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

Important results from the project

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 long term 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.