly arranged ferrite poles is known, for example, from US Pat DE 1565467 known.
  • the method should allow the use of larger batches and improve throughput due to improved cycle field efficiency and shorten cycle times, while ensuring that the casting process continues safely without contact of the melt with the coils or their poles.
  • the volume of the molten batch is preferably sufficient to fill the mold to an extent sufficient for the production of a cast body (“filling volume”). After filling the mold, the mold is allowed to cool or is 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 keep it in suspension.
  • a “floating state” is understood to mean a state of complete floating, so that the treated batch 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” in the context of this application.
  • coil and “induction coil” are also used synonymously next to each other.
  • the efficiency of the generated alternating electromagnetic field can be increased by moving the induction coil pairs closer together. This enables even heavier batches to be levitated.
  • the risk of the molten batch touching the coils or ferrite poles increases with a decreasing free cross section between the coils. Such contaminations are to be strictly avoided, since they are difficult and expensive to remove again and therefore result in a longer downtime of the system.
  • the induction coils with their cores according to the invention are movably supported at least in one pair.
  • the coils of a pair preferably move in opposite directions in a centrosymmetric manner around the center of the induction coil arrangement.
  • the coils are pushed into the melting position to melt the batch. If the batch has melted and is to be poured into the casting mold, the coils are not simply switched off or the current level is reduced, as is customary in the prior art, but are moved according to the invention to a casting position. This increases the distance between the coils, which on the one hand creates a larger free diameter for the melt on its way into the casting mold and on the other hand continuously and in a controlled manner reduces the load-bearing capacity of the induced magnetic field. In this way, the melt is safely kept away from the induction coils and their cores as they pass through the coil plane and only slowly passes into the case because the field is already weakened in the center, but is still strong enough at the coils to meet the requirements To prevent contact. This prevents contamination of the coils and ensures a clean cast into the mold without splashing.
  • the current intensity in these induction coils is reduced simultaneously with the movement of the induction coils in the pairs of induction coils from the melting position into the casting position.
  • the required displacement path of the induction coils can be reduced, since the induced magnetic field is no longer reduced only by the greater distance of the induction coils.
  • it is important to ensure that the reduction in the current intensity is coordinated with the shifting of the coils in such a way 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.
  • 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 less high-melting metal 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 particularly benefit from the advantages of the present invention.
  • the conductive material is titanium or a titanium alloy, in particular TiAl or TiAIV.
  • metals or alloys can be processed particularly advantageously because 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 rapid filling of the casting mold, a particular advantage can be realized for such metals. With the method according to the invention, castings 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 in the case of the high-melting metals in particular, the improved utilization of the induced eddy current and the exorbitant reduction in heat losses due to thermal contact have a noticeable effect on the cycle times. Furthermore, the load capacity of the generated magnetic field can be increased, so that even heavier batches can be kept 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 instantaneously solidifying when it comes into contact with the mold, whose temperature is below the melting temperature. It is achieved that the batch 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. The high loss of material from the cold crucible process on the crucible wall is avoided, as is contamination of the melt by crucible components.
  • the melt can be heated to a relatively high degree, since it can be operated in a vacuum or under protective gas and there is no contact with reactive materials.
  • 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 not only circular elements but also under "ring" angular, in particular quadrangular or polygonal ring elements can be understood. So that the movement of the induction coils according to the invention is possible, the ring elements are divided into sub-segments according to the number of coils, between which the respective induction coils with their poles move in a form-fitting manner.
  • the ferromagnetic element can furthermore have a plurality of rod sections which, in particular, project horizontally in the direction of the melting range.
  • 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 with 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 the person skilled in the art.
  • a device for levitation melting of an electrically conductive material comprising at least a pair of opposing induction coils with a core made of a ferromagnetic material for bringing about the levitation of a charge by means of alternating electromagnetic fields, the induction coils with their cores being arranged movably in relation to each other in each pair and move between a melting position with a small distance and a casting position with a large distance.
  • Figure 1 shows a batch (1) made of conductive material, which is in the area of influence of alternating electromagnetic fields (melting range), which are generated with the help of the coils (3).
  • Below the batch (1) there is an empty mold (2) which is held in the filling area by a holder (5).
  • the casting mold (2) has a funnel-shaped filling section (6).
  • the holder (5) is suitable for moving the mold (2) from a feed position into a casting position to lift what is symbolized by the drawn arrow.
  • a ferromagnetic material (4) is arranged in the core of the coils (3).
  • the axes of the pair of coils (3) are aligned horizontally, with two opposing coils (3) forming a pair.
  • the drawing shows the melting position of the coil arrangement at a short distance.
  • the batch (1) is melted in the process according to the invention in suspension and poured into the casting mold (2) after the melt has taken place.
  • the coils (3) as symbolized by the arrow shown, are separated from each other until the Lorentz force of the field can no longer compensate for the weight of the batch (1).
  • Figure 2 shows a plan view of an arrangement with two pairs of coils and a ferromagnetic annular element (7).
  • the ring-shaped element (7) is designed as an octagonal ring element.
  • Two coils (3) with their ferromagnetic material (4) lying on an axis A, B form a pair of coils.
  • the coil axes A, B are arranged at right angles to each other.
  • the figure shows the melting position of the coil arrangement with narrow distances between the coils (3).
  • the ferromagnetic materials (4) positively seated in the annular element (7) then move together with their coils (3), as indicated by the double arrows, to pour the levitating melt outwards.

Landscapes

  • 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 (5)

  1. Procédé de fabrication de corps moulés à partir d'une matière électriquement conductrice dans un procédé de fusion par lévitation, dans lequel des champs alternatifs électromagnétiques sont utilisés pour provoquer l'état flottant d'un lot (1), lesquels sont générés avec au moins une paire de bobines d'induction (3) opposées avec un noyau fabriqué à partir d'une matière ferromagnétique (4), dans lequel les bobines d'induction (3) sont agencées avec leurs noyaux dans chaque paire de manière mobile l'une par rapport à l'autre et se meuvent entre une position de fusion avec un faible espacement et une position de moulage avec un large espacement, comprenant les étapes suivantes consistant à :
    - déplacer les paires de bobines d'induction dans la position de fusion avec un faible espacement,
    - introduire un lot (1) d'une matière première dans la zone d'influence d'au moins un champ alternatif électromagnétique, de sorte que le lot (1) est maintenu dans un état flottant,
    - faire fondre le lot (1),
    - positionner un moule (2) dans une zone de remplissage en dessous du lot (1) flottant,
    - mouler le lot entier (1) dans le moule (2) par le déplacement des bobines d'induction (3) dans au moins une paire de la position de fusion avec un faible espacement vers la position de moulage avec un large espacement,
    - retirer le corps de moulage solidifié du moule (2).
  2. Procédé selon la revendication 1, caractérisé en ce que, lors du moulage du lot (1), l'intensité du courant dans les bobines d'induction (3) est réduite simultanément avec le mouvement des bobines d'induction (3) dans les paires de bobines d'induction de la position de fusion vers la position de moulage.
  3. Procédé selon la revendication 1 ou 2, caractérisé en ce que l'espacement des bobines d'induction (3) dans les paires de bobines d'induction de la position de fusion vers la position de moulage est augmenté de 5 à 100 mm, de préférence de 10 à 50 mm.
  4. Dispositif de fusion par lévitation d'une matière électriquement conductrice, comprenant au moins une paire de bobines d'induction (3) opposées avec un noyau fabriqué à partir d'une matière ferromagnétique (4) pour provoquer l'état flottant d'un lot (1) au moyen de champs alternatifs électromagnétiques, caractérisé en ce que les bobines d'induction (3) sont agencées avec leurs noyaux dans chaque paire de manière mobile l'une par rapport à l'autre et se meuvent entre une position de fusion avec un faible espacement et une position de moulage avec un large espacement.
  5. Dispositif selon la revendication 4, caractérisé en ce que l'espacement des bobines d'induction (3) dans les paires de bobines d'induction de la position de fusion vers la position de moulage est augmenté de 5 à 100 mm, de préférence de 10 à 50 mm.
EP19739553.6A 2018-07-17 2019-07-09 Procédé de fusion par lévitation au moyen d'unités d'induction mobiles Active EP3626028B1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
SI201930003T SI3626028T1 (sl) 2018-07-17 2019-07-09 Postopek lebdilnega taljenja s premičnimi indukcijskimi enotami
PL19739553T PL3626028T3 (pl) 2018-07-17 2019-07-09 Sposób topienia lewitacyjnego z ruchomymi jednostkami indukcyjnymi

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102018117300.8A DE102018117300B3 (de) 2018-07-17 2018-07-17 Schwebeschmelzverfahren mit beweglichen Induktionseinheiten
PCT/EP2019/068430 WO2020016061A1 (fr) 2018-07-17 2019-07-09 Procédé de fusion par lévitation au moyen d'unités d'induction mobiles

Publications (2)

Publication Number Publication Date
EP3626028A1 EP3626028A1 (fr) 2020-03-25
EP3626028B1 true EP3626028B1 (fr) 2020-06-03

Family

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EP19739553.6A Active EP3626028B1 (fr) 2018-07-17 2019-07-09 Procédé de fusion par lévitation au moyen d'unités d'induction mobiles

Country Status (13)

Country Link
US (1) US11197351B2 (fr)
EP (1) EP3626028B1 (fr)
JP (1) JP6931749B1 (fr)
KR (1) KR102217611B1 (fr)
CN (1) CN111771425B (fr)
DE (1) DE102018117300B3 (fr)
ES (1) ES2803427T3 (fr)
PL (1) PL3626028T3 (fr)
PT (1) PT3626028T (fr)
RU (1) RU2735331C1 (fr)
SI (1) SI3626028T1 (fr)
TW (1) TWI727370B (fr)
WO (1) WO2020016061A1 (fr)

Families Citing this family (1)

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Publication number Priority date Publication date Assignee Title
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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DE422004C (de) * 1925-11-23 Otto Muck Dipl Ing Verfahren und Vorrichtung zum Schmelzen, insbesondere von Leitern u. dgl. durch elektrische Induktionsstroeme
US2686864A (en) * 1951-01-17 1954-08-17 Westinghouse Electric Corp Magnetic levitation and heating of conductive materials
US2664496A (en) * 1952-11-25 1953-12-29 Westinghouse Electric Corp Apparatus for the magnetic levitation and heating of conductive materials
BE655473A (fr) 1963-11-21 1900-01-01
US4578552A (en) * 1985-08-01 1986-03-25 Inductotherm Corporation Levitation heating using single variable frequency power supply
SU1764189A1 (ru) * 1988-08-29 1992-09-23 Производственное объединение "Черниговский радиоприборный завод" Устройство дл бесконтакной плавки и очистки электропроводных материалов во взвешенном состо нии
US5033948A (en) * 1989-04-17 1991-07-23 Sandvik Limited Induction melting of metals without a crucible
SU1697283A1 (ru) * 1989-07-11 1991-12-07 Ленинградский институт инженеров железнодорожного транспорта им.акад.В.Н.Образцова Устройство дл плавки металла во взвешенном состо нии
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KR19990033628U (ko) * 1999-05-08 1999-08-16 김지순 고주파부양용해진공주조장치
KR100952904B1 (ko) * 2008-12-30 2010-04-16 김차현 2단계 고주파 부양용해를 이용한 진공주조장치 및 주조방법
DE102011082611A1 (de) * 2011-09-13 2013-03-14 Franz Haimer Maschinenbau Kg Induktionsspuleneinheit
CN102519249A (zh) * 2011-11-24 2012-06-27 吉林大学 压电超声波/高频电磁混合悬浮非接触熔炼的方法和装置
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Also Published As

Publication number Publication date
WO2020016061A1 (fr) 2020-01-23
EP3626028A1 (fr) 2020-03-25
SI3626028T1 (sl) 2020-08-31
US20210251054A1 (en) 2021-08-12
JP2021526302A (ja) 2021-09-30
DE102018117300B3 (de) 2019-11-14
CN111771425B (zh) 2021-05-14
TW202007225A (zh) 2020-02-01
RU2735331C1 (ru) 2020-10-30
JP6931749B1 (ja) 2021-09-08
KR20200105960A (ko) 2020-09-09
PL3626028T3 (pl) 2020-09-07
CN111771425A (zh) 2020-10-13
ES2803427T3 (es) 2021-01-26
KR102217611B1 (ko) 2021-02-19
PT3626028T (pt) 2020-07-07
TWI727370B (zh) 2021-05-11
US11197351B2 (en) 2021-12-07

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