Abstract
Electromagnetic metal casting (EMC) is a casting technique that uses electromagnetic energy to heat metal powders. It is a faster, cleaner, and less time-consuming operation. Solid metals create issues in electromagnetics since they reflect the electromagnetic radiation rather than consume it—electromagnetic energy processing results in sounded pieces with higher-ranking material properties and a more excellent microstructure solution. For the physical production of the electromagnetic casting process, knowledge of electromagnetic material interaction is critical. Even where the heated material is an excellent electromagnetic absorber, the total heating quality is sometimes insufficient. Numerical modelling works on finding the proper coupled effects between properties to bring out the most effective operation. The main parameters influencing the quality of output of the EMC process are: power dissipated per unit volume into the material, penetration depth of electromagnetics, complex magnetic permeability and complex dielectric permittivity. The contact mechanism and interference pattern also, in turn, determines the quality of the process. Only a few parameters, such as the environment's temperature, the interference pattern, and the rate of metal solidification, can be controlled by AI models. Neural networks are used to achieve exact outcomes by stimulating the neurons in the human brain. Additive manufacturing (AM) is used to design mold and cores for metal casting. The models outperformed the traditional DFA optimization approach, which is susceptible to local minima. The system works only offline, so real-time analysis and corrections are not yet possible.
Similar content being viewed by others
References
J. Sun, W. Wang, Q. Yue, Review on electromagnetic-matter interaction fundamentals and efficient electromagnetic-associated heating strategies. Materials 9(4), 231 (2016). https://doi.org/10.3390/ma9040231
E. Ghasali, A. Fazili, M. Alizadeh, K. Shirvanimoghaddam, T. Ebadzadeh, Evaluation of microstructure and mechanical properties of Al-TiC metal matrix composite prepared by conventional, electromagnetic and spark plasma sintering methods. Materials 10(11), 1255 (2017). https://doi.org/10.3390/ma10111255
D. Agrawal, Latest global developments in electromagnetic materials processing. Mater. Res. Innov. 14(1), 3–8 (2010). https://doi.org/10.1179/143307510x12599329342926
S. Singh, P. Singh, D. Gupta, V. Jain, R. Kumar, S. Kaushal, Development and characterization of electromagnetic processed cast iron joint. Eng. Sci. Technol. Int. J. (2018). https://doi.org/10.1016/j.jestch.2018.10.012
S. Singh, D. Gupta, V. Jain, Electromagnetic melting and processing of metal–ceramic composite castings. Proc. Inst. Mech. Eng. Part B J. Eng. Manuf. 232(7), 1235–1243 (2016). https://doi.org/10.1177/0954405416666900
S. Singh, D. Gupta, V. Jain, Novel electromagnetic composite casting process: theory, feasibility and characterization. Mater. Des. 111, 51–59 (2016). https://doi.org/10.1016/j.matdes.2016.08.071
J. Lucas, J, What are electromagnetics? LiveScience. (2018). https://www.livescience.com/50259-Electromagnetics.html
R. Samyal, A.K. Bagha, R. Bedi, the casting of materials using electromagnetic energy: a review. Mater. Today Proc. (2020). https://doi.org/10.1016/j.matpr.2020.02.255
S. Singh, D. Gupta, V. Jain, Processing of Ni-WC-8Co MMC casting through electromagnetic melting. Mater. Manuf. Process. (2017). https://doi.org/10.1080/10426914.2017.1291954
R. Singh, S. Singh, V. Mahajan, Investigations for dimensional accuracy of investment casting process after cycle time reduction by advancements in shell moulding. Procedia Mater. Sci. 6, 859–865 (2014). https://doi.org/10.1016/j.mspro.2014.07.103
R.R. Mishra, A.K. Sharma, On melting characteristics of bulk Al-7039 alloy during in-situ electromagnetic casting. Appl. Therm. Eng. 111, 660–675 (2017). https://doi.org/10.1016/j.applthermaleng.2016.09.122
S. Zhang, 10 Different types of casting process. (2021). MachineMfg.com, https://www.machinemfg.com/types-of-casting/
Envirocare, Foundry health risks. (2013). https://envirocare.org/foundry-health-risks/
S.S. Gajmal, D.N. Raut, A review of opportunities and challenges in electromagnetic assisted casting. Recent Trends Product. Eng. 2(1) (2019)
R.R. Mishra, A.K. Sharma, Electromagnetic-material interaction phenomena: heating mechanisms, challenges and opportunities in material processing. Compos. Part A (2015). https://doi.org/10.1016/j.compositesa.2015.10.035
S. Chandrasekaran, T. Basak, S. Ramanathan, Experimental and theoretical investigation on electromagnetic melting of metals. J. Mater. Process. Technol. 211(3), 482–487 (2011). https://doi.org/10.1016/j.jmatprotec.2010.11.001
C.R. Bird, J.M. Mertz, U.S. Patent No. 4655276. (U.S. Patent and Trademark Office, Washington, DC, 1987)
R.R. Mishra, A.K. Sharma, Experimental investigation on in-situ electromagnetic casting of copper. IOP Conf. Ser. Mater. Sci. Eng. 346, 012052 (2018). https://doi.org/10.1088/1757-899x/346/1/012052
V. Gangwar, S. Kumar, V. Singh, H. Singh, Effect of process parameters on hardness of AA-6063 in-situ electromagnetic casting by using taguchi method, in IOP Conference Series: Materials Science and Engineering, vol. 804(1) (IOP Publishing, 2020), p. 012019
X. Ye, S. Guo, L. Yang, J. Gao, J. Peng, T. Hu, L. Wang, M. Hou, Q. Luo, New utilization approach of electromagnetic thermal energy: preparation of metallic matrix diamond tool bit by electromagnetic hot-press sintering. J. Alloy. Compd. (2018). https://doi.org/10.1016/j.jallcom.2018.03.183
S. Das, A.K. Mukhopadhyay, S. Datta, D. Basu, Prospects of Electromagnetic processing: an overview. Bull. Mater. Sci. 32(1), 1–13 (2009). https://doi.org/10.1007/s12034-009-0001-4
K.L. Glass, D.M. Ashby, U.S. Patent No. 9050656. (U.S. Patent and Trademark Office, Washington, DC, 2015)
S. Verma, P. Gupta, S. Srivastava, S. Kumar, A. Anand, An overview: casting/melting of non ferrous metallic materials using domestic electromagnetic oven. J. Mater. Sci. Mech. Eng. 4(4), (2017). p-ISSN: 2393-9095; e-ISSN: 2393-9109
S.S. Panda, V. Singh, A. Upadhyaya, D. Agrawal, Sintering response of austenitic (316L) and ferritic (434L) stainless steel consolidated in conventional and electromagnetic furnaces. Scripta Mater. 54(12), 2179–2183 (2006). https://doi.org/10.1016/j.scriptamat.2006.02.034
Y. Zhang, S. Yang, S. Wang, X. Liu, L. Li, Microwave/freeze casting assisted fabrication of carbon frameworks derived from embedded upholder in tremella for superior performance supercapacitors. Energy Storage Mater. (2018). https://doi.org/10.1016/j.ensm.2018.08.006
D. Thomas, P. Abhilash, M.T. Sebastian, Casting and characterization of LiMgPO4 glass free LTCC tape for electromagnetic applications. J. Eur. Ceram. Soc. 33(1), 87–93 (2013). https://doi.org/10.1016/j.jeurceramsoc.2012.08.002
M.H. Awida, N. Shah, B. Warren, E. Ripley, A.E. Fathy, Modeling of an industrial Electromagnetic furnace for metal casting applications. 2008 IEEE MTT-S Int. Electromagn. Symp. Digest. (2008). https://doi.org/10.1109/mwsym.2008.4633143
P.K. Loharkar, A. Ingle, S. Jhavar, Parametric review of electromagnetic-based materials processing and its applications. J. Market. Res. 8(3), 3306–3326 (2019). https://doi.org/10.1016/j.jmrt.2019.04.004
E.B. Ripley, J.A. Oberhaus, WWWeb search power page-melting and heat treating metals using electromagnetic heating-the potential of electromagnetic metal processing techniques for a wide variety of metals and alloys is. Ind. Heat. 72(5), 65–70 (2005)
J. Campbell, Complete Casting Handbook: Metal Casting Processes, Metallurgy, Techniques and Design (Butterworth-Heinemann, 2015)
B. Ravi, Metal Casting: Computer-Aided Design and Analysis, 1st edn. (PHI Learning Ltd, 2005)
D.E. Clark, W.H. Sutton, Electromagnetic processing of materials. Annu. Rev. Mater. Sci. 26(1), 299–331 (1996)
A.D. Abdullin, New capabilities of software package ProCAST 2011 for modeling foundry operations. Metallurgist 56(5–6), 323–328 (2012). https://doi.org/10.1007/s11015-012-9578-8
J. Ha, P. Cleary, V. Alguine, T. Nguyen, Simulation of die filling in gravity die casting using SPH and MAGMAsoft, in Proceedings of 2nd International Conference on CFD in Minerals & Process Industries (1999) pp. 423–428
M. Sirviö, M. Woś, Casting directly from a computer model by using advanced simulation software FLOW-3D Cast Ž. Arch. Foundry Eng. 9(1), 79–82 (2009)
NOVACAST Systems, Nova-Solid/Flow Brochure, NOVACAST, Ronneby (2015)
AutoCAST-X1 Brochure, 3D Foundry Tech, Mumbai
EKK, Inc. Metal Casting Simulation Software and Consulting Services, CAPCAST Brochure
P. Muenprasertdee, Solidification modeling of iron castings using SOLIDCast (2007)
CasCAE, CT-CasTest Inc. Oy, Kerava
E. Dominguez-Tortajada, J. Monzo-Cabrera, A. Diaz-Morcillo, Uniform electric field distribution in electromagnetic heating applicators by means of genetic algorithms optimization of dielectric multilayer structures. IEEE Trans. Electromagn. Theory Tech. 55(1), 85–91 (2007). https://doi.org/10.1109/tmtt.2006.886913
B. Warren, M.H. Awida, A.E. Fathy, Electromagnetic heating of metals. IET Electromagn. Antennas Propag. 6(2), 196–205 (2012)
S. Ashouri, M. Nili-Ahmadabadi, M. Moradi, M. Iranpour, Semi-solid microstructure evolution during reheating of aluminum A356 alloy deformed severely by ECAP. J. Alloy. Compd. 466(1–2), 67–72 (2008). https://doi.org/10.1016/j.jallcom.2007.11.010
Penn State, Metal Parts Made In The Electromagnetic Oven. ScienceDaily. (1999) Retrieved May 8, 2021, from www.sciencedaily.com/releases/1999/06/990622055733.htm
R.R. Mishra, A.K. Sharma, A review of research trends in electromagnetic processing of metal-based materials and opportunities in electromagnetic metal casting. Crit. Rev. Solid State Mater. Sci. 41(3), 217–255 (2016). https://doi.org/10.1080/10408436.2016.1142421
D.K. Ghodgaonkar, V.V. Varadan, V.K. Varadan, Free-space measurement of complex permittivity and complex permeability of magnetic materials at Electromagnetic frequencies. IEEE Trans. Instrum. Meas. 39(2), 387–394 (1990). https://doi.org/10.1109/19.52520
J. Baker-Jarvis, E.J. Vanzura, W.A. Kissick, Improved technique for determining complex permittivity with the transmission/reflection method. Microw. Theory Tech. IEEE Trans. 38, 1096–1103 (1990)
M. Bologna, A. Petri, B. Tellini, C. Zappacosta, Effective magnetic permeability measurementin composite resonator structures. Instrum. Meas. IEEE Trans. 59, 1200–1206 (2010)
B. Ravi, G.L. Datta, Metal casting–back to future, in 52nd Indian Foundry Congress, (2004)
D. El Khaled, N. Novas, J.A. Gazquez, F. Manzano-Agugliaro. Microwave dielectric heating: applications on metals processing. Renew. Sustain. Energy Rev. 82, 2880–2892 (2018). https://doi.org/10.1016/j.rser.2017.10.043
H. Sekiguchi, Y. Mori, Steam plasma reforming using Electromagnetic discharge. Thin Solid Films 435, 44–48 (2003)
J. Sun, W. Wang, C. Zhao, Y. Zhang, C. Ma, Q. Yue, Study on the coupled effect of wave absorption and metal discharge generation under electromagnetic irradiation. Ind. Eng. Chem. Res. 53, 2042–2051 (2014)
K.I. Rybakov, E.A. Olevsky, E.V. Krikun, Electromagnetic sintering: fundamentals and modeling. J. Am. Ceram. Soc. 96(4), 1003–1020 (2013). https://doi.org/10.1111/jace.12278
A.K. Shukla, A. Mondal, A. Upadhyaya, Numerical modeling of electromagnetic heating. Sci. Sinter. 42(1), 99–124 (2010)
M. Chiumenti, C. Agelet de Saracibar, M. Cervera, On the numerical modeling of the thermomechanical contact for metal casting analysis. J. Heat Transf. 130(6), (2008). https://doi.org/10.1115/1.2897923
B. Ravi, Metal Casting: Computer-Aided Design and Analysis. (PHI Learning Pvt. Ltd., 2005)
J.H. Lee, S.D. Noh, H.-J. Kim, Y.-S. Kang, Implementation of cyber-physical production systems for quality prediction and operation control in metal casting. Sensors 18, 1428 (2018). https://doi.org/10.3390/s18051428
B. Aksoy, M. Koru, Estimation of casting mold interfacial heat transfer coefficient in pressure die casting process by artificial intelligence methods. Arab. J. Sci. Eng. 45, 8969–8980 (2020). https://doi.org/10.1007/s13369-020-04648-7
S.S. Miriyala, V.R. Subramanian, K. Mitra, TRANSFORM-ANN for online optimization of complex industrial processes: casting process as case study. Eur. J. Oper. Res. 264(1), 294–309 (2018). https://doi.org/10.1016/j.ejor.2017.05.026
J.K. Kittu, G.C.M. Patel, M. Parappagoudar, Modeling of pressure die casting process: an artificial intelligence approach. Int. J. Metalcast. (2015). https://doi.org/10.1007/s40962-015-0001-7
W. Chen, B. Gutmann, C.O. Kappe, Characterization of electromagnetic-induced electric discharge phenomena in metal-solvent mixtures. ChemistryOpen 1, 39–48 (2012)
J. Walker, A. Prokop, C. Lynagh, B. Vuksanovich, B. Conner, K. Rogers, J. Thiel, E. MacDonald, Real-time process monitoring of core shifts during metal casting with wireless sensing and 3D sand printing. Addit. Manuf. (2019). https://doi.org/10.1016/j.addma.2019.02.018
G.C. Manjunath Patel, A.K. Shettigar, M.B. Parappagoudar, A systematic approach to model and optimize wear behaviour of castings produced by squeeze casting process. J. Manuf. Process. 32, 199–212 (2018). https://doi.org/10.1016/j.jmapro.2018.02.004
G.C. Manjunath Patel, P. Krishna, M.B. Parappagoudar, An intelligent system for squeeze casting process—soft computing based approach. Int. J. Adv. Manuf. Technol. 86, 3051–3065 (2016). https://doi.org/10.1007/s00170-016-8416-8
M. Ferguson, R. Ak, Y.T. Lee, K.H. Law, Automatic localization of casting defects with convolutional neural networks, in 2017 IEEE International Conference on Big Data (Big Data) (Boston, MA, USA, 2017), pp. 1726–1735. https://doi.org/10.1109/BigData.2017.8258115.
P.K.D.V. Yarlagadda, Prediction of die casting process parameters by using an artificial neural network model for zinc alloys. Int. J. Prod. Res. 38(1), 119–139 (2000). https://doi.org/10.1080/002075400189617
G.C. ManjunathPatel, A.K. Shettigar, P. Krishna, M.B. Parappagoudar, Back propagation genetic and recurrent neural network applications in modelling and analysis of squeeze casting process. Appl. Soft Comput. 59, 418–437 (2017). https://doi.org/10.1016/j.asoc.2017.06.018
J. Zheng, Q. Wang, P. Zhao et al., Optimization of high-pressure die-casting process parameters using artificial neural network. Int. J. Adv. Manuf. Technol. 44, 667–674 (2009). https://doi.org/10.1007/s00170-008-1886-6
E. Mares, J. Sokolowski, Artificial intelligence-based control system for the analysis of metal casting properties. J. Achiev. Mater. Manuf. Eng. 40, 149–154 (2010)
K.S. Senthil, S. Muthukumaran, C. Chandrasekhar Reddy, Suitability of friction welding of tube to tube plate using an external tool process for different tube diameters—a study. Exp. Tech. 37(6), 8–14 (2013)
N.K. Bhoi, H. Singh, S. Pratap, P.K. Jain, Electromagnetic material processing: a clean, green, and sustainable approach. Sustain. Eng. Prod. Manuf. Technol. (2019). https://doi.org/10.1016/b978-0-12-816564-5.00001-3
K.S. Senthil, D.A. Daniel, An investigation of boiler grade tube and tube plate without block by using friction welding process. Mater. Today Proc. 5(2), 8567–8576 (2018)
E. Hetmaniok, D. Słota, A. Zielonka, Restoration of the cooling conditions in a three-dimensional continuous casting process using artificial intelligence algorithms. Appl. Math. Modell. 39(16), 4797–4807 (2015). https://doi.org/10.1016/j.apm.2015.03.056
C.V. Kumar, S. Muthukumaran, A. Pradeep, S.S. Kumaran, Optimizational study of friction welding of steel tube to aluminum tube plate using an external tool process. Int. J. Mech. Mater. Eng. 6(2), 300–306 (2011)
T. Adithiyaa, D. Chandramohan, T. Sathish, Optimal prediction of process parameters by GWO-KNN in stirring-squeeze casting of AA2219 reinforced metal matrix composites. Mater. Today Proc. 150, 1598 (2020). https://doi.org/10.1016/j.matpr.2019.10.051
B.P. Pehrson, A.F. Moore (2014). U.S. Patent No. 8708031 (U.S. Patent and Trademark Office, Washington, DC, 2014)
Liu, J., & Rynerson, M. L. (2008). U.S. Patent No. 7,461,684. Washington, DC: U.S. Patent and Trademark Office.
K. Salonitis, B. Zeng, H.A. Mehrabi, M. Jolly, The challenges for energy efficient casting processes. Procedia CIRP 40, 24–29 (2016). https://doi.org/10.1016/j.procir.2016.01.043
R.R. Mishra, A.K. Sharma, Effect of solidification environment on microstructure and indentation hardness of Al–Zn–Mg alloy casts developed using electromagnetic heating. Int. J. Metal Cast. 10, 1–13 (2017). https://doi.org/10.1007/s40962-017-0176-1
R.R. Mishra, A.K. Sharma, Effect of susceptor and Mold material on microstructure of in-situ electromagnetic casts of Al–Zn–Mg alloy. Mater. Des. 131, 428–440 (2017). https://doi.org/10.1016/j.matdes.2017.06.038
S. Kaushal, S. Bohra, D. Gupta, V. Jain, On processing and characterization of Cu–Mo-based castings through electromagnetic heating. Int. J. Metalcast. (2020). https://doi.org/10.1007/s40962-020-00481-8
S. Nandwani, S. Vardhan, A.K. Bagha, A literature review on the exposure time of electromagnetic based welding of different materials. Mater. Today Proc. (2019). https://doi.org/10.1016/j.matpr.2019.10.056
F.J.B. Brum, S.C. Amico, I. Vedana, J.A. Spim, Electromagnetic dewaxing applied to the investment casting process. J. Mater. Process. Technol. 209(7), 3166–3171 (2009). https://doi.org/10.1016/j.jmatprotec.2008.07.024
M.P. Reddy, R.A. Shakoor, G. Parande, V. Manakari, F. Ubaid, A.M.A. Mohamed, M. Gupta, Enhanced performance of nano-sized SiC reinforced Al metal matrix nanocomposites synthesized through electromagnetic sintering and hot extrusion techniques. Prog. Nat. Sci. Mater. Int. 27(5), 606–614 (2017). https://doi.org/10.1016/j.pnsc.2017.08.015
V.R. Kalamkar, K. Monkova, (Eds.), Advances in Mechanical Engineering. Lecture Notes in Mechanical Engineering. (2021) https://doi.org/10.1007/978-981-15-3639-7
V. Bist, A.K. Sharma, P. Kumar, Development and microstructural characterisations of the lead casting using electromagnetic technology. Manager’s J. Mech. Eng. 4(4), 6 (2014). https://doi.org/10.26634/jme.4.4.2840
A. Sharma, A. Chouhan, L. Pavithran, U. Chadha, S.K. Selvaraj, Implementation of LSS framework in automotive component manufacturing: a review, current scenario and future directions. Mater Today: Proc. (2021). https://doi.org/10.1016/J.MATPR.2021.02.374
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The authors declare that they have no competing interests.
Appendix
Appendix
EMC—Electromagnetic Metal Casting.
EHH—Electromagnetic Hybrid Heating.
XRD—X-ray Diffraction.
SEM—Scanning Electron Microscope.
EM—Electromagnetic Field.
Rights and permissions
About this article
Cite this article
Raj, A., Ram Kishore, S., Jose, L. et al. A survey of electromagnetic metal casting computation designs, present approaches, future possibilities, and practical issues. Eur. Phys. J. Plus 136, 704 (2021). https://doi.org/10.1140/epjp/s13360-021-01689-1
Received:
Accepted:
Published:
DOI: https://doi.org/10.1140/epjp/s13360-021-01689-1