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The study aims to maximize the efficiency of the process under a given current condition by changing the geometry of the coil. This optimization is economically justified by reducing the cost of the process.

The paper presents the author’s optimization process for a case requiring long computational time. The presented optimization is based on a 3D simulation model of an electromagnetic levitation melting (ELM) inductor.

The result of the work is to find a suboptimal inductor geometry for ELM.

To solve the presented problem, a procedure using an evolutionary algorithm was relied on. As for all global search algorithms, it is possible to find a local optimum instead of a global one.

The new inductor geometry for ELM, thanks to its higher process efficiency for its class of inductors, can lead to the reduction of the costs of the process by using this type of equipment.

The novelty of the article is a proprietary optimization algorithm and the use of an advanced 3D simulation model which was necessary due to the lack of symmetry of the ELM inductor.

A small size cold crucible offers possibilities for melting various electrically conducting materials with a minimal wall contact. Such small samples can be used for express contamination analysis, preparing limited amounts of reactive alloys or experimental material analyses. Aims to present a model to follow the melting process.

The presents a numerical model in which different types of axisymmetric coil configurations are analysed.

The presented numerical model permits dynamically to follow the melting process, the high‐frequency magnetic field distribution change, the free surface and the melting front evolution, and the associated turbulent fluid dynamics. The partially solidified skin on the contact to the cold crucible walls and bottom is dynamically predicted. The segmented crucible shape is either cylindrical, hemispherical or arbitrary shaped.

The model presented within the paper permits the analysis of melting times, melt shapes, electrical efficiency and particle tracks.

The purpose of this paper is to create a numerical model of electrode induction melting process for the gas atomization (EIGA) and process and investigate the complex interaction of the electromagnetic and thermal fields on the fluid flow with free surface.

The modelling approach is based on the free surface code SPHINX which includes time dependent electromagnetic, thermal and fluid flow with free surface modelling and the commercial software COMSOL for investigating 3D electromagnetic effects.

The melting dynamics, liquid film formation and the outflow free surface behavior are predicted by SPHINX using an optimized geometry. Quasi‐stationary AC electromagnetic solutions with COMSOL predict some 3D effects of the coil, including frequency dependent estimates of voltage, electric current and power.

The importance of magnetic forces controlling the free surface jet formation, partial semi‐levitation and the outflow superheat is uncovered by numerical modelling tools. An optimized geometry is presented for the EIGA process.

In this paper the authors review the recent numerical techniques proposed to solve the forward and inverse problems concerning the electromagnetic casting and electromagnetic levitation techniques of the metallurgical industry. In addition, the authors present a new topology optimization method to solve the inverse axisymmetric electromagnetic levitation problem.

The proposed method is based on an exact second-order topological expansion of a Kohn–Vogelius-like functional specially devised for this problem.

Through some examples the authors show that it can find suitable solutions efficiently.

The new method completes the set of efficient methods available to solve the inverse electromagnetic casting and the inverse axisymmetric electromagnetic levitation problems.

The purpose of this paper is to investigate a new type of nozzle which is free from erosion and non-contaminating the outflow metal. Cold crucible melting technique with electromagnetic induction is used to obtain reactive metal castings and produce high-quality metal powders for aerospace, automotive and medical applications. An important part of this technology is the nozzle used to pour the molten alloy through the bottom opening.

The paper uses mathematical modeling technique, previously validated on multiple similar cases, to investigate a new type of nonconsumable nozzle made of copper segments.

The design of the nozzle requires to satisfy the narrow balance between the thin solidified protective layer on the wall while avoiding the blockage of the outflow if the nozzle is frozen completely. The sensitivity of the outflow to the nozzle diameter is investigated. The AC electromagnetic force leads to high mixing rates, transitional flow structures and turbulence of the melt, contributing to the melt shape dynamics and the heat loss to walls.

The beneficial features of the cold crucible melting to purify the melt from particulate contamination are explained using the full melting and pouring cycle.

Introduces the fourth and final chapter of the ISEF 1999 Proceedings by stating electric and magnetic fields are influenced, in a reciprocal way, by thermal and mechanical fields. Looks at the coupling of fields in a device or a system as a prescribed effect. Points out that there are 12 contributions included ‐ covering magnetic levitation or induction heating, superconducting devices and possible effects to the human body due to electric impressed fields.

To provide a selective bibliography for researchers and graduate students who have an interest in induction processes applied to the electromagnetic processing of materials.

The objective is to provide references that identify seminal, early work, and references that represent the current state of the art. References are listed in categories that cover the broad range of induction modeling and application issues.

A brief overview of the key areas in induction processing of materials is provided, but greater emphasis and space is devoted to the references provided.

The middle years of each topic area are not covered.

A very comprehensive coverage of material is provided to those with an interest in induction processing of materials.

This paper fulfils an identified information/resources need.

A computational methodology, based on the coupling of the finite element and boundary element methods, is developed for the solution of magnetothermal problems. The finite element formulation and boundary element formulation, along with their coupling, are discussed. The coupling procedure is also presented, which entails the application of the LU decomposition to eliminate the need for the direct inversion of matrices resulting from FE‐BE formulation, thereby saving computation time and storage space. Corners for both FE‐BE interface and BE regions, where discontinuous fluxes exist, are treated using the double flux concept. Numerical results are presented for three different systems and compared with analytical solutions when available. Numerical experiments suggest that for magnetothermal problems involving small skin depths, a careful mesh distribution is critical for accurate prediction of the field variables of interest. It is found that the accuracy of the temperature distribution is strongly dependent upon that of the magnetic vector potential. A small error in the magnetic vector potential can produce significant errors in the subsequent temperature calculations. Thus, particular attention must be paid to the design of a suitable mesh for the accurate prediction of vector potentials. From all the cases examined, 4‐node linear elements with adequate progressive coarsening of meshes from the surface gave the results with best accuracy.

This study aims to review the recent advancements in high entropy alloys (HEAs) called high entropy materials, including high entropy superalloys which are current potential alternatives to nickel superalloys for gas turbine applications. Understandings of the laser surface modification techniques of the HEA are discussed whilst future recommendations and remedies to manufacturing challenges via laser are outlined.

Materials used for high-pressure gas turbine engine applications must be able to withstand severe environmentally induced degradation, mechanical, thermal loads and general extreme conditions caused by hot corrosive gases, high-temperature oxidation and stress. Over the years, Nickel-based superalloys with elevated temperature rupture and creep resistance, excellent lifetime expectancy and solution strengthening L12 and γ´ precipitate used for turbine engine applications. However, the superalloy’s density, low creep strength, poor thermal conductivity, difficulty in machining and low fatigue resistance demands the innovation of new advanced materials.

HEAs is one of the most frequently investigated advanced materials, attributed to their configurational complexity and properties reported to exceed conventional materials. Thus, owing to their characteristic feature of the high entropy effect, several other materials have emerged to become potential solutions for several functional and structural applications in the aerospace industry. In a previous study, research contributions show that defects are associated with conventional manufacturing processes of HEAs; therefore, this study investigates new advances in the laser-based manufacturing and surface modification techniques of HEA.

The AlxCoCrCuFeNi HEA system, particularly the Al0.5CoCrCuFeNi HEA has been extensively studied, attributed to its mechanical and physical properties exceeding that of pure metals for aerospace turbine engine applications and the advances in the fabrication and surface modification processes of the alloy was outlined to show the latest developments focusing only on laser-based manufacturing processing due to its many advantages.

It is evident that high entropy materials are a potential innovative alternative to conventional superalloys for turbine engine applications via laser additive manufacturing.

An excessive increase in temperature will reduce the lifespan and even burn the coil. The variety of materials in the structure of the electromagnet along with its multi-layer winding creates a complex and heterogeneous thermal structure. There are very few researches that are completely focused on the thermal analysis of electromagnets. The purpose of this paper is to provide an accurate, yet fast and simple method for the thermal analysis of cylindrical electromagnets in both transient and steady-state modes. For this purpose, a thermal equivalent circuit (TEC) is presented based on the nodding approach.

The results of TEC analysis of cylindrical electromagnet, for two orthogonal and orthocyclic winding coil technologies, were compared with the results of the thermal simulation in COMSOL. The authors also built a laboratory model of the cylindrical electromagnet, similar to those analyzed and simulated, and measured the temperature in different parts of it.

The comparison of the results obtained from different methods for the thermal analysis of the cylindrical electromagnet indicates that the proposed TEC has an error of less than 2%. The simplicity and high accuracy of the results are the most important advantages of the proposed TEC.

Comparing the information and results related to winding schemes, indicates that the orthogonal winding has less cost and weight due to the shorter length of the wire used. On the other hand, orthocyclic winding generates lower temperature and has more lifting force, and is simpler to implement. Therefore, in practice, orthocyclic winding technology is usually used.