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 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.

A method for casting aluminum on a rotor, comprising: installing casting equipment on a casting workbench and storing enough molten aluminum in the casting equipment, wherein the casting equipment comprises an heat preserving furnace and an electromagnetic pump arranged at a side of the heat preserving furnace; assembling a plurality of rotor iron cores with a plurality of dies respectively and preheating outside the casting workbench; installing the plurality of preheated dies on a plurality of liquid outlet gates at a top end of the electromagnetic pump, wherein each liquid outlet gate is matched with a liquid inlet gate of the dies; heating and keeping the installed die in a multi-stage heating mode; controlling the pressurizing pressure of the electromagnetic pump in time-period when the electromagnetic pump is used for casting; and after completing casting, moving the plurality of dies out of the casting workbench to be cooled. According to the method for casting aluminum through the rotor, the casting efficiency is improved by reasonably distributing the heating time and the one-time multi-casting mode; the top-down temperature gradient is matched with accurate pressure control, so that the compensation capacity is improved.

The invention relates to a levitation melting process and a device for producing castings with movable induction units. In this process, induction units are used in which the opposite ferrite poles with the induction coils are movable and move in opposite directions. In this way, the induction units for melting the batches can be arranged close together in order to increase the efficiency of the induced magnetic field. When casting the molten batch, the induced magnetic field is reduced by increasing the distance between the ferrite poles with the induction coils, thus preventing the melt from touching the ferrite poles or the induction coils.

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 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.

An electromagnetic device for pumping, circulating or transferring non-ferrous molten metal has a duct made of a refractory material with a first aperture at a first end of the duct and a second aperture at a second end of the duct. The duct conveys a body of non-ferrous molten metal between the first and second apertures. The duct encloses the body of non-ferrous molten metal between the first and second apertures. The duct has opposing first and second external side surfaces. A first inductor assembly extends adjacent to the first side surface. The first inductor assembly comprises a plurality of inductors arranged along a length of the duct adjacent to the first side surface. An electronic circuit generates direct current pulses that energise each inductor of the plurality of inductors in a sequence, so as to generate a moving magnetic field within the body of non-ferrous molten metal which propels the body of non-ferrous molten metal along the duct.

A system for melting metals for casting includes one or more arc welding power supplies configured to provide one or more arc welding outputs, and one or more electrodes operatively connected to the one or more arc welding outputs. A solid metal holder is configured to hold a solid metal to be melted by one or more arcs formed between the one or more electrodes and the solid metal to generate a molten metal. A container is positioned proximate the solid metal holder to receive the molten metal. A robot is proximate both the container and a mold and/or a die cast machine. The robot has an arm configured to manipulate the container containing the molten metal and pour the molten metal from the container into the mold and/or the die cast machine for casting.

A method for casting aluminum on a rotor, comprising: installing casting equipment on a casting workbench and storing enough molten aluminum in the casting equipment, wherein the casting equipment comprises an heat preserving furnace and an electromagnetic pump arranged at a side of the heat preserving furnace; assembling a plurality of rotor iron cores with a plurality of dies respectively and preheating outside the casting workbench; installing the plurality of preheated dies on a plurality of liquid outlet gates at a top end of the electromagnetic pump, wherein each liquid outlet gate is matched with a liquid inlet gate of the dies; heating and keeping the installed die in a multi-stage heating mode; controlling the pressurizing pressure of the electromagnetic pump in time-period when the electromagnetic pump is used for casting; and after completing casting, moving the plurality of dies out of the casting workbench to be cooled. According to the method for casting aluminum through the rotor, the casting efficiency is improved by reasonably distributing the heating time and the one-time multi-casting mode; the top-down temperature gradient is matched with accurate pressure control, so that the compensation capacity is improved.

The invention relates to a levitation melting process and a device for producing castings with movable induction units. In this process, induction units are used in which the opposite ferrite poles with the induction coils are movable and move in opposite directions. In this way, the induction units for melting the batches can be arranged close together in order to increase the efficiency of the induced magnetic field. When casting the molten batch, the induced magnetic field is reduced by increasing the distance between the ferrite poles with the induction coils, thus preventing the melt from touching the ferrite poles or the induction coils.