Frequency and Current Analysis for Aluminum Billet Lifting with a Longitudinal Electromagnetic Levitator Prototype

Magnetic levitation enables the confinement and melting of conductive metals using alternating magnetic fields, eliminating the need for a crucible or other contact supports. This makes the technology particularly suitable for applications where container use is impractical, such as preventing contamination between the melt and the crucible, handling high-purity materials, or facilitating in-orbit operations. For a given coil design and load, selecting the appropriate feeding parameters, such as the current and frequency, is crucial to ensure the correct operation of the device. This study investigates the optimal current and frequency values required to levitate an aluminum billet using a proposed longitudinal electromagnetic levitator, which represents an initial prototype of a more complex system for automated material manipulation. The analysis was conducted through 2D and 3D finite element method (FEM) simulations, assessing the equilibrium position and stability with respect to translations and rotations under various operating conditions. The study identifies an operating configuration that ensures vertical stability while minimizing excessive heating, in order to obtain a sufficiently long confinement time before the melting point is reached. A fully coupled 2D thermal simulation was then performed to assess the billet’s heating rate under the selected operating conditions. Finally, an experiment was conducted on a prototype to confirm billet levitation.