Superalloys are melted using three different combinations of the above processes vimvar, vimesr, and vimesrvar. The pressure electroslag remelting process is a recent advancement and allows for the manufacture of new high nitrogen alloys with unique properties under pressures of several atmospheres. Computational modeling of electroslag remelting esr process used for the production of highperformance. The electroslag remelting ingots are then used as a charge for remelting in a vacuum induction furnace according to a standard. Electroslag remelting of the metal wastes of nickel alloys. The advantages of both esr and var are combined in one process.
Many factors influence the nonmetallic inclusions in electroslag steel including furnace atmosphere and inclusions content in the consumable electrode, slag amount and its composition, power input, melting rate, filling ratio, and so on. I0 sciencedirect journal of iron and steel research, international. The electroslag remelting esr process is now more than 40 years old. Vacuum arc and electroslag remelting process metal and. The laboratoryscale remelting experiments had been. It uses a reactive, fluid slag as the protective refining. For the most advanced quality requirements, the material has to undergo several refining steps such as in a triple melt process consisting of consecutive vim vacuum induction melting, esr electroslag remelting and var vacuum arc remelting processes. The method, which significantly increases the quality of the metals and alloys produced, was. Evaluation of the electroslag remelting process in medical. Vacuum arc remelting furnace vacuum consumable melting furnace or vacuum.
Electro slag remelting article about electro slag remelting. In this paper, the causes of arc point were analyzed for 200kg ironchromium alloy esr ingot and influence factors of causing arc point were studied by industrial experiment. Friedrich1 1 ime process metallurgy and metals recycling, rwthaachen university, intzestr. Electrode exchange furnaces always utilize two esr furnace heads, and can be designed to exchange into either a static melt station or a withdrawal melt station that is. The pickup of hydrogen during electroslag remelting process for several slags consisting of caf2al2o3caosio2mgo had been investigated. Electroslag remelting an electrometallurgical process in which a metal in the form of a consumable electrode is remelted in a bath of an electrically conducting synthetic slag by the action of heat released upon the passage of electric current through the slag. To clarify the effect of vacuum on cleanliness of steel during electroslag remelting, the interaction between slag and steel under air, ar and vacuum condition were investigated by laboratory experiments. In this process, there is a slowly melting consumable electrode and a watercooled mold for solidification, as in vacuum arc remelting, but the melting is conducted under normal atmosphere and is accomplished by a thick, superheated layer of slag on top of. This makes it possible to increase the annual output and to use greater reductions. Electroslag remelting of heavy forging ingots at the end of the 1960s, the concept of using esr plants to manufacture large forging ingots gained acceptance. Electroslag melting and refining linkedin slideshare. Pdf application of mathematical models for different electroslag. Figure 1 shows electroslag technologies combine on the basis of specific features used for the production of large forging ingots. Multiple electrode electroslag remelting furnaces consarc electrode eschange esr furnaces utilize multiple electrodes, one at a time in series, to form a single larger ingot.
Effects of electrode immersion depth and remelting rate on electroslag remelting process song jinchun, wang changzhou and li song northeastern university, shenyang 110819, china abstract. Electroslag technology of production of large forging. Electroslag remelting furnaces in the 1960s consarcs engineers conceived a new approach to electroslag remelting, quite different from others in use at the time. Electroslag remelting esr is a secondary refining process for metals. Electroslag remelting esr, also known as electroflux remelting, is a process of remelting and refining steel and other alloys for missioncritical applications in aircraft, thermal power stations, nuclear power plants, military technology, etc the electroslag remelting esr process is used to remelt and refine steels and various superalloys, resulting in highquality ingots. New insights into the electroslag remelting process using. Oct, 2016 electroslag welding for stiffeners in ibeam anf box columns. New insights into the electroslag remelting process using mathematical modeling ashish d. The electroslag remelting esr process is used for the production of defectfree ingots of highperformance alloys for the manufacture of components in aerospace and land based turbines. In addition to the varieties of classic electroslag remelting and, only electroslag feeding is used. Pdf the influence of slag composition and process parameters on the behavior of electrical parameters and the refining capability with regard.
It is used for further purification after completion of the primary extraction and refining operations. Effect of electroslag remelting on the properties of. Based on more than forty years of experience with both processes, deutsche edelstahlwerke have excellent knowhow and process engineering in place, which is optimally adapted to. Pdf electroslag remelting of high technological steels. Pdf hydrogen pickup during electroslag remelting process. Electroslag remelting how is electroslag remelting abbreviated. Investigation into critical parameters which determine the. This furnace is also capable of using multiple electrodes to melt that same 150,000 kg ingot via electrode exchange into a static crucible. The process in brief, the electroslag remelting process involves the gradual melting of the lower end of a cast or forged.
Rezaei3 1 institute of advanced technologies for metallic materials, tarbiat modares university, tehran, iran. Electro slag remelting esr ald vacuum technologies. Electroslag remelting chooses slag system whose melting point is lower 100200degc than copper alloy, slag is thorough dry before remelting. The key to topquality steel electroslag remelting process and superalloys the electrode is a cast ingot that dips into, and melts in, a resistanceheated molten bath of electroflux. Its composition should be selected to ensure the desired chemical reactions. Electroslag remelting furnaces background consarc esr technology breakthroughs in the 1960s consarcs engineers conceived a new approach to elctroslag remelting, quite different from others in use at the time. The resulting improvements in the efficiency and performance of the process established consarc as the leading manufacturer of esr systems worldwide. Parameters determining solidification structure and process. The pressure electroslag remelting process pesr total. An electroslag remelting process esr starts when the lower tip of a consumable electrode is immersed into a pool of molten slag. Poirier author see all formats and editions hide other formats and editions.
Patel carpenter technology, corp, 101 w bern st, reading pa 19601, usa 2kanchan m. Combine the different input power and fill ratio, the characteristic. Conventional esr is carried out under air atmosphere, and it is difficult to reduce the oxygen content in the steel because of the severe electrode surface oxidation 12. Vim, electroslag remelting esr, and vacuum arc remelting var. Electroslag technology of production of large forging ingots. The use of esr for beryllium bronze eliminates resegregation, reduces the oxygen content, refines inclusions, and improves the ductility. Fluoride containing slag, which influences the nonmetallic inclusions to a great extent, has been widely used for the electroslag remelting process. The process controlled solidification background coaxial esr furnaces esr configurations esr product development flexible starting practices reliability assured by proprietary power supply. Large electroslag remelting furnaces inductotherm group. Influencing the electroslag remelting process by varying. In addition to the varieties of classic electroslag remelting and, only electroslag feeding is used now in the industry for producing forging ingots. Jul 01, 2010 figure 1 shows electroslag technologies combine on the basis of specific features used for the production of large forging ingots.
Among these, ebr and var use vacuum as the protective and refining medium while esr is the most widely used remelting process today. Based on more than forty years of experience with both processes, deutsche edelstahlwerke have excellent knowhow and process engineering in place, which is optimally adapted to meet their customers requirements. Electroslag remelting for iron chromium aluminum alloy youtube. The thermal characteristics of the electroslag remelting process. Recovery can be defined as metal out wt% di vided by metal in. Wu2 1 cdlaboratory for multiphase modelling of metallurgical processes, 2university of leoben, franzjoseph strasse, 8. Vesr features o combined process var and esr o avoid hydrogen and nitrogen pick up o no moisture from slag o no oxidation of the melt o danger of white spots reduced to a minimum. Pdf the electroslag remelting esr process has been effectively applied to produce. Oct 10, 2012 the electroslag remelting of the metal wastes of nickel alloys is studied, and the obtained results demonstrate that the chemical composition and the physicomechanical and service properties of the ingots meet the requirements of the specifications for these alloys. The results show that the number, size and area fraction of inclusions decreases in the remelted steel. Ludwig all with leybold durferrit gmbh, erlenseegermany introduction the titanium metal as an engineering material came into use in the 1950s in the usa in response to the critical demands far low density, high strength material for aircrafts and emerging space technologies. Electro slag remelting under vacuum vesr remelting is carried out under vacuum as in var, however, using a slag. Our equipments are 1t and 500kg vacuum furnaces, 2t and 750kg medium frequency induction furnaces, electroslag refining furnaces.
Features of slagmetal interaction at electroslag remelting of heavy. A wide variety of electroslag remelting furnace options are available to you. Electroslag remelting esr has the absolute advantages in the removal of. The esr process involves the gradual melting of the lower end of a cast or. In the electroslag remelting process, the electrode molten state is a critical factor determining.
Review on modeling and simulation of electroslag remelting. Other articles where electroslag remelting is discussed. Some advantages and limita tions of the competing vacuum processes are given in table 1. Large electroslag remelting furnaces consarc has built the worlds largest single electrode static esr with a final ingot weight of 150,000 kg. Metallurgy of northeastern university combining with. A read is counted each time someone views a publication summary such as the title, abstract, and list of authors, clicks on a figure, or views or downloads the fulltext. Effect of slag on inclusions during electroslag remelting. Elimination of oxide inclusions by chemical reduction. Electroslag remelting esr can effectively improve the cleanliness and. Role of vacuum on cleanliness improvement of steel during. Pdf numerical simulation of the formation and the dripping. The problems of oxidation of the melt do not arise.
In the past few years, electroslag re melting has gained tremendous populari ty as a valuable processing technique for superalloys, tool steels and other high performance matisrials. Usage of worked out metallurgical slag in electroslag. Mechanism of slag composition change during electroslag. Rendering of electroslag remelting apparatus and crosssections electroslag remelting esr, also known as electroflux remelting, is a process of remelting and refining steel and other alloys for missioncritical applications in aircraft, thermal power stations, nuclear power plants, military technology, etc. Electroslag remelting esr shows strong ability to remove inclusions and harmful element s, and provides cooling condition for directional solidification. I did like to know the difference and would appereciate it if you kindly let me know your opinion about this. Evaluation of the electroslag remelting process in medical grade of 316lc stainless steel s. Electroslag remelting for iron chromium aluminum alloy. Cleanliness improvement and microstructure refinement of ingot. Pdf influencing the electroslag remelting process by varying. Much higher levels of nitrogen can be achieved due to the pressure applied above the slag which can be increased significantly above normal atmospheric.
Electroslag remelting furnaces inductotherm group italy. May 14, 2014 many factors influence the nonmetallic inclusions in electroslag steel including furnace atmosphere and inclusions content in the consumable electrode, slag amount and its composition, power input, melting rate, filling ratio, and so on. Usage of worked out metallurgical slag in electroslag remelting processes vasily e. Influencing the electroslag remelting process by varying fluorine content of the utilized slag proceedings of emc 2015 5 longitudinal discs from the ingot center were used to visualize the macro structure and to obtain information about the depth and shape of the liquid metal pool see figure 3, left. Its melting point must be lower than that of the metal to be remelted. Pdf this interim report describes research conducted at the massachusetts institute of technology on macrosegregation in ingots produced by the. Increasing demand for larger electrical power generating units required forging ingots weighing 100 tons. Remelting is carried out under vacuum as in var, however, using slag.
The vimvar process has been the standard melting practice used for superalloys subjected to critical stress applications. The esr process can include a computerized melt control system that fully automates the melting process. There are economically and technically effective technologies of steel producing with low level of sulfur. Study on arcing phenomenon in electroslag remelting process. Electroslag remelting under vacuum vacesr electroslag remelting under vacuum is another newly developed process. Combining the vacuum condition and esr process, the vacuum esr process is. Oct 22, 2016 vacuum arc remelting furnace vacuum consumable melting furnace or vacuum consumable melting furnace duration. The premelted slag possessing electrical conductivity is located on the watercooled mold base connected to a power supply.
During electroslag remelting, the temperature of the slag, which consists of various components caf 2, cao, sio 2, al 2 o 3, and others, exceeds 2500c. Copper alloy electroslag remelting process belongs to field of copper alloy production technology. Influencing the electroslag remelting process by varying fluorine content of the utilized slag proceedings of emc 2015 5 longitudinal discs from the ingot center were used to visualize the macro structure and to obtain information about the depth and shape of. After quenching and aging or mtt of beryllium bronze bnt1. Electroslag remelting its status, mechanism and refining. Electroslag remelting esr is a consumable electode remelting process in which liquid metal droplets are refined with contact of a molten slag providing a cleaner, more uniform alloy with minimum segregation. Electroslag remelting of titanium ginatta tecnologie. To perform its intended functions, the slag must have some welldefined properties, such as. In fact, our vendor of the steam turbine driver of a compressor has changed the material of the blades from a4222 to a4223 and the difference was in the manufacturing process which a4222 is by vacuum arc and the a4223 is by electroslag. Kinetics of phosphorus transfer during industrial electroslag.
Electroslag remelting esr in this process, there is a slowly melting consumable electrode and a watercooled mold for solidification, as in vacuum arc remelting, but the melting is conducted under normal atmosphere and is accomplished by a thick, superheated layer of slag on top of the shallow metal pool. Cn1580300a copper alloy electroslag remelting process. Increasing demand for larger electrical power generating units required forging ingots weighing 100 tons or more for manufacturing of generator and turbine shafts. Meltflowesr reference manual, innovative research, inc. Effects of electrode immersion depth and remelting rate on. Review on modeling and simulation of electroslag remelting abdellahkharicha, ebrahimkarimisibaki,menghuaiwu,andreasludwig,andjanbohacek the electroslag remelting esr is an advanced technology for the production of high quality materials, for example, hot work tool steels or nickel base alloys. Additional information on some of these processes is available in. As the drops of melting metal fall through the molten electroflux, impurities and mineral inclusions migrate from the drops into the. Electroslag remelting article about electroslag remelting. Multiple electrode electroslag remelting furnaces consarc. Arcing often happens in the electroslag remeltingesr process and will lead arc point on the ingot surface which affect the quality seriously of esr ingot. Drops of the molten electrode metal pass through the slag layer to form a layer of metal underneath. Vacuum arc remelting furnace vacuum consumable melting furnace or vacuum consumable melting furnace duration.
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