METAL CASTING METHOD AND SYSTEM

Abstract

A system (1) for casting metal (2), the system (1) comprising a mold (6) with a feeder (4) supplying a casting section (3). The system (1) comprises an insulating sleeve (10) surrounding at least a portion of the feeder (4) and an induction coil element (20) for placement outside the insulating sleeve (10). The induction coil element (20) comprises an induction coil (21) and a cooling channel (22) for controlling the temperature of the metal (2) within the feeder (4). The system (1) comprises a control unit (30) connected to the induction coil element (20) for controlling power to the induction coil (21) and for providing a flow of coolant to the cooling channel (22). The system further comprises a temperature sensor (40) for sensing a temperature at a fixed location within the feeder (4), the temperature sensor (40) being in communication with the control unit (30).

Description

[Technical Field]

[0001] The present invention relates to metal casting, and more particularly to improving feeder utilization in metal casting.

[0002] Background technology In metal casting, feeders are utilized to fill the metal volume of the casting section that has been reduced by thermal contraction. As the temperature of the metal decreases, the metal density increases. The feeder is the volume of the mold occupied by molten metal when the metal is in its liquid phase and acts as a reservoir to supply the metal to the casting section once it solidifies. The primary principle behind feeder design has traditionally been to design the mold with sufficient feeder volume to ensure that the metal in the lower part of the feeder closest to the casting section solidifies after the casting section. It is also desirable to prevent negative solidification effects such as cavitation, material tension, material quality degradation, and cracking within the casting section. To achieve this, and to provide some margin, feeders have traditionally been designed to be quite large, resulting in significant heating costs, additional material costs, and excessive material handling costs.

[0003] It is known to provide a heat-generating sleeve around a feeder to delay solidification in the feeder, i.e., to prolong the liquid phase of the metal in the feeder. This heat-generating sleeve can control the temperature of the metal in the feeder, and such an element can be placed on an insulating sleeve surrounding the feeder to directly or indirectly control the temperature of the metal in the feeder. It is also known to provide an insulating sleeve around the feeder to confine the molten metal and define the feeder volume. Due to their shape and material constraints, known insulating sleeves are prone to significant heat transfer from the molten metal to the surrounding mold.

[0004] Furthermore, there has been no technical solution capable of delivering metal castings with a 100% metal yield target in the feeder. Traditionally, the volume of metal in the feeder is large, resulting in wear and tear on machinery and equipment, excessive energy usage, and limited by available furnaces and crucibles. Accurately controlling the delivery of molten metal from the feeder to the casting section is a problem in the field of metal casting due to solidification within the feeder itself. This leads to excessive use of molten metal and energy to melt the solidified metal. Current technologies for delivering metal castings are directly related to both the total volume of the casting, which determines the amount of metal needed from the feeder, and the largest sphere in the casting section. This determines the solidification time and, therefore, the time required for delivery. A system is needed to precisely regulate the temperature of the metal in the feeder, accurately control the solidification of the metal in the feeder, and thus maximize feeder utilization.

[0005] The typical metal casting process involves several tedious steps, including one-time use. The preparation of mold and feeder designs, the installation of insulating sleeves, etc., make traditional metal casting a laborious process that is not well suited to serial production of cast parts.

[0006] Therefore, there is a need for an improved method and system for metal casting that reduces or eliminates the above-mentioned shortcomings of known techniques. References useful for understanding this field include Japanese Patent No. 4494868, Japanese Patent Laid-Open No. 9-314310, and U.S. Patent No. 8,056,608.

[0007] Summary of the Invention The present invention aims to mitigate, alleviate, or eliminate one or more of the above-identified deficiencies and drawbacks of the prior art, or at least solve the above-mentioned problems. It is also an object of the present invention to provide a method and structure that can minimize or at least reduce the size of the feeder and the amount of molten metal therein. It is an object of the present invention to reduce the cost of heating the feeder. It is an object of the present invention to minimize the excess material volume of the resulting casting and minimize material inventory for the casting process. It is an object of the present invention to provide a method and structure that can improve the quality of the resulting casting with respect to manufacturing cost, reduction or elimination of structural defects such as voids and cracks, phase uniformity, and surface tension.

[0008] According to a first aspect, there is provided a system for casting metal, the system comprising: a mold having a feeder feeding a casting section; an insulating sleeve surrounding at least a portion of the feeder; an induction coil element for placement outside the insulating sleeve, the induction coil element comprising an induction coil and cooling channels for controlling the temperature of the metal in the feeder; a control unit connected to the induction coil element for controlling power to the induction coil and for providing coolant flow to the cooling channel; a temperature sensor for sensing temperature at a fixed position within the feeder, the temperature sensor being in communication with the control unit; Equipped with.

[0009] According to one embodiment, the temperature sensor is connected to the induction coil element by a sensor support element.

[0010] According to one embodiment, the sensor support element comprises a base for fixing on top of induction coil elements of different diameters and a holding element for fixing the temperature sensor in the vertical direction.

[0011] According to one embodiment, the insulating sleeve comprises a disk element removably connected to a tube element.

[0012] According to one embodiment, the tube element comprises a stop element, the disc element comprises an opening, the disc element has an outer diameter extending radially outward from the stop element, and the disc element is configured to be threaded onto the tube element and abut against the stop element.

[0013] According to one embodiment, the disk element is made of an insulating material and the tube element is made of a thermal shock resistant material.

[0014] According to one embodiment, the induction coil element is a tubular element, and the induction coil and cooling channels are embedded in the induction coil element.

[0015] According to a second aspect, there is provided a method of casting metal, the method comprising: providing a mold comprising a feeder and an insulating sleeve, the insulating sleeve surrounding at least a portion of the feeder; placing an induction coil element on the insulating sleeve; connecting the induction coil element to a control unit for controlling the temperature of the metal in the feeder; filling the mold with molten metal; measuring or predicting a temperature at a fixed location within the feeder; controlling the solidification of metal in the feeder by controlling the temperature generated by the induction coil element; removing the induction coil element from the insulating sleeve and mold; Includes.

[0016] According to one embodiment, the step of providing a mold comprising a feeder and an insulating sleeve further comprises the step of providing a dummy coil element, the dummy coil element surrounding at least a portion of the insulating sleeve, and the method further comprises the step of removing the dummy coil element from the insulating sleeve prior to the step of placing the induction coil element on the insulating sleeve.

[0017] According to one embodiment, the induction coil element comprises an induction coil and a cooling channel, and controlling the temperature generated by the induction coil element includes adjusting the power of the induction coil based on a measured or predicted temperature at a fixed position in the feeder.

[0018] Aspects of the present invention, including its particular features and advantages, will be readily understood from the following detailed description and the accompanying drawings, which are provided to illustrate the general structure of the invention, and like reference numerals refer to like elements throughout. [Brief explanation of the drawings]

[0019] [Figure 1] 1 is an isometric view of elements of a system for casting metal, including a casting part, an insulating sleeve, an induction coil element, and a control unit. FIG. [Figure 2] 1 is a cross-sectional view through elements of a mold for casting metal, the metal in liquid phase being shown in the casting section and the feeder; [Figure 3] FIG. 1 is an isometric exploded view of an insulating sleeve, an induction coil element, and a temperature sensor. [Figure 4a] 1A-1D are cross-sectional views illustrating steps in a method for casting metal. [Figure 4b] 1A-1D are cross-sectional views illustrating steps in a method for casting metal. [Figure 4c] 1A-1D are cross-sectional views illustrating steps in a method for casting metal. [Figure 4d] 1A-1D are cross-sectional views illustrating steps in a method for casting metal. [Figure 4e] 1A-1D are cross-sectional views illustrating steps in a method for casting metal. [Figure 4f] 1A-1D are cross-sectional views illustrating steps in a method for casting metal. [Figure 4g] 1A-1D are cross-sectional views illustrating steps in a method for casting metal.

[0020] MODE FOR CARRYING OUT THE INVENTION The present invention will now be described with reference to the accompanying drawings, in which preferred exemplary embodiments of the invention are shown. However, the present invention may be embodied in other forms and should not be construed as limited to the embodiments disclosed herein. The disclosed embodiments are provided so that the scope of the invention will be fully conveyed to those skilled in the art.

[0021] It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting. It should be noted that, as used in this specification and the appended claims, the articles "a," "an," and "the" are intended to mean that there are one or more of an element, unless the context clearly dictates otherwise. Thus, for example, reference to "a unit" or "the unit" may include several devices, etc. Furthermore, the use of "comprising," "including," "containing," and similar expressions does not exclude other elements or steps.

[0022] Referring to Figures 1, 2, and 3, a system 1 for casting metal 2 is shown. When a casting part 3 is cast, metal 2 resides within the volume of the casting part 3, within a feeder 4, and within a runner or gate 5 (not shown in Figures 1-3, see Figures 4a-4g). The casting part 3 is shown as a sphere. A mold 6 is not shown in Figures 1-3; it is shown in Figures 4a-4g. Thus, the feeder 4 is part of the casting part 3 and is utilized to fill the metal volume of the casting part 3 that has been reduced by thermal contraction. The volume of the feeder 4 is therefore dependent on the volume of metal 2 that is delivered to the casting part 3 and subsequently solidifies. Metal 2 is delivered to the casting part 3 and feeder 4 through the gate 5, which will be described in more detail with reference to Figures 4a-4g.

[0023] An insulating sleeve 10 defines the feeder 4 within the mold. The insulating sleeve 10 is positioned on top of the casting section 3. At least a portion of the insulating sleeve 10 is thermal shock resistant. The insulating sleeve 10 functions as an insulating layer between the molten metal 2 inside the feeder 4 and the surrounding mold (both radially from the feeder 4), but also serves to separate the volume outside the feeder 4 from the underlying casting section 3. The insulating sleeve 10 comprises two separate elements: a disk element 10a and a tube element 10b. The disk element 10a may be a substantially flat element, for example, manufactured from a plate. The disk element 10a comprises an opening 11. The opening 11 preferably extends through the disk element 10a in a direction perpendicular to the disk element 10a. The opening 11 may be located in the center of the disk element 10a so that the disk element 10a has the shape of a cross-section of revolution.

[0024] The tube element 10b can have an outer diameter that corresponds to or is slightly smaller than the diameter of the opening 11 of the disk element 10a. The disk element 10a is therefore configured to be screwed onto the tube element 10b. The tube element 10b further comprises a stop element 12. The stop element 12 is preferably provided at a longitudinal end of the tube element 10b. The disk element 10a has an outer diameter that extends radially outward from the stop element 12. The stop element 12 may preferably be a circumferential flange extending around the tube element 10b. The stop element 12 is configured to abut against the disk element 10a, so that the disk element 10a can rest on the stop element 12, as shown in FIG. 2.

[0025] Because the insulating sleeve 10 is made from two separate elements, manufacturing and shipping of the insulating sleeve 10 is greatly simplified. The disk element 10a can be manufactured, for example, by stamping a plate, casting in a mold, or by other known methods of manufacturing disk elements. Manufacturing of the tube element 10b can also be greatly simplified. Shipping of the insulating sleeve 10 can also be more efficient in that the disk element 10a and the tube element 10b can be shipped separately, thus allowing a plurality of the two separate elements to be shipped in a much more compact and space-efficient manner.

[0026] The disk element 10a may be made from a different material than the tube element 10b, allowing for optimal material properties for each of the two elements of the insulating sleeve 10. The disk element 10a is not in direct contact with the molten metal 2 and can have different material properties than the tube element 10b. In one embodiment, the tube element 10b is made from a thermal shock resistant material, preferably a fibrous thermal shock resistant material, while the disk element 10a is made from a material with enhanced insulating properties, but may not be thermal shock resistant. Preferably, the insulating sleeve 10 is not made from metal, as this would prevent induction heating of the metal 2 in the feeder 4.

[0027] The system 1 includes an induction coil element 20. The induction coil element 20 is preferably a tubular element including an induction coil 21 and cooling channels 22. The cooling channels 22 may be embedded in the induction coil 21, as in the illustrated embodiment. The induction coil element 20 may be configured to be disposed outside the insulating sleeve 10, threaded onto the insulating sleeve 10, and rest on the disk element 10a. The insulating sleeve 10 acts as an insulating layer between the molten metal 2 in the feeder 4 and the induction coil element 20. Therefore, the induction coil element 20 can be installed or removed independently of the presence of the metal 2 in the feeder 4. When power is supplied to the induction coil element 20, the induction coil 21 works in conjunction with the metal 2 in the feeder 4 to heat or maintain the temperature of the metal 2 by induction heating.

[0028] The induction coil 21 and cooling channels 22 are preferably embedded within the induction coil element 20 and are therefore protected by the outer surface of the coil element 20. The induction coil element 20 is thus a single element that can be relocated from one mold to another and includes a means for controlled heating and cooling of the feeder 4. When the induction coil element 20 is threaded onto the insulating sleeve 10, the induction coil 21 and cooling channels 22 are thus positioned around the feeder 4. The induction coil element 20 may include a hoisting means 23 to provide easy and reliable lifting and hoisting of the induction coil element 20. The hoisting means 23 may be a pad eye or similar means known in the art of hoisting. The induction coil element 20 may be lifted by a crane, forklift, or other means known in the art of hoisting. Thus, the induction coil element 20 can be easily lifted, for example, from one system 1 for casting metal to another.

[0029] In one embodiment, the induction coil 21 includes two induction coils: a first induction coil 21a and a second induction coil 21b. Thus, the induction coil element 20 may include at least one induction coil, and preferably at least two induction coils. The first and second induction coils 21a, 21b are preferably arranged consecutively along the length of the induction coil element 20. The at least two induction coils 21a, 21b may be independently controlled so that power is distributed to both induction coils 21a, 21b when the feeder 4 is filled with metal 2, but as the level of metal 2 in the feeder 4 decreases, power is distributed only to the lower, second induction coil 21b. This makes the system 1 energy efficient.

[0030] The induction coil element 20 is connected to the control unit 30 by a connection means 31, as shown in FIG. 1. The connection means 31 may include cables and tubes for transmitting power and supplying and receiving coolant from the induction coil element 20. The coolant is preferably a liquid coolant. Furthermore, the control unit 30 may communicate wirelessly with the induction coil element 20. The control unit 30 is preferably a separate unit configured to supply power to the induction coil 21. The power input to the induction coil element 20 (and thus the frequency of the induction coil 21) depends on the volume, alloy, and temperature of the metal 2 in the feeder 4. The power input may also take into account heat loss through the insulating sleeve 10. The control unit 30 may also control the flow of coolant into the cooling channel 22. The flow rate of the coolant may be constant. The control unit 30 may also cool the coolant as it is received from the induction coil element 20. Thus, the control unit 30 can control the temperature of the metal 2 in the feeder 4.

[0031] The system 1 includes a temperature sensor 40 for detecting the temperature of the metal 2 at a fixed position within the feeder 4. The temperature sensor 40 may include an elongated element. The elongated element allows the temperature sensor to be connected to the induction coil element 20 and supported in a fixed position, for example, away from the location where the actual temperature is measured. In one embodiment, the temperature sensor 40 may be a thermocouple, as in the illustrated embodiment. The temperature sensor 40 is preferably fixed to the induction coil element 20. More preferably, the temperature sensor 40 is fixed to the upper part of the induction coil element 20. The induction coil element 20 may have end faces at each lateral end thereof. Thus, the temperature sensor 40 may be connected to the upper surface 24 of the induction coil element 20. More preferably, the temperature sensor 40 may be connected to the induction coil element 20 by a sensor support element 41. The sensor support element 41 may be releasably connected to the upper surface 24. Preferably, the sensor support element 41 includes a base 42 for fastening to the induction coil element 20. The base 42 is configured to connect to induction coil elements 20 of different diameters. The base 42 may include a curved portion, as in the illustrated embodiment. The base 42 may further include an elongated slot 43 that may provide a fastening means, for example, to easily accommodate the top surface 24 of induction coil elements 20 of different diameters.

[0032] The sensor support element 41 may further include a retaining element 44. A first element of the retaining element 44 may be fixed to the base 42. A second element may be adjustable and lockable to bias and hold the temperature sensor 40 within the retaining element 44. The second element may be tightened to securely hold the temperature sensor 40 in place. Because the temperature is measured at a fixed position inside the molten metal 2, detailed information such as temperature, feeder volume, etc. can be monitored and used to precisely control the temperature and solidification of the metal 2 within the feeder 4. The data may also be used in subsequent casting.

[0033] The temperature sensor 40 may be positioned within the feeder 4 so that the temperature is measured generally at the radial center of the feeder 4 (and thus at the center of the insulating sleeve 10 and the induction coil element 20). The temperature sensor 40 may further be positioned so that the temperature is measured at a lower portion of the feeder, for example, next to the casting section 3. Once the metal 2 in the casting section 3 and feeder 4 finally solidifies, the temperature sensor 40 can be adjusted and positioned before the molten metal 2 is poured into the mold, so that the temperature sensor 40 is not embedded in the solidified metal. The temperature sensor 40 can therefore be reused later in the casting process. Due to the high utilization of the metal 2 in the feeder 4, the temperature sensor 40 may be fixedly mounted on the feeder 4 adjacent to the casting section 3.

[0034] The temperature sensed by the temperature sensor 40 is communicated to the control unit 30. Communication may be wireless or via a connection means 31. Depending on the sensed temperature, the control unit 30 may increase or decrease the power to the induction coil element 20 to increase or decrease the temperature of the metal 2 in the feeder 4. Furthermore, since the solidification temperature of the metal 2 in the system 1 is known, the control unit 30 determines the amount of power to transmit to the induction coil 21 to generate an optimal solidification sequence. Alternatively, the control unit 30 may also control the amount of coolant delivered to the cooling channel 22. The amount of heat supplied to the feeder 4 by the induction coil element 20 is based on the sensed temperature in the feeder 4. Because the exact temperature in the feeder 4 is known and controlled, it is not necessary to consider the maximum sphere size of the casting, which provides a significant advantage to the system 1.

[0035] Referring now to FIGS. 4a-4g, a method for casting metal 2 will be described. The control unit 30 is not shown in FIGS. 4a-4g. First, as shown in FIG. 4a, a system 1 is provided that includes a mold 6. In one embodiment, the mold 6 may include a sand mold, but in other embodiments, it may include other molds, such as high-pressure die casting. The mold 6 includes a feeder 4 and a sprue 5. The feeder 4 is defined by an insulating sleeve 10 that forms part of the mold 6. The system 1 may further include a dummy coil element 50. The mold 6 may be fabricated by placing the dummy coil element 50 on the insulating sleeve 10, and providing the mold 6 may include providing the dummy coil element 50. The dummy coil element 50 can prevent sand from the mold 6 from entering the space where the induction coil element 20 will be placed in a later step and can also enable easy removal of the induction coil element 20 by occupying more space than the induction coil element 20. The step of providing the insulating sleeve 10 and the dummy coil element 50 makes it possible to prepare the mold 6 before filling it with the molten metal 2. In this way, the induction coil element 20 may be provided only when necessary, i.e., during filling of the mold 6 and solidification of the metal 2 in the feeder 4.

[0036] The insulating sleeve 10 is preferably made from two separate elements as previously described with reference to Figure 3. The insulating sleeve 10 surrounds at least a portion of the feeder 4.

[0037] When the mold 6 with the dummy coil elements 50 is provided, the dummy coil elements 50 are removed, as shown in Figure 4b. A space 51 in the form of an annulus remains empty in the mold 6 around the insulating sleeve 10. In a next step, the induction coil elements 20 are placed in the space 51, which allows for an efficient use of the induction coil elements 20 and allows for an efficient continuous production.

[0038] The next step is to install the induction coil element 20 in the mold 6, which is shown in FIG. 4c. The induction coil element 20 is screwed onto the insulating sleeve 10 and into the space 51. The induction coil element 20 comprises an induction coil and cooling channels (not shown in FIGS. 4a-4g), as described with reference to FIG. 2. The method further comprises connecting the induction coil element 20 to a control unit 30 (not shown in FIGS. 4a-4g), as described with reference to FIG. 1. Alternatively, the induction coil element 20 may be connected to the control unit 30 before being installed in the mold 6.

[0039] When the induction coil element 20 is installed in the mold 6, it occupies most of the space 51, as shown in FIG. 4d. The temperature sensor 40 may be provided on the induction coil element 20 after the induction coil element 20 is installed on the insulating sleeve 10, and the temperature sensor 40 may be connected to the induction coil element 20 as described with reference to FIGS. 2 and 3. Thus, the temperature sensor 40 can measure the temperature at a fixed position within the feeder 4. Alternatively, the temperature sensor 40 may be provided on the induction coil element 20 before the induction coil element 20 is installed on the insulating sleeve 10. For example, if the level of the solidified metal in the feeder 4 is known before the casting process begins, the lowest part of the temperature sensor 40 is advantageously positioned so that it is directly above the solidified metal 2 in the feeder 4. Once the induction coil element 20 is connected to the control unit 30, the mold 6 is ready to receive the molten metal.

[0040] The next step is filling the mold 6 with molten metal 2. Figure 4e shows the molten metal 2 in the mold 6. The molten metal 2 is fed into the casting section 3 through the sprue 5. The molten metal 2 rises through the casting section 3 and is also present in the feeder 4 as the mold 6 is filled. The metal 2 is shown in a honeycomb pattern in Figure 4e. The solidification of the metal 2 occurs from Figure 4e to Figure 4f. If the density of the solidified metal is higher than that of the molten metal, the volume of the metal 2 decreases as it solidifies. The solidification of the metal 2 in the feeder 4 is controlled by monitoring the temperature of the metal 2 in the feeder 4 and maintaining its liquid phase as the casting section 3 solidifies. By maintaining the temperature of the metal 2 in the feeder 4 higher than the temperature of the casting section 3, the metal 2 is prevented from solidifying in the feeder 4. This is achieved by the control unit controlling the temperature generated by the induction coil element 20. The temperature of the metal 2 in the feeder 4 can be accurately monitored by the temperature sensor 40. Thus, the exact temperature of the metal 2 in the feeder 4 can be monitored and maintained just above the solidification temperature, for example, to minimize energy usage and accommodate controlled and optimized solidification. If the temperature sensor 40 is located directly above the casting section 3 (i.e., at the bottom of the feeder 4), the temperature of the top of the casting section 3 is known and the temperature of the metal 2 in the feeder 4 can be monitored even more accurately.

[0041] Figure 4g shows the removal of the induction coil element 20 from the insulating sleeve 10 and mold 6. This step can occur when the casting 3 solidifies or when the feeder 4 is no longer needed. The induction coil element 20 can be removed immediately when it is no longer needed, thus maximizing its utilization. The temperature sensor 40 can be removed along with the induction coil element 20, and the induction coil element 20 and temperature sensor 40 can be reused in the next metal casting process. If the next metal casting is identical to the previous one, the induction coil element 20 can remain connected to the control unit, allowing the next metal casting to begin quickly. When similar metal castings are performed, data from the detected temperature of the temperature sensor 40 can be used to predict the solidification of subsequent casting processes, and the temperature sensor 40 can even be omitted. Temperature data, such as the temperature curves of the system 1 and mold 6 at the measured fixed position in the center of the feeder 4, can be stored and used, for example, to predict other temperature curves and train a program to predict the solidification of metal 2 in the system 1 that is not directly measured.

[0042] As is known in the art of manufacturing cast metal parts, it may be necessary to further process the cast part 3. However, because the amount of metal 2 in the feeder 4 is minimized, the cast part 3 requires less such processing, resulting in less waste from the casting process.

[0043] Although the invention has been described with reference to the above embodiments, it should be understood that modifications and variations can be made without departing from the scope of the invention, and that such modifications and variations shall remain within the sphere and scope of the invention as defined by the appended claims.

Claims

1. A system (1) for casting metal (2), comprising: a mold (6) equipped with a feeder (4) supplying the casting section (3); an insulating sleeve (10) surrounding at least a portion of the feeder (4); an induction coil element (20) for placement outside the insulating sleeve (10), the induction coil element (20) comprising an induction coil (21) and cooling channels (22) for controlling the temperature of the metal (2) in the feeder (4); a control unit (30) connected to the induction coil element (20) for controlling power to the induction coil (21) and for providing a flow of coolant to the cooling channel (22); a temperature sensor (40) for sensing temperature at a fixed position within the feeder (4), the temperature sensor (40) being in communication with the control unit (30); A system (1) for casting metal (2), comprising:

2. 2. The system (1) for casting metal (2) according to claim 1, wherein the temperature sensor (40) is connected to the induction coil element (20) by a sensor support element (41).

3. 3. The system (1) for casting metal (2) according to claim 2, wherein the sensor support element (41) comprises a base (43) for fixing on top of induction coil elements (20) of different diameters and a holding element (44) for fixing the temperature sensor (40) in a vertical direction.

4. 4. The system (1) for casting metal (2) according to any one of claims 1 to 3, wherein the insulating sleeve (10) comprises a disk element (10a) removably connected to a tube element (10b).

5. 5. The system (1) for casting metal (2) according to claim 4, wherein the tube element (10b) comprises a stop element (12), the disk element (10a) comprises an opening (11), the disk element (10a) has an outer diameter extending radially outwardly of the stop element (12), and the disk element (10a) is configured to be threaded onto the tube element (10b) and abut against the stop element (12).

6. 6. The system (1) for casting metal (2) according to claim 4 or 5, wherein said disk element (10a) is made of an insulating material and said tube element (10b) is made of a thermal shock resistant material.

7. 7. The system (1) for casting metal (2) according to any one of claims 1 to 6, wherein the induction coil element (20) is a tubular element, and the induction coil (21) and the cooling channels (22) are embedded in the induction coil element (20).

8. A method for casting a metal (2), comprising the steps of: providing a mold (6) comprising a feeder (4) and an insulating sleeve (10), said insulating sleeve (10) surrounding at least a portion of said feeder (4); placing an induction coil element (20) on the insulating sleeve (10); connecting the induction coil element (20) to a control unit (30) for controlling the temperature of the metal (2) in the feeder (4); Filling the mold (6) with molten metal (2); measuring or predicting said temperature at a fixed location within said feeder (4); controlling the solidification of the metal (2) in the feeder (4) by controlling the temperature generated by the induction coil element (20); removing the induction coil element (20) from the insulating sleeve (10) and the mold (6); A method for casting a metal (2), comprising:

9. 9. The method for casting metal (2) according to claim 8, wherein the step of providing a mold (6) comprising a feeder (4) and an insulating sleeve (10) further comprises the step of providing a dummy coil element (50), the dummy coil element (50) surrounding at least a portion of the insulating sleeve (10), and the method further comprises the step of removing the dummy coil element (50) from the insulating sleeve (10) before the step of placing the induction coil element (20) on the insulating sleeve (10).

10. 10. The method for casting metal (2) according to claim 8 or 9, wherein the induction coil element (20) comprises an induction coil (21) and a cooling channel (22), and wherein controlling the temperature generated by the induction coil element (20) comprises adjusting the power of the induction coil (21) based on the measured or predicted temperature at a fixed position in the feeder (4).

Images