Large-scale levitation melting and casting of titanium alloys

S. Spitans¹ - H. Franz¹ - E. Baake² - A. Jakoviċs³

¹ ALD Vacuum Technologies GmbH, 63457 Hanau, Germany
² Institute of Electrotechnology, Leibniz University of Hanover, 30167 Hanover, Germany
³ University of Latvia, LV1002 Riga, Latvia

Abstract
In this work, large-scale electromagnetic levitation melting of metals in two-frequency horizontal fields is investigated. A coupled electromagnetic field and free surface flow problems are solved with a three-dimensional model that incorporates a Large Eddy Simulation turbulence description. The developed numerical model is used to design a pilot furnace for stable levitation melting of Al and Ti-6Al-4V samples up to 500 g. The new FastCast concept that utilizes the novel crucibleless levitation melting method for industrial mass production of single-shot castings (e.g., Ti-6Al-4V turbocharger impellers up to 500 g) is introduced. Figs 7, Refs 8.