Low Energy Casting: Novel induction technologies for energy efficient rapid melting

The project aims to develop new technologies to significantly improve the energy efficiency of metal casting processes for the production of quality castings with high structural integrity using the CRIMSON casting technique. CRIMSON (Constrained Rapid Induction Melting Single Shot Up-casting) is a novel counter gravity casting approach designed for improving the energy efficiency in casting processes and lowering the environmental footprint of foundries. It mainly comprises induction melting of only the precise quantity of metal for a single casting, using high quality raw materials, followed by filling the mould by controlled (turbulence-free) counter gravity flow of molten alloy.
Novel methods of electromagnetic and mechanical confinement of metallic melts will be investigated using CFD simulations and experiments able to control the hydrodynamic behaviour of the liquid metals during rapid induction melting and improve the electromagnetic coupling. The project will primarily focus on Al and ferrous alloys to study benefits in the process energy efficiency as well as the structure and properties of cast materials.