The student Pablo García Michelena obtained an EXCELLENT CUM LAUDE grade
The student Pablo García Michelena obtained an EXCELLENT CUM LAUDE grade
The student Pablo García Michelena obtained an EXCELLENT CUM LAUDE grade
- Thesis title: Enhancement of Vacuum Induction Melting through Numerical and Experimental Investigation
Court:
- Presidency: Ricardo Torres Cámara (Universitat Politècnica de Catalunya)
- Vocal: Carl Slater (University of Warwick)
- Vocal: Iñaki Hurtado Hurtado (Mondragon Unibertsitatea)
- Vocal: Iñaki Madariaga Rodríguez (ITP Aero)
- Secretary: Daniel Bernal Rodriguez (Mondragon Unibertsitatea)
Abstract:
The aeronautic industry is renowned for its remarkable level of innovation and development of its products and processes. A constant pursuit in this field is enhancing the thermodynamic efficiency of engine cycles through the utilization of high-performance materials like nickel-based alloys in turbine and compressor components. The complex and precise chemical composition of these alloys necessitates advanced manufacturing processes. To achieve components of superior metallurgical quality with complex geometries and near-net-shaped criteria, the investment casting technology and Vacuum Induction Melting (VIM) are effectively combined.
The success of VIM technology lies in its vacuum atmosphere, which minimizes oxidation and the removal of alloying chemical elements from the liquid metal, ensuring precise composition of the final component. Moreover, it achieves high electrical efficiency through magnetic induction and resistive heating within the metal, along with rapid melting cycles. Although, the complex control of the process is challenging due to the coexistence of multiple physical phenomena during melting and various process variables, hindering the process improvement. In this field, numerical tools based on models are the optimal choice due to their balance between accuracy, speed, and cost.
This research project aims to enhance the VIM process by developing multi-physics models encompassing the main physical phenomena, including magnetic fields, fluid dynamics, and heat transfer, in a coupled manner. These models will be integrated and capture the interactions between these different fields while also allowing for the study of the impact of various process variables and deepening the understanding of VIM technology.
To validate the theoretical studies, a comparison with experimental references is necessary. Therefore, specific experimental tests were designed and conducted at the laboratory-scale VIM furnace to collect data on melting variables. In this manner, it has been possible to correlate with the numerical results and determine the uncertainty of the simulations. Once the validated tool was obtained, several case studies were considered, incorporating different configurations of industrial-scale VIM furnaces and dynamic operating conditions based on real industrial melting procedures. Finally, an improved melting procedure is proposed, aiming to increase thermal efficiency and reduce the process cycle time.