Abstract: An apparatus and process are provided for controlling the heating and melting of a material that is non-electrically conductive in the solid state and is electrically conductive in the non-solid state. Power is selectively directed between coil sections surrounding different zones of the material in a susceptor vessel by changing the output frequency of the power supply to the coil sections. Coil sections comprise at least one active coil section, which is connected to the output of the power supply, and at least one passive coil section, which is not connected to the power supply, but is connected in parallel with a tuning capacitor so that the at least one passive coil section can be selectively operated at, or near, resonant frequency when the transition material in the vessel is molten.

Abstract: An electromagnetic pump has a supply section and a magnetic force pumping section wherein flow of an electrically conductive material through the supply section is opposite to the flow of the material in the magnetic force pumping section in some examples. Multiple coils surround the supply and magnetic force pumping sections. Current flowing through the multiple coils creates magnetic fields that magnetically couple with a magnetic material disposed between the supply and magnetic force pumping sections so that the fields penetrate the electrically conductive material in the magnetic force pumping section substantially perpendicular to the desired flow direction which maximizes the magnitudes of magnetic forces applied to the electrically conductive material.

Abstract: An apparatus and process are provided for induction heating of a workpiece. The workpiece is moved through an inductor to inductively heat treat the workpiece with electric power of varying frequency and duty cycle or amplitude control to control the magnitude of electric power as the frequency changes. Alternatively the workpiece may be stationary and the inductor can be moved along the workpiece, or combined and coordinated movement of both the workpiece and inductor can be used.

Abstract: An apparatus and process are provided for bonding of materials by induction heating of an electrically conductive material upon which a second material is bonded. The electrically conductive material is induction heated between a first induction heating plate, and the combination of a frame and a second induction heating plate that is disposed within the frame. The second induction heating plate is removed from the surface of the electrically conductive sheet, while the frame continues to hold the electrically conductive sheet flat, and the second material, in liquid form, is poured into the interior opening of the frame in which the second induction heating plate was originally placed. The liquid material solidifies and bonds to the electrically conductive sheet to produce a bonded product.

Abstract: A molten material can be heated, melted and directly solidified in a single vessel. Induction heating and melting of the molten material is achieved by magnetically coupling the field produced by current flow in a plurality of induction coils surrounding the vessel with either the molten material in the vessel, or a susceptor surrounding molten material in the vessel. Current flow is selectively removed from the plurality of induction coils, and a cooling medium surrounding the vessel, such as water flowing through hollow induction coils, solidifies the molten metal into a highly purified crystalline solid.

Abstract: A system and method for computing the parameters of a forge welding machine for the forge welding of one or more materials is provided. A computer program executes a self-tuning routine to compute the operating frequency and operating power setting for the forge welding machine in response to an inputted width of the heat affected zone and an inputted weld temperature.

Abstract: An apparatus and process are provided for gradient induction heating or melting of a workpiece with a plurality of induction coils, each of the plurality of induction coils is connected to a power supply that may have a tuning capacitor connected across the input of an inverter. The plurality of induction coils are sequentially disposed around the workpiece. The inverter has a pulse width modulated ac power output that may be in synchronous control with the pulse width modulated ac power outputs of the other power supplies via a control line between the controllers of all power supplies.

Abstract: An impeder for use in an electric induction welding process is provided. Optionally the impeder does not require internal forced cooling. In embodiments using internal forced cooling a high efficiency cooling system is provided.

Abstract: An apparatus and process are provided for controlling the heating or melting of an electrically conductive material. Power is selectively directed between coil sections surrounding different zones of the material by changing the output frequency of the power supply to the coil sections. Coil sections comprise at least one active coil section, which is connected to the output of the power supply, and at least one passive coil section, which is not connected to the power supply, but is connected in parallel with a tuning capacitor so that the at least one passive coil section operates at a resonant frequency and the output frequency of the power supply is changed so that the induced power in the at least one passive coil section changes as the frequency is changed.

Abstract: An apparatus and process are provided for scan induction heating of a workpiece. The workpiece is moved through an inductor to inductively heat treat features of the workpiece with electric power of varying frequency and duty cycle to control the magnitude of electric power as the frequency changes.

Abstract: An apparatus and process are provided for supporting a billet inside an induction coil while the billet is being heated by electric induction. Two or more rails of a heat resistant ceramic material provide a curvilinear surface on which the billet can slide into and out of the coil and sit on during the heating process. Rail position adjustment means may be provided for moving the rails to accommodate billets of various sizes.

Abstract: An induction heating apparatus having a refractory vessel for holding a quantity of material to be heated by the apparatus. The vessel being surrounded by, but does not touch, an induction coil having a plurality of helical turns. The turns of the induction coil have a surface on which is disposed a layer of high temperature superconducting material.

Abstract: In one embodiment, an induction furnace is disclosed having a crucible, first and second set of induction coils surrounding the crucible and master and slave inverters, whereas in another embodiment, related to a channel-type induction furnace, the lower portion of the crucible houses at least first and second induction coils. The master and slave inverters each have a switching device with known turn-off-time characteristics for generating an alternating polarity output voltage across a load. The master inverter monitors the current, detects the zero-crossing of the current in the first induction coils, and generates a control signal in response to such detection of zero-crossing. The control signal is generated at an interval following the detection of the zero-crossing which is greater than the turn-off-time characteristic of the switching device.

Abstract: An apparatus for directing electromagnetic flux near an induction coil comprises a loop-shaped member adapted to conduct electromagnetic flux, defining an axis parallel to the central axis of the induction coil and extending substantially the length of the coil. The loop-shaped member acts as a return circuit for minimizing a stray magnetic field external to the coil.

Abstract: Power is controllably supplied to a resistive load. Power is passed from a power supply through a selectably operable switch directly to the resistive load and simultaneously to an energy storage device in parallel with the load. After a predetermined interval, the energy storage means causes the switch to open, thus causing the energy stored in the energy storage means to be transferred to the load. The switch is periodically closed according to a predetermined frequency.

Abstract: The instant invention is directed to a stopper rod spatial control mechanism for use in combination with a bottom discharge holding reservoir for molten metal having a nozzle. The mechanism comprises a base, an outer tube and an inner tube. The outer tube has a longitudinal axis which is perpendicular to the base. The outer tube is swingably mounted about an axis parallel to and spaced away from the longitudinal axis. The inner tube is telescopically mounted within the outer tube. The inner tube is reciprocally movable along the longitudinal axis and is rotatable about the longitudinal axis. A servomotor is mounted at a lower end of the outer tube. A ball screw is connected to and rotated by the motor. A ball nut is affixed to the inner tube and cooperates with the ball screw. A boom having a first end and a second end is affixed to the inner tube adjacent its first end and rotates with the inner tube about the longitudinal axis. A stopper rod depends from the second end of the boom.

Abstract: An apparatus and method for controlling the pour of molten metal into individuals molds. The apparatus comprises a reservoir for holding molten metal to be poured into at least one mold having a sprue and a mold gating system, and a flow control device operatively associated with the reservoir for controlling the flow of molten metal from the reservoir into the mold. A sensor continuously senses the image of the surface of the molten metal in the mold and generates image area information representative of the surface area of the metal relative to the surface of the mold. A sampling circuit repetitively samples the image area information during a pour and generates sampled image area information at a preselected sampling rate. A comparator repetitively compares the sampled image area information to a preselected reference area value and generates a difference value representative of the difference between the image area information and the reference area value.