Low Energy Casting: Novel induction technologies for energy efficient rapid melting

该项目旨在开发新技术，以显着提高金属铸造工艺的能效，利用深红铸造技术生产具有高结构完整性的优质铸件。CRIMSON是一种新型的反重力铸造方法，旨在提高铸造过程的能效，降低铸造厂的环境污染。它主要包括感应熔炼单个铸件的精确数量的金属，使用高质量的原材料，然后用可控的(无湍流的)合金反重力流填充模具。金属熔体的电磁和机械约束的新方法将通过CFD模拟和实验来研究，这些方法能够控制快速感应熔炼中液态金属的流体动力学行为，并改善电磁耦合。该项目将主要集中在铝和铁合金上，以研究工艺能效以及铸造材料的结构和性能方面的好处。

The project aims to develop new technologies to significantly improve the energy efficiency of metal casting processes for the production of quality castings with high structural integrity using the CRIMSON casting technique. CRIMSON (Constrained Rapid Induction Melting Single Shot Up-casting) is a novel counter gravity casting approach designed for improving the energy efficiency in casting processes and lowering the environmental footprint of foundries. It mainly comprises induction melting of only the precise quantity of metal for a single casting, using high quality raw materials, followed by filling the mould by controlled (turbulence-free) counter gravity flow of molten alloy.Novel methods of electromagnetic and mechanical confinement of metallic melts will be investigated using CFD simulations and experiments able to control the hydrodynamic behaviour of the liquid metals during rapid induction melting and improve the electromagnetic coupling. The project will primarily focus on Al and ferrous alloys to study benefits in the process energy efficiency as well as the structure and properties of cast materials.