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The purpose of this paper is to introduce a numerical calculation method to study the uniformity of the magnetic field in a cold crucible used for directional solidification (DS) and provide information for designing a cold crucible that can induce a uniform magnetic field.

To obtain the characteristics of the magnetic field in a cold crucible and its influence on the directional solidification processing, based on experimental verification, 3‐D finite element (FE) models with different crucible configuration‐elements and power parameters were established to study the uniformity of the magnetic field in a cold crucible. In addition, different TiAl ingots were directionally solidified with different cold crucibles, and the solid/liquid (S/L) interfaced were examined to investigate the effect of the magnetic field on the macrostructure of those ingots.

The uniformity of the magnetic field in a given domain can be quantitatively analyzed by statistical methods. Numerical calculation results showed that the uniformity of the magnetic field can be improved by optimizing the crucible configuration and adopting lower frequency. Better uniformity of the magnetic field in a cold crucible is beneficial to directional solidification.

The calculation of the uniformity of the magnetic field is proposed as a method for quantitative study of the distribution characteristics of the magnetic field in a cold crucible. The relationship between the S/L interfaces of TiAl ingots and the uniformity of the magnetic field is initially characterised; additionally, techniques for improving the uniformity of the magnetic field in a cold crucible are suggested.

Aims to present recent activities in numerical modeling of cold crucible melting process.

3D numerical analysis was used for electromagnetic problem and 3D large eddy simulation (LES) method was applied for fluid flow modeling.

The comparative modeling shows, that higher H/D ratio of the melt is more efficient when total power consumption is considered, but this advantage is held back by higher heat losses through the crucible walls. Also, calculations reveal that lower frequencies, which are energetically less effective, provide better mixing of the melt.

3D electromagnetic model, which allows to take into account non‐symmetrical distribution of Joule heat sources, together with transient LES fluid flow simulation gives the opportunity of accurate prediction of temperature distribution in the melt.

The purpose of this paper is obtaining the optimal parameters of induction heating and melting systems by use of the new programs ELectro-Thermal Analysis (ELTA) 8.0 and Induction Crucible Furnace (ICF) to improve a quality of final products.

Simulation of continuous through heating prior a drawing through the draw plate is realized by an optimization procedure. Additional application of ELTA 8.0 “Heating of Wire” reveals the relationship between power, time and thermal profile of load during heating. Rational variants of ICFs for melting processes are obtained using several step-by-step iterations.

ELTA 8.0 program permits to optimize the continuous heating of copper, steel, titanium and other wires. ICF ELTA program was used at the initial stage of the development of new technological processes and the ICFs. This program provides a preliminary evaluation of an induction melting process and system before the use of more sophisticated 2D or 3D programs. Results of optimization allowed to find a rational decision of an induction system, the required parameters of a refractory and a power supply. Non-conductive and graphite crucibles of the furnace were compared from electrical and economical points of view.

Fast calculation of ELTA programs allows the designer to provide the required temperature distribution in a cross section and along the part to control the real-time processes of heating and melting.