Optimization of induction devices for aluminium casting to electromagnetic crystallizer

The paper studies the innovative way of continuous casting based on use of electrodynamic impact of variation magnetic field on liquid metal. The problems of ingot quality improvement, economy of resources are solved. These problems are connected with improvement of an electromagnetic crystallizer design as the crystallizer exerts direct impact on formation of internal structure and a surface of an ingot. Correctly specified geometrical parameters of electromagnetic crystallizer allow minimizing the power consumption during casting, eliminating surface laps and reducing the ingot consertal structure to a minimum. The benefits of the electromagnetic crystallizer for continuous casting are: absence of physical contact between a die and an ingot; possibility to reduce metal circulation to a minimum; manufacturing efficiency increase; working conditions improvement; metal technological properties improvement. In the course of studies, a series of structures was calculated. As a result of the analysis the optimization chart of EMC with a passive screen was plotted. It was revealed that the major optimization criteria for this technology are power inputs. When designing the EMC the parameters of electromagnetic shift inside the inductor and the change of electromagnetic screen skew angle were used as optimization parameters. The optimization of the EMC structures was conducted, subsequent to the results of which the optimization chart was plotted. This permits revealing the least power-consuming structures.