The development and experimental validation of a numerical model of an induction skull melting furnace
The development and experimental validation of a numerical model of an induction skull melting furnace
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DOI：
10.1007/s11663-004-0019-3
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发表时间：
2004-08-01
影响因子：
3
通讯作者：
Wickins, M
中科院分区：
文献类型：
--
作者：
Bojarevics, V;Harding, RA;Wickins, M
感应颅骨熔炼(ISM)是一种广泛使用的工艺，用于在铸造涡轮叶片、发动机气门、涡轮增压机转子和医疗假体之前，熔化某些在熔化条件下非常活跃的合金，如钛、TiAl和锆基合金。已经开展了一项重大研究项目，具体目标是开发改进的TiAl组件铸造技术。其目的包括增加金属熔体中的过热度，以允许铸造薄壁部件，改善铸造部件的质量，并提高工艺的能源效率。作为这项工作的一部分，格林威治大学(联合王国)与伯明翰大学(联合王国)密切合作，开发了一个以光谱方法为基础的ISM过程的动态计算机模型，在伯明翰大学进行了广泛的熔化试验。本文详细描述了时变液态金属包络内湍流、相变换热、交直流磁流体力学(MHD)的耦合影响的数值模型。对Al、Ni和TiAl合金进行了相关的实验测量，以获得验证模型的数据。测量数据包括施加到感应线圈的真实均方根(RMS)电流、从熔融金属到坩埚冷却水的热传递以及半悬浮金属的形状。通过研究几何参数和操作参数的变化对优化设计的影响，给出了模型在ISM炉优化设计中的应用实例。
Induction skull melting (ISM) is a widely used process for melting certain alloys that are very reactive in the molten condition, such as those based on Ti, TiAl, and Zr, prior to casting components such as turbine blades, engine valves, turbocharger rotors, and medical prostheses. A major research project has been undertaken with the specific target of developing improved techniques for casting TiAl components. The aims include increasing the superheat in the molten metal to allow thin section components to be cast, improving the quality of the cast components and increasing the energy efficiency of the process. As part of this, the University of Greenwich (United Kingdom) has developed a dynamic, spectral-method-based computer model of the ISM process in close collaboration with the University of Birmingham (United Kingdom), where extensive melting trials have been undertaken. This article describes in detail the numerical model that encompasses the coupled influences of turbulent flow, heat transfer with phase change, and AC and DC magneto-hydrodynamics (MHD) in a time-varying liquid metal envelope. Associated experimental measurements on Al, Ni, and TiAl alloys have been used to obtain data to validate the model. Measured data include the true root-mean-square (RMS) current applied to the induction coil, the heat transfer from the molten metal to the crucible cooling water, and the shape of the semi-levitated molten metal. Examples are given of the use of the model in optimizing the design of ISM furnaces by investigating the effects of geometric and operational parameter changes.