Toms Beinerts

Arrays of Rotating Permanent Magnet Dipoles for Stirring and Pumping of Liquid Metals

Abstract Multiple configurations of synchronously rotating permanent magnet cylinders magnetized across the axes are proposed for liquid metal stirring for homogenization as well as for pumping. Universal analytical model is used for an initial parameter analysis. Then experimental setups were built to perform physical modelling of the industrial applications, e.g. large-scale metallurgical furnaces. Velocity distribution in the liquid metal was measured using different methods: the Ultrasound Doppler anemometry and the potential difference probes. The study shows that the cylindrical permanent magnet setups can achieve up to 10 times higher energy efficiency compared to AC inductors and have potential of wide-range industrial application, e.g. can be used as stirrers for secondary aluminium furnaces with up to 50 cm thick walls.

Permanent magnet centrifugal pump for liquid aluminium stirring

In liquid aluminium processing, it is important to ensure continuous mixing of the molten metal to ensure temperature and composition homogeneity, and to improve degassing of the metal. Aluminium and its alloys are often processed in special degassing chambers after preparation in order to avoid segregation and to improve material structure, and to avoid gas pores. This extra step increases material costs and may cause material contamination. In this article, we present the idea to use centrifugal permanent magnet stirrer to induce liquid aluminium motion through thick furnace wall by creating high-speed local liquid metal jet. Analytical estimation, numerical modelling and experimental tests using GaInSn alloy has been done and are presented in the article. Model experiments are used to elaborate dimensionless parameters to verify the feasibility of this technology for liquid aluminium.

Direct chill casting of aluminium alloys under electromagnetic interaction

Direct chill casting is one of the methods used in industry to obtain good microstructure and properties of aluminium alloys. Nevertheless, for some alloys grain structure is not optimal. In this study, we test the principle of using electromagnetic interaction to modify melt convection near the solidification interface. Solidification under electromagnetic interaction has been widely studied, but usually at low solidification velocity and high thermal gradient, where influence by electromagnetic interaction is demonstrated. This type of interaction may succeed fragmentation of dendrite arms and transport of solidification nuclei thus leading to improved material structure and properties. Casting of 10 mm diameter Al alloy rod under electromagnetic interaction caused by DC magnetic field and electric current has been done.

Use of Permanent Magnets in Electromagnetic Facilities for the Treatment of Aluminum Alloys

The possibility of applying the electromagnetic induction pump with permanent magnets for the transportation and stirring of aluminum melts in metallurgical furnaces is investigated. The electromagnetic and hydraulic characteristics of the pump have been investigated theoretically and experimentally with regard to its position in the furnace. The results of the experiments performed with a model in a eutectic InGaSn melt are in good agreement with the calculation data. Extrapolation of the experimental results on the physical characteristics of aluminum melts allows recommending such pumps for contactless control of motion and heat/mass transfer in aluminum melts in different technological processes. A high temperature and the aggressive properties of aluminum alloys make it complicated to use different mechanical devices to solve technological problems, such as liquid metal transportation, dosing, stirring, etc. In this case, any device units or elements moving in or contacting with the melt suffer from corrosion polluting the melt. Therefore, of more importance and topicality are contactless electromagnetic methods for processing of molten metals.