Improved fluidity using induction heating of critical areas in lightweight steel castings

Purpose and goal:

The aim of the project was to test and evaluate a new concept to improve the melt flowability. The idea was to locally apply heat to a thin segment with an induction coil during casting. The impact of the project was that a new methodology and equipment was developed which enabled casting with an induction coil. The project also identify important factors that need to be considered in a continuation project.

Expected results and effects:

In the project, various concepts have been evaluated and have resulted in a successful test methodology. The concept involves that an induction field can be applied to a thin channel during a steel casting. Through the project, the concept can be further developed, and more areas of use can be identified. A continuation project would enable the casting of new lightweight components that cannot be cast today. The concept can be applied to various casting operations and materials.

Approach and implementation:

The project has increased the knowledge about induction heating and identified important requirements. A demonstrator has been determined and theoretically evaluated. The project has identified the limitations and important process parameters for thin-walled steel castings.

However, it was not possible to confirm that induction heating improves the flowability. Still, a casting simulation program has been evaluated and important development needs have been identified. This feasibility study is considered successful and will be the basis for a continuation project.