Analysis and Design of Induction Liquid Metal Processes Using Advanced Numerical Modelling

Comprehensive knowledge of the turbulent flows, heat and mass transfer processes in the melt of induction applications is required to realize efficient metallurgical processes. Therefore, the process oriented development, design and optimization of induction furnaces for melting and casting of metals require praxis oriented simulation and analysis of the complex in-stationary turbulent melt flows and temperature distributions as well as the heat and mass transfer processes in the liquid metal. The studies, presented in this paper, demonstrate the possibilities of using advanced three-dimensional transient numerical modelling for successful simulation of the melt flow as well as heat and mass transfer processes in metallurgical applications. Along selected examples like classical induction crucible furnace and the cold crucible induction furnace for melting and casting of TiAl alloys as well as the innovative electromagnetic levitation melting where the free surface dynamics has to be taken into account the successful development and application of experimentally verified numerical simulation techniques will be demonstrated.