Introduction Cold Crucible Induction · PDF file · 2011-02-10Introduction ! Cold...
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2010.06.08
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! Introduction
! Cold Crucible Induction Melting – Description of the process
– Advantage/Disadvantage
! Physical experimentation (work in progress)
! Numerical modelling (work in progress)
! Conclusions
2 2010.06.08
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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INTRODUCTION
This work is being developed by the Advanced Material Forming Processes group of the Engineering Faculty of Mondragon Unibertsitatea.
In the name of the investigation group, Advanced Material Forming Processes, are included two key words of their investigating activity: Processes and Materials. The generation of knowledge for the development and optimization of both as a whole is the central core of the scientific activity of the group, without losing sight of the functionality of the formed material and higher added value.
From an operative point of view, the activity of the group is organized in a matrix form. In one axis there are the command of the different technologies and knowledge areas. For example, the metallic materials (Al, Mg, Steel, …), the deformation of sheet materials (superplastic forming, microforming, hydroforming, hot deep drawing, …), the transformation of bulk materials (thixoforming, sintering, hot forging, …) and the monitoring, modeling and control of materials and processes. In the other axis there are the sectors to which that knowledge is transferred. For example automotive, aeronautics, goods and services, health (implants), etc.
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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! Titanium and its alloys are getting much attention " Why? – Light weight.
– Excellent balance of mechanical properties.
– Excellent corrosion resistance.
– Excellent biocompatibility.
INTRODUCTION
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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! Main challenge: difficult to cast these alloys by conventional casting techniques because the titanium at high temperatures reacts with the crucible and mould components.
COLD CRUCILBE INDUCTION MELTING
An innovative process for melting titanium alloys
INTRODUCTION
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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! COLD CRUCILBE INDUCTION MELTING An innovative process where the casting and the melting is made in vacuum (or in a
controlled atmosphere) and we use a water cooled segmented cooper crucible instead of a typical ceramic crucible.
COLD CRUCIBLE INDUCTOIN MELTING
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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! Process steps 1) Casting:
The magnetic field supplied by the induction coil passes through the crucible segments and the induced currents heat and melt the metal charge (joule effect). As the titanium alloy melts, it solidifies against the wall, forming a thin skin or “skull” on the surface. Titanium has a low thermal conductivity, so the skull insulates the molten metal from the cooling effect of the crucible. Moreover, the effective power input is so high that the molten metal is partially levitated, which further reduces heat exchange between the liquid metal and the skull.
2) Melting: The molten metal is tilted in order to pour its content into a ceramic mould. As the conventional SiO2 refractory investment casting cause big reactions among metal and ceramic, it is important to consider mold materials containing MgO, Al2O3, ZrO2, Y2O3 and CaO in order to minimize these reactions.
COLD CRUCIBLE INDUCTOIN MELTING
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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! Advantages – Melting in vacuum and absence of ceramics.
– Melting stock for ISM can be anything that fits into the crucible.
– A controlled superheat.
– Good chemical composition control due to the stirring. ! Disadvantage: Poor efficiency
Physical experiments + Numerical Modelling
Optimization of process parameters: Power supply, frequency, coil design, crucible design,…
COLD CRUCIBLE INDUCTOIN MELTING
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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! The installation of Mondragon University
PHYSICAL EXPERIMENTATION
Seco\Warwick Pour operation view port, Melting operation view
port, Electrical power feedthroughs, Thermocouple feedthrough, Vacuum system, Rotating mold table,
Temperature control, Alloy additions feeder, Argon
gas partial pressure
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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! Experimental work – Fabrication of a prototype
– Temperature measurement
– Meniscus height
– Microestructural characterization
– Mechanical testing
PHYSICAL EXPERIMENTATION
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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! Numerical modelling of the step 1 of the process (casting)
NUMERICAL MODELLING
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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! First step of the process: Physical principles
– Ampere’s Law.
– Faraday’s Law.
– Importance of slits.
– Joule effect.
– Phase change " solid-liquid.
– Lorentz forces.
– Liquid movement " temperature homogenization.
NUMERICAL MODELLING
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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NUMERICAL MODELLING
ELECTROMAGNETIC ANALISIS
HEAT TRANSFER
ANALISIS
PHASE CHANGE
SOLID-LIQUID
FLUID FLOW ANALISIS
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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! Linear problem 1) Electromagnetic fields (Maxwell’s equations) (frequency domain)
2) Thermal field (Poisson equation) (time domain)
NUMERICAL MODELLING
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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! Non-Linear problem (time domain) 1) Fluid flow phenomena (Navier Stokes)
NUMERICAL MODELLING
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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! Literature review
– Ernst et al.
– Bojarevics et al.
! Ernst et al. (2005,2007) – COMSOL
NUMERICAL MODELLING
3D electromagnetic model
2D electromagnetic/fluid mechanic coupled model in
deformed mesh
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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NUMERICAL MODELLING
3D electromagnetic/fluid mechanic coupled model in
deformed mesh
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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! Bojarevics et al. (2009) – Pseudo-spectral solution
– Time dependent turbulent flow and heat transfer equations
NUMERICAL MODELLING
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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! Our approach (preliminary work) – We use COMSOL
– Axisymetric approximation (verification)
NUMERICAL MODELLING
A radiation of a loop antenna wrapped around a metallic cylinder into a conductive medium
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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! Our approach (preliminary work) – Analytical results (Pazynski et al.)
NUMERICAL MODELLING
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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! Our approach (preliminary work) – Numerical modeling results
NUMERICAL MODELLING
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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! Our approach (preliminary work) – Computational domain
– Geometry
NUMERICAL MODELLING
Air domain
Wire
I=1000 A
f=20000 Hz
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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! Our approach (preliminary work) – Computational domain
NUMERICAL MODELLING
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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! Our approach (preliminary work)
NUMERICAL MODELLING
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
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! Conclusions – Cold Crucible Induction Melting an innovative technology
– Comparison of experimental work and simulation
– Simulation step by step
– Electromagnetic analysis
– Computational domain
CONCLUSIONS
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Thanks for your attention
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INTRODUCTION
2010.06.08 COLD CRUCIBLE INDUCTION MELTING FOR THE FABRICATION OF TITANIUM MEDICAL PROSTHESES
COLD CRUCIBLE INDUCTION MELTING
PHYSICAL EXPERIMENTATION CONCLUSIONS NUMERICAL
MODELLING
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! Our approach (preliminary work)
NUMERICAL MODELLING