At present, the most alloyed welding wires for welding and additive technologies, which provide high strength of welded seams and deposited layers, are wires made of Sv1571 and Scalmalloy aluminum alloys. These alloys are alloyed with scandium, which dissolves well in aluminum and does not form primary intermetallic compounds in the ingot even with a Sc content of ~ 0.7 wt%. Experiments on the creation of wires alloyed with transition metals have shown that an effective way to obtain a dispersed structure of transition metal intermetallic compounds in aluminum is the use of the method of electromagnetic crystallization when casting an ingot of small diameter. Based on the research results, it can be concluded that casting small-section ingots with a diameter of 8-12 mm into an electromagnetic crystallizer is a promising method for creating wire for additive technology.

Casting technology in an EMC gave a colossal effect in comparison with casting in a direct chill mold due to the reduction of waste in the preparation of ingots for further processing. The surface of the ingots from the direct chill mold is stripped to a thickness of up to 20 mm, and the ingot from the EMC comes out with a mirror surface. Moreover, RPC MHD managed to reduce the size of the ingot to the size of the boundary zone of ultrafast crystallization of the metal due to accelerated cooling. The proposed equipment has great potential both for the development of technology and for the production of new alloys with unique physical and mechanical properties, structure and chemical composition.

The technology is fundamentally different from the existing ones. Crystallization of liquid metal occurs in a high-frequency electromagnetic field with a direct supply of coolant to the ingot. Due to this and the intense magnetohydrodynamic effect at the phase interface, high cooling rates (over 100 K / s) are achieved, which ensures the production of long billets with a dispersed structure, as in the granular technology, which is complex and expensive. At the same time, all the regularities revealed during the development of granular aluminum alloys can be transferred and used when choosing alloys manufactured using this technology.

When casting the alloy proposed by us on this equipment, it was possible to obtain a high-strength heat-resistant wire. Now we are in the process of determining its physical and mechanical properties, and the first results are already quite impressive. The direct deformation of the long billet - rolling and drawing - was carried out without using the homogenization and quenching operations traditional for aluminum alloys. The key feature was the casting and annealing modes, which make it possible to obtain a structure from thermally stable nanoparticles containing copper, manganese, and zirconium.

The combination of many processes and their mutual influence during casting in an EMC is a vivid example of a synergistic effect that arises in the problems of applied magnetohydrodynamics and is expressed in the qualitative properties of a bar stock. One of the most difficult tasks facing us in the development of technology and the formation of its theoretical foundations was to establish and quantitatively characterize these relationships. An accurate understanding of the nature of the interaction of electromagnetic, thermal and hydrodynamic fields, as well as the regularities of the formation of the microstructure of ingots, made it possible to find the conditions for stabilizing casting in a semi-weighted state. After more than 15 years of work and the work of many engineers and scientists, it was possible to create a full-fledged high-tech industrial complex that meets the modern need for high-alloyed alloys with improved physical and mechanical properties.

The technology of casting into an electromagnetic crystallizer was developed by the Soviet scientist Z.N. Getselev. and has shown a number of advantages when casting large-sized flat and cylindrical ingots in comparison with casting into a direct chill mold. With the advent of reliable high-frequency semiconductor generators, the idea was proposed to obtain a solid-cast aluminum wire in a similar way. Experimental work on casting small-section ingots into an electromagnetic crystallizer showed a radical change in the microstructure. The structure and physical and mechanical properties were found to be close to the samples obtained by granular technology. More in-depth studies have shown that this technology also contributes to the complete removal of non-metallic inclusions without the use of additional refining equipment. Thus, an alternative to the granule technology was developed, devoid of its disadvantages. The production of ingots with unique properties stimulated the creation of a complex of experimental industrial equipment and technology ElmaCast™.