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Induction skull melting (ISM) technology could melt metals with avoiding contamination from crucible. A long-standing problem of ISM is that the low charge energy utilization and inhomogeneous fields have obstructed its application in many critical metal materials and manufacturing processes. The present work investigated the problem through the structure optimization strategy and established a numerical electromagnetic-field model to evaluate components' eddy current loss. Based on the model, the effect of crucible and inductor structure on charge energy utilization, etc. was studied. Furtherly, the charge energy utilization was increased from 27.1 to 45.89% by adjusting the system structure. Moreover, structure modifications are proposed for enhancing electromagnetic intensity and uniformity, charge soft contact and uniform heating. The work constructed a basis for framing new solutions to the problem through ISM device structure optimization. [ABSTRACT FROM AUTHOR]

High-purity melting is critical for casting metallic glass components, which would be achieved by developing the induction skull melting (ISM) technology used in casting process. The melting process of metallic glass components during ISM is urgently desired to be understood, which is rare so far. Based on this, a full-scale coupling simulation model for ISM technology with finite element method (FEM) was proposed, which contains all physical fields engaged in the melting processes. Furthermore, the metallic glass melting process was experimentally and numerically investigated based on the full-scale coupling model. The distribution of the multi-physics field within the charge was elaborated based on the numerical simulation results, especially electromagnetic field contribution, heat transfer, meniscus shape and melt reflux zone. Furthermore, due to its high viscosity, a long holding time to improve melt homogeneity is necessary for metallic glass melt. The chief aim of this work is to understand of induction melting process for melting amorphous master alloys using induction skull melting technology and to provide a foundation for the casting method to form bulk metallic glasses. [ABSTRACT FROM AUTHOR]