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Vacuum Arc Remelting (VAR) Improving the Structure and Uniformity of the Cast Ingot

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Vacuum Arc Remelting (VAR) Improving the Structure and Uniformity of the Cast Ingot ALD Vacuum Technologies High Tech is our Business CRUCIBLE SHAPE Technical Data Disc Round Round/Square Round/Square Laboratory Remelting Systems LK 6 L 200 F 240 R 240 Non-consumable Electrode Technique • + – – Round, rectangular and ring-shaped. Equipment variable from 3 dishes Melt Disc Geometry (Ø 2.5 mm) up to 1 dish (Ø 150 mm). – – The height depends on the material and the melting power. Skull Melting + + • • Pouring Weight (Titanium) max. [kg] 0.2 2 – – Melting Power Supply [A] 500-2000 5000-7500 5000-7500 5000-7500 Consumable Electrode Technique • Laboratory Remelting Systems Mold Sizes Ø min. [mm] – 70 170 150 Ø max. [mm] – 200 240 240 for Pilot Production and R&D Length max. [mm] – 800 1300 1100 Ingot Weight max. [kg] – 200 350 370 Vacuum/Pressure Standard [mbar] 10-2 10-2 1 bar 70 bar With Diffusion Pump [mbar] 10-4 10-4 – 10-4 Cooling Water Consumption [l/min] 60-100 250 400 400 • Standard equipment + Extra equipment – Not available MetaCom / Labaratory Remelting Systems / 12.14 Systems Remelting / Labaratory MetaCom Vacuum Arc Remelting (VAR) Improving the structure and uniformity of the cast ingot 1. Copper mold 2. Melt bath 3. Non-consumable electrode 4. Consumable electrode 5. Casting mold 6. Water-cooled crucible 4 4 3 2 6 1 2 5 1 2 Non-consumable Electrode Technique Consumable Electrode Technique Skull Melting The Laboratory Systems Accessories: Vacuum Arc Remelting (VAR) ALD has continously developed Accessories that increase flexibility and The Vacuum Arc Remelting process is various laboratory systems that range of applications: using an arc between a massive source operate with non-consumable and O Automatic gas-inlet system electrode (cathode) of the material consumable electrode techniques. O Material-feed mechanism to be remelted and a water cooled Each of these product lines consist O Glove-box connection copper mold (anode). The material is of modular systems designed for a O Automatic guidance of the electrode transferred from the electrode on a wide variety of applications and can be ram for melting by the non-consumable drop by drop basis which improves the implemented easily and economically. electrode technique structure and uniformity of the cast O Magnetic coil for electromagnetic ingot, while the vacuum environment The laboratory Vacuum Arc Remelting stirring removes the gases and volatile furnace is primarily used to produce O Video monitoring system elements. Typical materials to be button samples, small ingots and O Automatic melt control processed are: Ti, Ta, Zr, Fe- and precision cast parts. These pieces are O Helium ingot cooling Ni-based and Cu-alloys. used for example: To examine the O Fully automated process mechanical, physical and chemical O Drip short control properties of refractory and reactive O Oil booster pump metals and their alloys. Vacuum Arc 1 Remelting (VAR) 2 O LK Line for non-consumable 3 electrode technique Schematic diagram of 4 the VAR-model LK6: O L200 Line for both non-consumable and consumable electrodes 1. Electrode drive motor 5 1. Copper mold 2. Vacuum seal 2. Melt bath 3. Viewing port 6 3. Non-consumable electrode 4. Movable electrode 4. Consumable electrode 5. Melt chamber 5. Casting mold 6. Melt dishes 7 6. Water-cooled crucible 7. Clamp for water jacket t Vacuum Arc Furnace Model LK6 u Vacuum Arc Furnace Model L200 The LK Line The L200 Line This furnace offers a single solution Various melting power packages and This furnace can operate both with non- for all melting applications with the vacuum systems make it possible to consumable and consumable electrodes. non-consumable electrode technique, operate with a melting current of up to The proven electrode feed control under vacuum or inert gas atmosphere 2000 A and evacuation pressure as low systems are used during remelting. with overpressure of 1 bar and higher as 10-4 mbar. possible. The maximum ingot weight with the The use of different crucibles with different consumable electrode technique is 200 kg. In the LK line the non-consumable melting dishes permits production of a electrode technique means the the arc wide variety of sample shapes. For all its Vacuum Arc Remelting furnaces ignites and burns between a cooled ALD supplies partially and fully automated tungsten finger and the molten material control systems to ensure that the results in the crucible. of the remelting process can be monitored at all times and will be consistently reproducible. Electro Slag Remelting (ESR) Refining and Solidification Control Electro Slag Remelting Furnace Model F240 Electro Slag Remelting (ESR) Accessories: The F240 Line The Electro Slag Remelting process Accessories that increase flexibility and The F240 Line is using the consumable in general is very similar to the VAR range of application: electrode technique with a maximum process. In ESR the ingot is formed O Automatic gas-inlet system mold diameter of 240 mm for 340 kg under a superheated slag in which O Slag and material feed system ingot weight. the electrode is immersed and melted O Automatic guidance of the off using an alternating current. electrode ram The furnace is designed to use different Remelted ingots are free from porosity, O Automatic melt control oxide slag types to produce primarily macro-segregation and contain Fe- and Ni-based alloys. minimum content on non metallic inclusions. Melt start can be performed in automatic mode by using an additional ESR is the most flexible process in port to feed the slag into the crucible. regard to material quality characteristics. Remelting under a totally closed environment is possible. ALD Multiple Purpose Remelting (VAR, ESR, PESR, IESR VESR) VAR/ESR Furnace Model R240 Multiple Purpose Remelting Accessories: The R240 Line (VAR, ESR, PESR, IESR, VESR) Different remelting processes can Accessories that increase flexibility The following processes can be be carried out in one chamber type and range of application: carried out: furnace using alternating or direct O Automatic gas inlet O Vacuum Arc Remelting using high current to remelt one consumable O Automatic pressure control vacuum level. electrode into one ingot above or O Slag and material feed system O Pressure Electro Slag Remelting below atmospheric pressure. O Automatic guidance of the up to 70 bar can be carried out to electrode ram produce high nitrogen single ingots. O Magnetic coil for electromagnetic O Inertgas Electro Slag Remelting stirring using different slag and gas types O Electrode welding function can be used to produce single ingots. O Automatic melt control O Vacuum Electro Slag Remelting or O Oil booster pump Low Pressure Remelting can be O Drip short control carried out to avoid hydrogen pick up in the final ingots. ALD CRUCIBLE SHAPE Technical Data Disc Round Round/Square Round/Square Laboratory Remelting Systems LK 6 L 200 F 240 R 240 Non-consumable Electrode Technique • + – – Round, rectangular and ring-shaped. Equipment variable from 3 dishes Melt Disc Geometry (Ø 2.5 mm) up to 1 dish (Ø 150 mm). – – The height depends on the material and the melting power. Skull Melting + + • • Pouring Weight (Titanium) max. [kg] 0.2 2 – – Melting Power Supply [A] 500-2000 5000-7500 5000-7500 5000-7500 Consumable Electrode Technique • Mold Sizes Ø min. [mm] – 70 170 150 Ø max. [mm] – 200 240 240 Length max. [mm] – 800 1300 1100 Ingot Weight max. [kg] – 200 350 370 Vacuum/Pressure Standard [mbar] 10-2 10-2 1 bar 70 bar With Diffusion Pump [mbar] 10-4 10-4 – 10-4 Cooling Water Consumption [l/min] 60-100 250 400 400 • Standard equipment + Extra equipment – Not available ALD Vacuum Technologies GmbH Otto-von-Guericke-Platz 1 D-63457 Hanau, Germany Phone +49 (0) 6181 307-0 Fax +49 (0) 6181 307-3290 E-Mail [email protected] You can find the addresses of all our sales partners and Internet www.ald-vt.com subsidiaries on www.ald-vt.com. / 12.14 Systems Remelting / Labaratory MetaCom.
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