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Melting furnaces
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Furnace / electron beam - EB/PVD
Increasingly stringent demands are being imposed on the efficiency of gas turbine engines employed in the aerospace and power generation industries. This is driven by the...
Furnace / electron beam - EB/PVD
Increasingly stringent demands are being imposed on the efficiency of gas turbine engines employed in the aerospace and power generation industries. This is driven by the requirement to reduce consumption of fossil fuels and thus operating cost. The major means for improving turbine efficiency is by increasing operating temperatures in the turbine section of the engines. The materials employed must withstand the higher temperatures as well as mechanical stresses, corrosion, erosion and other severe conditions during operation, while providing extended lifetime as required by the end users. This is an area where EB/PVD coating processes make a significant contribution today.
Furnace / electron beam - EB
Electron beam melting is distinguished by its superior refining capacity and offers a high degree of flexibility of the heat source. Thus, it is...
Furnace / electron beam - EB
Electron beam melting is distinguished by its superior refining capacity and offers a high degree of flexibility of the heat source. Thus, it is ideal for remelting and refining of metals and alloys under high vacuum in water-cooled copper molds. Today the process is mainly employed for the production of refractory and reactive metals (tantalum, niobium, molybdenum, tungsten, vanadium, hafnium, zirconium, titanium) and their alloys. It plays an important role in manufacturing of ultra-pure sputtering target materials and electronic alloys and the recycling of titanium scrap.
Slag remelting furnace / electric - ESR
ESR has been known since the 1930s, but it took approx. 30 years before it became an...
Slag remelting furnace / electric - ESR
ESR has been known since the 1930s, but it took approx. 30 years before it became an acknowledged process for mass production of high-quality ingots. The ESR technology is of interest not only for the production of smaller weight ingots of tool steels and superalloys, but also of heavy forging ingots up to raw ingot weights of 165 tons.
Remelting furnace / vacuum / electric arc - VAR
VAR is widely used to improve the cleanliness and refine the structure of standard air-melted or vacuum induction melted ingots, then called consumable electrodes. VAR steels and superalloys as well as titanium and zirconium and its alloys are used in a great number of highintegrity applications where cleanliness, homogeneity, improved fatigue...
Remelting furnace / vacuum / electric arc - VAR
VAR is widely used to improve the cleanliness and refine the structure of standard air-melted or vacuum induction melted ingots, then called consumable electrodes. VAR steels and superalloys as well as titanium and zirconium and its alloys are used in a great number of highintegrity applications where cleanliness, homogeneity, improved fatigue and fracture toughness of the final product are essential. Aerospace, power generation, defense, medical and nuclear industries rely on the properties and performance of these advanced remelted materials.
Process Technology and Process Characteristics
VAR is the continuous remelting of a consumable electrode by means of an arc under vacuum. DC power is applied to strike an arc between the electrode and the baseplate of a copper mold contained in a water jacket. The intense heat generated by the electric arc melts the tip of the electrode and a new ingot is progressively formed in the water-cooled mold. A high vacuum is being maintained throughout the remelting process.
The basic design of the VAR furnace has been improved continuously over the years particularly in computer control and regulation with the objective of achieving a fully- automatic remelting process. This in turn has resulted in improved reproducibility of the metallurgical properties of the products.
Process Technology and Process Characteristics
VAR is the continuous remelting of a consumable electrode by means of an arc under vacuum. DC power is applied to strike an arc between the electrode and the baseplate of a copper mold contained in a water jacket. The intense heat generated by the electric arc melts the tip of the electrode and a new ingot is progressively formed in the water-cooled mold. A high vacuum is being maintained throughout the remelting process.
The basic design of the VAR furnace has been improved continuously over the years particularly in computer control and regulation with the objective of achieving a fully- automatic remelting process. This in turn has resulted in improved reproducibility of the metallurgical properties of the products.
Melting furnace / vacuum / induction - VIM
The majority of vacuum investment castings like turbine blades and vanes for the aircraft and industrial gas turbine industries are made from Ni-base...
Melting furnace / vacuum / induction - VIM
The majority of vacuum investment castings like turbine blades and vanes for the aircraft and industrial gas turbine industries are made from Ni-base superalloys and are produced in a vacuum induction melting and precision casting furnace. In vacuum precision casting furnaces, a master alloy composition is inductively melted and then cast into an investment mold. The solidification structure of the casting can be adjusted to be equiaxed (E) (uncontrolled, from outside to inside) or, through the use of an additional mold heater, directionally solidified (DS) or single crystal (SC).
Remelting furnace / vacuum / electric arc
Consarc is well known to primary producers of speciality steel, superalloys, and reactive metals. We pioneered commercial ingot production using automated Vacuum Arc Remelting...
Remelting furnace / vacuum / electric arc
Consarc is well known to primary producers of speciality steel, superalloys, and reactive metals. We pioneered commercial ingot production using automated Vacuum Arc Remelting (VAR) furnaces. We were the first to apply load cell weighing of electrodes to improve process control. We developed coaxial furnace designs to minimize uncontrolled stirring. And we fully computerized the controls to optimize reproducibility and ease of operation. Users of Consarc VAR furnaces get proven process technology, state-of-the-art control and fully computerized controls to optimize reproducibility and ease of operation from the industry's most innovative and experienced resource.
Melting furnace / heating / slag remelting / electric
In brief, the Electroslag Remelting process involves the gradual melting of the lower end of a cast or forged electrode through a layer of molten slag into a water-cooled copper mold.
The slag which is usually calcium fluoride, with addition of lime, magnesia, alumina and other oxides, serves several functions. In its molten state, it is electrically conductive,...
The slag which is usually calcium fluoride, with addition of lime, magnesia, alumina and other oxides, serves several functions. In its molten state, it is electrically conductive,...
Melting furnace / heating / slag remelting / electric
In brief, the Electroslag Remelting process involves the gradual melting of the lower end of a cast or forged electrode through a layer of molten slag into a water-cooled copper mold.
The slag which is usually calcium fluoride, with addition of lime, magnesia, alumina and other oxides, serves several functions. In its molten state, it is electrically conductive, acting somewhat like a resistance heating element when a high current is passed between the electrode and the mold. The slag becomes superheated with the continued passage of electric current, causing the electrode tip immersed in it to become molten. Any inclusions in this molten metal are dissolved by and become part of the slag, leaving a purified metal to pass as droplets through the slag layer into the bottom of the mold.
After the process has continued for some time, a purified ingot having a controlled solidification structure is built up in the mold. The slag, which also acts to prevent oxidation of the molten metal in the usual case of operation in air atmosphere, floats on top of the liquid metal at the top of the ingot due to its relatively low density.
Towards the end of the process, the power is gradually reduced. This reduces the volume of liquid metal on top of the ingot. At the same time, additional metal is added from the electrode at a reduced rate to compensate for solidification shrinkage. The result is a sound ingot top with a high yield of useful product.
The slag which is usually calcium fluoride, with addition of lime, magnesia, alumina and other oxides, serves several functions. In its molten state, it is electrically conductive, acting somewhat like a resistance heating element when a high current is passed between the electrode and the mold. The slag becomes superheated with the continued passage of electric current, causing the electrode tip immersed in it to become molten. Any inclusions in this molten metal are dissolved by and become part of the slag, leaving a purified metal to pass as droplets through the slag layer into the bottom of the mold.
After the process has continued for some time, a purified ingot having a controlled solidification structure is built up in the mold. The slag, which also acts to prevent oxidation of the molten metal in the usual case of operation in air atmosphere, floats on top of the liquid metal at the top of the ingot due to its relatively low density.
Towards the end of the process, the power is gradually reduced. This reduces the volume of liquid metal on top of the ingot. At the same time, additional metal is added from the electrode at a reduced rate to compensate for solidification shrinkage. The result is a sound ingot top with a high yield of useful product.
Melting furnace / induction - ISM
Rapid and cost effective melting and processing of reactive metals...
Melting furnace / induction - ISM
Rapid and cost effective melting and processing of reactive metals (e.g. Titanium, Zirconium and their alloys), super clean superalloys and other metals requiring low inclusion content can be provided by Consarc with the Induction Skull melting furnace system.
Melting furnace / induction - 2.5 - 60 t | CR
Coreless induction furnace for melting scrap and turnings in iron and...
Melting furnace / induction - 2.5 - 60 t | CR
Coreless induction furnace for melting scrap and turnings in iron and steel to prepare any type of high quality cast-iron for producing castings in grey, malleable and ductile iron.
Standard capacity from 2.5 t up to 60 t with melting rate ranging from 1 t/h up to 18 t/h
Standard capacity from 2.5 t up to 60 t with melting rate ranging from 1 t/h up to 18 t/h
Melting furnace / induction - 3 - 100 t, 200 - 2 500 kW | Duplex
Furnace Type "Duplex" for Holding and Superheating Cast-Iron
Channel induction furnace for Duplexing...
Channel induction furnace for Duplexing...
Melting furnace / induction - 3 - 100 t, 200 - 2 500 kW | Duplex
Furnace Type "Duplex" for Holding and Superheating Cast-Iron
Channel induction furnace for Duplexing (receiving, holding and superheating) of any type of cast-iron. Standard capacity from 3 t up to 100 t with interchangeable inductors from 200 kW up to 2.500 kW.
Up to 500 kW by unique air-cooling and for higher power cooling by mixed system of air and water. Melting rate ranging from 0,5 t/h up to 6 t/h.
Channel induction furnace for Duplexing (receiving, holding and superheating) of any type of cast-iron. Standard capacity from 3 t up to 100 t with interchangeable inductors from 200 kW up to 2.500 kW.
Up to 500 kW by unique air-cooling and for higher power cooling by mixed system of air and water. Melting rate ranging from 0,5 t/h up to 6 t/h.
Pouring furnace / induction - 1.2 - 8 t, 100 - 500 kW | Dx-C
Automatic tilting channel induction furnace with rear inductor for holding, superheating and direct casting of any type of cast-iron...
Pouring furnace / induction - 1.2 - 8 t, 100 - 500 kW | Dx-C
Automatic tilting channel induction furnace with rear inductor for holding, superheating and direct casting of any type of cast-iron including ductile iron into green sand automatic indexed moulding line, pouring from up to 3 spouts for concurrent pouring into three moulds.
Pouring up to 500 moulds/h. Standard capacities from 1.2 t up to 8 t with unique air-cooled (patented) interchangeable inductor with power ranging from 100 kW up to 500 kW. One , two or three spouts for pouring also different casting weights.
Pouring up to 500 moulds/h. Standard capacities from 1.2 t up to 8 t with unique air-cooled (patented) interchangeable inductor with power ranging from 100 kW up to 500 kW. One , two or three spouts for pouring also different casting weights.
Melting furnace / induction - CRMF
Medium frequency coreless induction furnace for melting iron and steel to prepare any type of high quality cast-iron for producing castings in grey, malleable and ductile iron.
Melting furnace / induction - 0.6 - 30 t, max. 2 000 kW | RM
Channel induction furnace for melting and refining of brass, copper scrap and turnings to produce refined high...
Melting furnace / induction - 0.6 - 30 t, max. 2 000 kW | RM
Channel induction furnace for melting and refining of brass, copper scrap and turnings to produce refined high quality brass billets or ingots for gravity or pressure die-casting foundry application to produce taps, sanitary fittings, water meters and valves.
Standard capacity from 0.6 t up to 30 t with melting rate ranging from 0.35 t/h to 13 t/h and with power inductors up to 2000 kW. Up to 350 kW by unique air-cooled system
Standard capacity from 0.6 t up to 30 t with melting rate ranging from 0.35 t/h to 13 t/h and with power inductors up to 2000 kW. Up to 350 kW by unique air-cooled system