Segmented induction skull melting crucible and method
FIELD OF THE INVENTION 
     The invention relates to the induction melting of metals and alloys in a cooled, segmented, metal crucible. 
     BACKGROUND OF THE INVENTION 
     Induction melting processes and apparatus using a water cooled, segmented, copper crucible have been developed by the U.S. Bureau of Mines, for example as described in U.S. Pat. Nos. 3,775,091 and 4,058,668. These patents illustrate use of a CaF 2  skull in the crucible and refractory packing material/spacers between the crucible segments to electrically isolate the crucible segments. The CaF 2  type skull prevents contact between the molten metal and the crucible segments. Typically, the CaF 2  is melted and solidified on the cooled inner walls of the metal crucible segments to form an insulating lining or skull between the melt and the crucible. 
     U.S. Pat. No. 4,738,713 illustrates an induction melting process wherein a reactive metal is melted in a water cooled, segmented copper crucible in the absence of a CaF 2  lining or skull. In this patent, a refractory packing material is required between the tubular segments of the crucible to avoid molten metal penetration therebetween and subsequent skull locking. 
     Crucible designs of the type shown in these patents typically are based on fabrication of the segmented crucible sidewalls from a single monolithic copper forging wherein a sidewall of the forging is cut or machined to form a plurality of side-by-side segments with a relatively large gap width between the segments; e.g., a gap width of 0.010 inch or greater. As mentioned above, alumina spacers and/or refractory packing materials are provided in each gap to keep the crucible segments electrically separated and to inhibit molten metal penetration into the intersegment gaps. 
     Recent trends in the aerospace industry have sought to improve part service life by increasing cleanliness of the part; i.e., by reducing the quantity of harmful nonmetallic inclusions in the part microstructure. Although aforementioned U.S. Pat. Nos. 3,775,091 and 4,058,668 replace the ceramic melting pot heretofore used in conventional induction melting with the water cooled, segmented Cu crucible as a way to eliminate a known source of melt contamination (i.e., the ceramic melting pot), the use of a CaF 2  type lining in the crucible unfortunately introduces another source of melt contamination as recognized in Technical Bulletin 675 &#34;The Inductoslag Melting Process&#34;, U.S. Department Of The Interior, Bureau of Mines (1982). Moreover, the ceramic spacers and/or, refractory packing material positioned in the gaps between the crucible segments have been found to constitute still another source of contamination. For example, the ceramic spacers have been observed to break up during melting, presumably from thermal shock, with pieces of the spacers falling into the casting mold when the crucible is tilted to cast the melt into the mold. 
     Moreover, although U.S. Pat. No. 4,738,713 eliminates the need for the CaF 2  type lining (skull) in a segmented, copper crucible, this patent still requires a high temperature refractory packing in the gap between the segments from the top to the bottom thereof to prevent molten metal penetration between the segments. Thus, a source of melt contamination is still present in the crucible in the form of the refractory material packed in the intersegment gaps. 
     Furthermore, water cooled, segmented, copper crucibles heretofore used are known to suffer physical damage in use. This damage is in the form of outward spreading and/or bending of the upper portions of the crucible segments resulting from loading of the metal charge into the crucible chamber and from removing of the skull from the crucible. Segment spreading and/or bending is harmful to the casting process in that the CaF 2  type lining, if used, and/or refractory packing material between the segments can break loose and fall into and contaminate the melt. 
     There thus is a need in the art for a segmented, metal crucible which eliminates altogether the presence of a CaF 2  type lining in the crucible and also refractory packing material and/or spacers in the gaps between crucible segments so as to improve melt cleanliness. There is also a need in the art to provide a segmented, metal crucible wherein outward spreading and/or bending of the crucible segments is substantially eliminated to improve crucible durability in production applications where downtime is to be minimized. 
     SUMMARY OF THE INVENTION 
     The invention contemplates an improved segmented, metal crucible for use in the induction melting of metals that eliminates potential sources of contamination heretofore associated with segmented, metal crucibles. 
     The invention also contemplates an improved segmented, metal crucible for use in the induction melting of metals wherein the crucible includes means for substantially preventing spreading of the crucible segments during use. 
     The invention further contemplates an improved method of melting non-reactive metals, reactive metals, refractory metals as well as intermetallic compounds in a segmented metal crucible under vacuum or inert gas backfill conditions wherein sources of melt contamination heretofore associated with the crucible are substantially eliminated to improve melt cleanliness. 
     In one embodiment of the invention, the crucible includes an upstanding sidewall formed of a plurality of upstanding metal segments disposed in side-by-side relation about a longitudinal axis of said crucible. Each segment includes an inner wall facing the longitudinal axis for forming, together with the inner walls of other segments, a chamber for receiving the metal. Each segment is spaced apart from a next adjacent segment by a longitudinal gap that communicates with the chamber and extends outwardly from the chamber to the exterior of the sidewall. Each gap is free of refractory or other packing material that could constitute a potential source of melt contamination. Moreover, each gap is so sized in a width dimension where the gap and the chamber communicate as to substantially prevent penetration therein of metal in the molten state when the inner walls are initially directly contacted by the metal in the molten state. The crucible further includes means for inducing an alternating electrical current in the metal in the chamber to heat the metal to the molten state and means for cooling the segments to eventually form a solidified metal skull directly on the inner walls of the segments. 
     In another embodiment of the invention, the crucible includes an upstanding sidewall formed of a plurality of upstanding metal segments disposed in spaced apart side-by-side relation about a longitudinal axis of said crucible to form a chamber for receiving the metal, and restraining means disposed about upper portions of the crucible segments for preventing outward expansion or spreading of said segments away from said longitudinal axis. 
     The crucible of the invention can be used to melt a metal charge for over-the-lip casting processes, continuous ingot withdrawal processes and other processes requiring delivery or a source of molten metal. For over-the-lip casting, the crucible includes a base plug to form a bottom of the crucible chamber. For the continuous ingot withdrawal process, the crucible includes an open bottom to accommodate an ingot withdrawal mechanism. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a longitudinal cross-sectional view of a crucible constructed in accordance with the invention. 
     FIG. 2 is a cross-sectional view taken along lines 2--2 of FIG. 1 showing the individual metal segments arranged side-by-side about the longitudinal axis of the crucible. 
     FIG. 3 is a side elevation of an individual crucible segment. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     FIGS. 1-2 illustrate a crucible 10 in accordance with the invention. The crucible 10 includes an upstanding sidewall 11 formed of a plurality of individual upstanding segments 12 made of a highly heat conductive metal, such as preferably cooper. The crucible segments 12 are arranged in a side-by-side, annular relationship or array on a support base 14 about a longitudinal axis L of the crucible to form a crucible chamber 15. The crucible chamber 15 receives the metal (not shown) to be melted and contains the melt formed when the metal is subsequently heated by energization of induction coil 17 disposed about the sidewall 11. 
     Each segment 12 includes a lower segment foot 16, an upstanding segment sidewall 18 and an upper flange 20 extending radially outward relative to the axis L. Defined between the opposite radial sides 22, 24 of each segment is an inner wall 25. From FIGS. 1-2, it is apparent that the inner walls 25 of the segments 12 face the longitudinal axis L and collectively define the crucible chamber 15. As will be explained in more detail hereinbelow, the segments 12 are spaced apart from one another by longitudinal gaps G that communicate on the inside with the crucible chamber 15 (i.e., the gaps G open into the chamber 15) and that extend outwardly to the exterior side 29 of the sidewall 11 to break up induced electrical currents in the sidewall 11, thereby permitting the induction field generated by induction coil 17 to couple with the metal charge in the crucible chamber 15 to heat and melt same. The exterior side 29 may include chamfered corners as shown in FIG. 2 to reduce the amount of copper used in the sidewall 11. 
     As mentioned, the segments 12 are arranged in an annular, side-by-side array on the support base 14 which includes lower and upper base members 14a, 14b that constitute part of a water manifold assembly of the crucible 10 as will be described in detail hereinbelow. The lower foot 16 of each segment 12 is supported on the upper base member 14b when the segments 12 are arranged in the annular, side-by-side array. In particular, the lower foot 16 of each segment 12 includes a bottom wall 26 (FIG. 3) resting on the upper base member 14b and having a threaded hole 27 extending upwardly from the bottom wall 26 on the inner periphery thereof. As a result, each segment 12 can be releasably fastened to the support base 14 by a cap screw 30 extending through the lower and upper base members 14a, 14b and threaded into the tapped hole 27 of each segment 12 as shown in FIG. 1. Moreover, an arcuate, outer, radial shoulder 28 of each segment foot 16 is also releasably clamped to the support base 14 by an annular clamping ring 32 and a plurality of circumferentially spaced apart cap screws 34 extending through the lower and upper base members 14a, 14b and threaded into tapped holes 36 in the clamping ring 32. In this way, the segments 12 are releasably held in the annular, side-by-side array on the support base 14. 
     When the segments 12 are so held on the support base 14, the inner walls 25 of the segments 12 collectively form the crucible chamber 15 as mentioned hereinabove. In addition, the foot 16 of each segment 12 includes a lower inner wall 42. The inner walls 42 of the segments 12 collectively form a central cylindrical recess at the base of the crucible chamber 15. Received in the cylindrical recess is a metal base plug or member 46 that forms the bottom of the crucible chamber 15. The base plug 46 may be made of the same metal; e.g., copper, as the segments 12 or it may be made of another metal, for example, a refractory metal or a metal which is the same as the metal being melted in chamber 15. 
     The base plug 46 includes a downturned lip 46a that sealingly abuts a portion of the upper base member 14b and a central base member 14c. The central base member 14c is received in a central aperture 14d in the upper base member 14b and is fastened to the upper base member 14b by a plurality of circumferentially spaced apart screws 49. 
     As referred to hereinabove, the lower and upper base members 14a, 14b in part form a water manifold assembly for cooling the segments 12 as well as the base plug 46. The lower base member 14a includes an outer, annular water inlet manifold 40 receiving cooling water from a conventional source (not shown) through an inlet fitting 51. A portion of the cooling water in the inlet manifold 40 is circulated throuqh each segment 12 while the remainder of the cooling water in the inlet manifold 40 is circulated beneath the base plug 46. In particular, referring to FIG. 1, the inlet manifold 40 supplies cooling water to a flexible conduit 52, an inlet bore 54 in the central base member 14c and then into a cooling chamber 60 formed beneath the base plug 46. The cooling water is exhausted from chamber 60 via an outlet passage 62 in the central base member 14c and through flexible outlet conduit 64 to drain or to a heat exchanger for reuse. 
     Again referring to FIG. 1, the inlet manifold 40 supplies cooling water to each segment 12 through an apertured manifold ring 66, annular manifold chamber 68 formed in the upper base member 14b and then into a cooling passage 70 provided in each segment 12. The cooling water flows upwardly in each cooling passage 70 around a coolant return tube 72 disposed concentrically in each cooling passage 70. The cooling water then flows into the upper open end 72a of the coolant return tube 72 and downwardly out the open lower end 72b into an inner, annular, exhaust manifold 72 formed in the lower base member 14a. An outlet fitting (not shown) is connected to exhaust manifold 72 for discharging the cooling water to drain or to a heat exchanger for reuse. 
     In FIG. 1, the manifold ring 66 is shown disposed between the inlet manifold 40 in the lower base member 14a and the annular manifold chamber 68 formed in the upper base member 14b. The manifold ring 66 comprises a one-piece annulus having outer apertures 66a spaced circumferentially therearound so as to be disposed beneath each segment 12 for providing a flow of cooling water to the cooling passage 70 in each segment 12. The manifold ring 66 also includes inner apertures 66b spaced circumferentially apart so as to be disposed beneath the lower end 72b of each respective return tube 72, as shown, so as to receive the cooling fluid therefrom. The lower end 72b of each tube 72 is brazed at B to the manifold ring 66. 
     Suitable o-ring seals 80, 82, 84, 86, 88 are provided about the manifold ring 66 as shown in FIG. 1 to prevent leakage of cooling water between the manifold ring 66 and the lower and upper base members 14a, 14b. Similarly, the bottom wall 26 of each segment 12 includes an o-ring seal 90 extending about the bottom end of each coolant passage 70 as shown to prevent coolant leakage between each segment foot 16 and the upper base member 14b. 
     The longitudinal gaps G are provided between adjacent segments 12 to maintain sufficient electrical resistance between the segments 12 around the circumference of the crucible 10 to hinder and break up undesirable induced circumferential electrical eddy currents in the crucible and thus allow the induction field (generated by induction coil 17) to couple with the metal in the crucible chamber 15 for purposes of heating and melting the metal to the molten state. Each longitudinal gap G includes an inner portion GI so reduced in-a circumferential width dimension w where the inner portion GI and the crucible chamber 15 communicate as to substantially prevent the molten metal from penetrating into the gaps G upon initial melting of the metal charge in the chamber 15 prior to the development of a solidified metal skull against the inner walls 25. In particular, during initial melting of the metal charge as a result of energization of the induction coil 17, the molten metal directly contacts the inner walls 25 of the segments 12 for a period of time until the internal water cooling of the segments causes a solidified metal skull to freeze directly against the inner walls 25. The width dimension w is selected to prevent the molten metal from entering the gaps G during that period of time prior to the formation of the solidified metal skull directly against the inner walls 25. A circumferential width dimension w of less than 0.006 inch, preferably less than 0.003 inch, is selected for this purpose. 
     Importantly, in spite of the smallness of the width dimension w of each inner portion GI, the thin oxide tarnish or film formed in-situ in ambient air on the facing sides 22, 24 of the segments 12 has been found to provide sufficient electrical resistance between the adjacent segments 12 at the narrow inner portion GI to break up induced equatorial eddy currents to a sufficient degree to allow the induction field to couple with the metal charge in the crucible chamber 15. This insulative capability of the oxide tarnish or film at the inner portions GI of the gaps G is unexpected and surprising given the thinness of such ambient air-formed oxide films. Although not required, the thickness of the oxide film on each side 22, 24 can be increased by subjecting the segments 12 to an intentional higher temperature oxidizing pretreatment in air prior to assembling the segments 12 in the annular, side-by-side array on the support base 14. 
     The radial dimension r, FIGS. 2-3, of each inner portion GI is controlled to maintain the area of each narrow inner portion GI to a minimum consistent with its intended function as stated hereinabove. A radial dimension r of about 0.12 inch has been used successfully to this end. 
     Each longitudinal gap G also includes an outer portion GO that contributes to the electrical isolation of one crucible segment 12 from the next adjacent crucible segment. To this end, each outer portion GO is enlarged in a circumferential width dimension w, and radial dimension r, compared to the inner gap portion GI (i.e., compared to dimensions w and r of the inner portion GI). 
     As shown best in FIG. 2, each longitudinal gap G is formed between the sides 22, 24 of adjacent segments 12. In particular, the side 22 of each segment 12 includes an outer recess 110 and an inner raised land 112 while the facing side 24 of each segment 12 is configured as a vertical, planar surface such that the gap G is formed between adjacent segments 12 when they are arranged in the annular, side-by-side array on the support base 14. 
     From FIG. 2, it is apparent that the longitudinal gaps G are completely free of refractory or other packing and spacer material (hereafter collectively referred to as packing material) that constitute potential sources of melt contamination heretofore associated with prior art segmented crucible constructions used in the induction melting of metals. As will be discussed more fully hereinbelow, the cleanliness of the melt contained in the crucible chamber 15 is thereby significantly improved. 
     Referring to FIG. 1, the upper flanges 20 of the segments 12 are restrained against outward (radial) expansion or spreading away from the axis L by a restraining means in the form of a non-conductive (e.g., MICRATA® phenolic resin material), one-piece retaining ring 120. A portion of the retaining ring 120 is received in a recess 122 formed beneath each flange 20 adjacent its outer periphery for protection from potential damage by the introduction of the solid metal charge into the crucible chamber 15 as well as molten metal confined in the chamber and poured over the flanges 20 if the crucible is used in over-the-lip casting applications. That portion of the retaining ring 120 received beneath each flange 20 is fastened to the flange 20 of each segment 12 using a nylon or other electrically non-conductive screw 124 threaded into a threaded hole 126 on the underside of each flange 20. The retaining ring 120 includes a plurality of threaded holes 128 and associated counterbores 130 aligned coaxially with the holes 126 for receiving a respective screw 122. 
     Referring to FIG. 1, the retaining ring 120, when fastened to the flanges 20, will exert a radially inward restraining pressure on upper portions of the segments by virtue of the chamfered inner annular surface 120a of the retaining ring 120 engaging a complimentarily chamfered or tapered outer, arcuate surface 20a machined on each flange 20. 
     A crucible 10 as shown in FIGS. 1-2 was fabricated and installed in a vacuum chamber for successively melting two charges of IN713C nickel base superalloy. The first charge melted in the crucible included 10 pounds of the IN713C superalloy in ingot form. The second charge melted included 15 pounds of the IN713C in the same form. These first and second charges were successfully melted in succession in the crucible without the use of a CaF 2  type lining (skull) and without any packing or other material whatsoever in the gaps G between the crucible segments 12. The charges melted easily and superheats of at least 30° F. were attained. The molten charge was allowed to solidify in the crucible in each melting trial and the resulting solidified slugs were easily extracted from the crucible. There was no evidence of metal penetration into the intersegment gaps G, suggesting that no skull locking problem will be experienced with the crucible 10. 
     Examination of the crucible segments 12 verified that no arcing or localized melting between the crucible segments 12 occurred during use. The combination of the longitudinal gaps G and the oxide tarnish or film separating adjacent sides 20, 22 of the segments 12 was sufficient to inhibit equatorial induced current flow around the crucible circumference and permit the induction field generated by the induction coil 90 to heat and melt the metal charge in the crucible chamber 15. No evidence of outward spreading of the upper portions of the crucible segments 12 was observed following these casting trials. 
     The crucible and melting process of the invention described hereinabove are advantageous in that there is no need for a CaF 2  type crucible lining (skull) and no need for refractory packing material in the gaps G between the segments 12. The invention thus provides a clean, &#34;ceramicless&#34; crucible which reduces melt contamination from sources heretofore associated with segmented, metal crucibles and enables the production of cleaner castings with reduced levels of inclusion contaminants. Moreover, the crucible and method of the invention are further advantageous in that the outward spreading of upper portions of the crucible segments is substantially prevented, rendering the crucible durable enough to perform over extended time periods in a production environment. 
     In addition, since the crucible segments 12 are preferably individually machined with the features described hereinabove and are releasably secured at their lower ends to the support base 14 and releasably restrained against outward expansion at their upper portion, any damaged segment can be easily replaced with a like, individually machined segment 12 without the need to replace any other undamaged segment 12 of the crucible. However, the invention is not limited to use of individually machined segments 12 to form the crucible 10. For example, although less preferred, the crucible 10 can be machined from a single monolithic copper forging. 
     The crucible 10 may be used to melt a metal charge for over-the-lip casting processes, continuous ingot withdrawal processes (e.g., as shown in U.S. Pat. 3,775,091) and other processes requiring delivery or a source of molten metal. Those skilled in the art will appreciate that the crucible 10 can be modified within the scope of the present invention for carrying out a particular casting process. For example, for the continuous ingot withdrawal process, the bottom of the crucible 10 would be open to permit entry and movement of an ingot withdrawal mechanism such as shown in aforementioned U.S Pat. No. 3,775,091. 
     In accordance with the method of the invention, non-reactive metals (such as superalloys), refractory metals (such as hafnium, molybdenum, niobium), reactive metals (such as titanium and its alloys) and intermetallics (such as aluminides) are melted in the crucible 10 described hereinabove by suitable energization of the induction coil 17 and under vacuum or an inert gas backfill, as desired, to improve melt cleanliness and the melt is then cast using the aforementioned over-the-lip casting process, ingot withdrawal process or other casting process. 
     Although less preferred in accordance with the invention, a thin layer (not shown) of low conductivity metal, such as titaniun, or non-conductive refractory material, such as boron nitride, may be present in the inner portions GI of the gaps G to enhance the action of the induction field on the metal charge in the crucible chamber 15 and thereby improve melting efficiency. The metal or refractory material can be applied directly to one or both of the sides 22, 24 of the segments 12. This approach may be used, for example, in melting a charge in the crucible chamber 15 where cleanliness of the melt is of less concern but where it is necessary to minimize outward spreading of the upper portions of the segments 12 by use of the retaining ring 120. 
     Furthermore, while the invention has been described hereinabove in terms of specific embodiments thereof, it is not intended to be limited thereto but rather only to the extent set forth hereafter in the following claims.