The invention relates to a levitation melting process and an apparatus for producing castings comprising a ring-shaped element of a conductive material for introducing the casting of a molten batch into a casting mould. In the process, the ring-shaped element is introduced into the region of the alternating electromagnetic field between the induction coils in order to cast the molten batch, thereby initiating a targeted run-off of the melt into the casting mould by influencing the induced magnetic field.

The invention relates to a levitation melting method and an apparatus for producing casting bodies with tilted induction units. During this method, induction units are employed in which the opposing ferrite poles with the induction coils are not arranged lying in one plane, but tilted at a determined angle to the levitation plane. In this way, an increase in efficiency of the induced magnetic field for melting the batches can be achieved with the induction units. The tilted arrangement increases the portion of the induced magnetic field that effectively contributes to the holding force of the field for levitation of the melt.

The invention relates to a method and a device for casting a melt 4 of a metallic material by means of a furnace 2 of a low pressure casting device, which furnace 2 has a receiving space 3 and a riser tube protruding into said receiving space 3. By pressurizing the receiving space 3 with compressed air, the melt 4 in the riser tube 12 of the furnace 2 is pressed into a mold cavity 10 of a mold 7, wherein simultaneously, a magnetic field acting against the conveying direction 23 of the melt 4 is applied to the melt 4 of the metallic material by means of a magnetic element 16 arranged in the region of the riser tube 12.

The invention relates to a levitation melting method and an apparatus for producing casting bodies with tilted induction units. During this method, induction units are employed in which the opposing ferrite poles with the induction coils are not arranged lying in one plane, but tilted at a determined angle to the levitation plane. In this way, an increase in efficiency of the induced magnetic field for melting the batches can be achieved with the induction units. The tilted arrangement increases the portion of the induced magnetic field that effectively contributes to the holding force of the field for levitation of the melt.

An induction coil assembly associated with controlling the flow of molten material used in casting or deposition of precious and/or non-precious metals on a substrate is disclosed. The assembly comprises one or more induction coils associated with induction melting of electrically conductive material by applying a predetermined current value. The assembly further comprises a crucible comprising the electrically conductive material in which an electromagnetic field is generated therein by the predetermined current value applied to the induction coils. The electromagnetic field associated with the electrically conductive material is modulated; and is used to generate smaller units of the electrically conductive material by interrupting velocity of a flow of the material in order to produce grains or apply layers on the substrate. Corresponding methods are also disclosed.

This disclosure pertains to a system, methods, and apparatus configured for generating singulated metal droplets and collecting powder metal. The system comprises crucible apparatus each including a crucible housing, a gas inlet, and an alloy nozzle. The crucible housing is operatively coupled to an induction heating element and power supply to provide induction heating of the crucible housing and electromagnetically levitate a mass of molten metal. The gas inlet is operatively coupled to a gas supply and configured to receive a pressurized gas pulse via the gas supply, the pressurized gas pulse being directed at the mass of molten metal. The alloy nozzle is configured to release a metal droplet singulated from the mass of molten level due to the pressurized gas pulse. The system includes a powder collection unit configured to collect powder from one or more dispensing channel configured to catch the falling singulated liquid metal droplet.

The invention relates to a method for producing casting bodies in a levitation melting method in which a batch of an electrically conductive material is brought into the sphere of influence of at least one alternating electromagnetic field by means of a starting material having a plurality of pre-separated batches separated by regions of reduced cross-section so that the batch is kept in a state of levitation. The regions are designed in such a way that separation of the pre-separated batches takes place only during melting in an alternating electromagnetic field. The melt is then cast into casting moulds.

A method for producing cast items in a casting method, wherein a charge of a conductive material is introduced into the sphere of influence of at least one alternating electromagnetic field, so that the charge is kept in a levitating state. The melt is poured into moulds in order to produce turbine blades, prostheses or turbocharger impellers.

An induction coil assembly associated with controlling the flow of molten material used in casting or deposition of precious and/or non-precious metals on a substrate is disclosed. The assembly comprises one or more induction coils associated with induction melting of electrically conductive material by applying a predetermined current value. The assembly further comprises a crucible comprising the electrically conductive material in which an electromagnetic field is generated therein by the predetermined current value applied to the induction coils. The electromagnetic field associated with the electrically conductive material is modulated; and is used to generate smaller units of the electrically conductive material by interrupting velocity of a flow of the material in order to produce grains or apply layers on the substrate. Corresponding methods are also disclosed.

A three-dimensional (3D) metal object manufacturing apparatus is equipped with a vessel having a receptacle that holds melted metal. The vessel has one or more electrical coils positioned at an upper end of the vessel near an inlet for solid metal that is melted within the receptacle. AC electrical current is passed through the one or more electrical coils to produce traveling magnetic fields in the melted metal at the upper end of the receptacle in the vessel to stir the melted metal and attenuate the formation of dross in the melted metal.