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Zhang C, Zhang L, Cao F, Jin Z, Cao G, Shen H, Huang Y, Sun J. Optimizing energy efficiency in induction skull melting process: investigating the crucial impact of melting system structure. Sci Rep 2024; 14:6303. [PMID: 38491172 PMCID: PMC10943189 DOI: 10.1038/s41598-024-56966-7] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/28/2023] [Accepted: 03/13/2024] [Indexed: 03/18/2024] Open
Abstract
Induction skull melting (ISM) technology could melt metals with avoiding contamination from crucible. A long-standing problem of ISM is that the low charge energy utilization and inhomogeneous fields have obstructed its application in many critical metal materials and manufacturing processes. The present work investigated the problem through the structure optimization strategy and established a numerical electromagnetic-field model to evaluate components' eddy current loss. Based on the model, the effect of crucible and inductor structure on charge energy utilization, etc. was studied. Furtherly, the charge energy utilization was increased from 27.1 to 45.89% by adjusting the system structure. Moreover, structure modifications are proposed for enhancing electromagnetic intensity and uniformity, charge soft contact and uniform heating. The work constructed a basis for framing new solutions to the problem through ISM device structure optimization.
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Affiliation(s)
- Chaojun Zhang
- National Key Laboratory of Precision Hot Processing of Metals, Harbin Institute of Technology, Harbin, 150001, China
- School of Materials Science and Engineering, Harbin Institute of Technology, Harbin, 150001, China
| | - Lunyong Zhang
- National Key Laboratory of Precision Hot Processing of Metals, Harbin Institute of Technology, Harbin, 150001, China.
- School of Materials Science and Engineering, Harbin Institute of Technology, Harbin, 150001, China.
| | - Fuyang Cao
- National Key Laboratory of Precision Hot Processing of Metals, Harbin Institute of Technology, Harbin, 150001, China.
- School of Materials Science and Engineering, Harbin Institute of Technology, Harbin, 150001, China.
| | - Zhishuai Jin
- National Key Laboratory of Precision Hot Processing of Metals, Harbin Institute of Technology, Harbin, 150001, China
- School of Materials Science and Engineering, Harbin Institute of Technology, Harbin, 150001, China
| | - Guanyu Cao
- National Key Laboratory of Precision Hot Processing of Metals, Harbin Institute of Technology, Harbin, 150001, China
- School of Materials Science and Engineering, Harbin Institute of Technology, Harbin, 150001, China
| | - Hongxian Shen
- National Key Laboratory of Precision Hot Processing of Metals, Harbin Institute of Technology, Harbin, 150001, China
- School of Materials Science and Engineering, Harbin Institute of Technology, Harbin, 150001, China
| | - Yongjiang Huang
- National Key Laboratory of Precision Hot Processing of Metals, Harbin Institute of Technology, Harbin, 150001, China
- School of Materials Science and Engineering, Harbin Institute of Technology, Harbin, 150001, China
| | - Jianfei Sun
- National Key Laboratory of Precision Hot Processing of Metals, Harbin Institute of Technology, Harbin, 150001, China.
- School of Materials Science and Engineering, Harbin Institute of Technology, Harbin, 150001, China.
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