Numerical Optimization of the Coil Geometry in a Large-Scale Levitation Melting Device—With Titanium as a Case Study

Electromagnetic levitation melting offers the opportunity for the energy-efficient processing of reactive and high-purity metals. This paper concerns a new levitator design that significantly expands the achievable mass of molten metal by processing a toroidal load within a device featuring an annular trough-shaped coil. However, this unconventional arrangement necessitates the optimization of the coil’s geometry and supply current to ensure the stable levitation of the charge. This paper discusses the methodology for such optimization, considering two variants of coil geometry modification. This developed methodology was initially validated using numerical simulation, based on a two-physics, coupled 2D process model, with a 2.6 kg titanium toroidal charge as an example.