This report is also published as a pdf document, available for free download. Report of the committee on electroslag remelting and plasma arc. An introduction to premium melting carpenter technology. Review on modeling and simulation of electroslag remelting. Test methods for electroslag remelting furnaces are specified in iec 60779. 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. Instead of a vacuum atmosphere, a layer of slag floats on top of the molten steel, protecting it from oxygen and other. By remelting under inert gas the oxide cleanliness can be further improved. Can the author please an estimate of the number of tonnes of steel treated by esr p.
Critical melting points and reference data for vacuum heat treating. Pdf effect of electroslag remelting on the nonmetallic. Committee on electroslag remelting and plasma arc melting. The variation in landau free energy while melting platinum was investigated at a number of temperatures using computer simulation with a model potential. Applies to electroheat installations for remelting and, in some cases, for refining processes of metals through direct resistance heating of a conductive slag. Electroslag remelting furnace is a special kind of smelting equipment used to melt consumable electrodes in the slag pool by using the heat generated by the remelting current. Electro slag remelting esr process has been known since the 1930s, but it took approximately 30 years before it became an acknowledged process for mass production of highquality ingots.
Calcination of slags for electroslag remelting sciencedirect. 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. 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 its status, mechanism and refining. On the comparative advantages of smelting lead ore by the. Electro slag remelting esr is used in the production of highquality special steel, premium grade super alloys and titanium alloys for. Electro slag remelting esr ald vacuum technologies. Appendixes electroslag remelting and plasma arc melting.
For further optimisation of microscopic purity, the vacuum arc remelting procedure is used. On melting of electrodes during electroslag remelting abdellah kharicha,1 andreas ludwig2 and menghuai wu1 1 christian doppler lab for advanced simulation of solidification and melting, dept. Among these, ebr and var use vacuum as the protective and refining medium while esr is the most widely used remelting process today. That is, when you create an annotation of any kind on the. Other articles where electroslag remelting is discussed. Vacuum ingot pouring is often employed to produce very large ingots that are subsequently processed, in expensive forging and machining operations, into such products as rotors for power generators. Apr 01, 2016 advantages 1 uniform mechanical properties in the longitudinal and sectional direction. Electroslag melting and refining linkedin slideshare. Report of the committee on electroslag remelting an.
Apart from the deposition of macroscopic inclusions, the microscopic cleanliness is also significantly improved. Just like with var vacuum furnace, in the esr process an air melted ingot is suspended over a vessel into which the ingot is melted by electrical current, to reform drip by drip as a new ingot. One was composed of 70% of cafz and 30% of alzq, named slag lo in this study, which was the conventional slag used in electroslag remelting process, and the other consisting of caf2 caoal2o3sio2mgo was named slag l1. 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. Electroslag remelting furnace,smelting equipment manufacturer. Electroslag remelting esr slags for removal of radioactive. Influencing the electroslag remelting process by varying.
Effect of electroslag remelting on the nonmetallic inclusions in h11 tool steel. Effects of electrode immersion depth and remelting rate on. The metal droplet is then crystallized into esr ingot in the watercooled crystallizer after being cleansed with the slag liquid. Pdf hydrogen pickup during electroslag remelting process. On the comparative advantages of smelting lead ore by the blasthearth and the reverberatory furnace is an article from proceedings of the royal irish academy 18361869, volume 4. University of groningen surface engineering matthews, david. Unfortunately, this book cant be printed from the openbook. Primary aluminium ingots for remelting for aircraft. 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.
With every increase of the requirements of the users and the properties of thick plates and forgings and the appropriate increase of the complexity of the alloying systems of steel and alloys this problem becomes more acute, in particular in the production of certain. The resulting improvements in the efficiency and performance of the process established consarc as the leading manufacturer of esr systems worldwide. The electroslag remelting ingots are then used as a charge for remelting in a vacuum induction furnace according to a standard. Other than for strictly personal use, it is not permitted to download or to forwarddistribute the. I did like to know the difference and would appereciate it if you kindly let me know your opinion about this. In the experiment, sensors were used to detect the parameters during the electrode remelting process, including the furnace. Large electroslag remelting furnaces consarc engineering. A process overview article pdf available in materiali in tehnologije 506. 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. Electroslag remelting esr slags for removal of radioactive oxide contaminants from stainless steel, annual report 19981999 showing 14 of 35 pages in this report. Electroslag remelting furnaces in the 1960s consarcs engineers conceived a new approach to electroslag remelting, quite different from others in use at the time. An electroslag remelting process esr starts when the lower tip of a consumable electrode is immersed into a pool of molten slag. Features of slag metal interaction at electroslag remelting.
The laboratoryscale remelting experiments had been carried out in open air and water free argon atmosphere, and then the influencing factors were analyzed. As a result, esrrefined grades offer the highest strength. Read chapter summary of conclusions and recommendations. Residual stresses at laser surface remelting and additive. Then you can start reading kindle books on your smartphone, tablet, or computer no kindle device required.
Pdf electroslag remelting of high technological steels. Electroslag technology of production of large forging ingots. These calculated results are the smallest theoretical times and distances over. By default, the annotations made in pdf annotator are editable.
For the manufacture of special products, refining and solidification processes are often combined. Enter your mobile number or email address below and well send you a link to download the free kindle app. Adobe acrobat reader dc downloaden gratis pdfviewer voor. Electroslag remelting article about electroslag remelting. Esr and var electroslag remelting electroslag remeltingesr. It also acts as a solvent for nonmetallic oxides, removes free oxygen and sulfur, protects. The electroslag remelting process esr is important because it provides better control of the solidification microstructure and. Jul 01, 2010 the task of producing highquality large ingots from highalloy steels and alloys has not as yet been completely fulfilled.
Esr is primarily concerned with the remelting of ingots having a precise composition. Electroslag remelting how is electroslag remelting abbreviated. Drops of the molten electrode metal pass through the slag layer to form a layer of metal underneath. Large electroslag remelting furnaces consarc has built the worlds largest single electrode static esr with a final ingot weight of 150,000 kg. 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. Physicalchemical model of heavy ingot remelting in protective atmosphere. If you need to print pages from this book, we recommend downloading it as a pdf. Vacuum arc and electroslag remelting process metal and. The electroslag remelting of highspeed steel using a. Oct 22, 2016 vacuum arc remelting furnace vacuum consumable melting furnace or vacuum consumable melting furnace duration.
The initial mass of slag makes 2500kg, height of slag layer 306 mm. High laser power applied at laser cladding 6 assured elevated temperature of the whole. Download free adobe acrobat reader dc software for your windows, mac os and android devices to view, print, and comment on pdf documents. The article refers to electroslag remelting esr as common practice in europe. Oct, 2016 vacuum arc remelting furnace vacuum consumable melting furnace or vacuum consumable melting furnace duration. Electroslag remelting of the metal wastes of nickel alloys. In order to promote public education and public safety, equal justice for all, a better informed citizenry, the rule of law, world trade and world peace, this legal document is hereby made available on a noncommercial basis, as it is the right of all humans to know and speak the laws that govern them.
Fluoride containing slag, which influences the nonmetallic inclusions to a great extent, has been widely used for the electroslag remelting process. 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. Crackfree laserremelted layers can be obtained with preheating 7,8. Plasma arc melting technology electroslag remelting. Electroslag remelting for iron chromium aluminum alloy youtube.
It is a process used for remelting and refining of steels and special alloys which are used for critical applications in aircraft, thermal and nuclear power. Effect of slag on inclusions during electroslag remelting. On melting of electrodes during electroslag remelting. It uses a reactive, fluid slag as the protective refining. The electromagnetic forces that arise from the interaction between the outside direct magnetic field and the onephase electric current of the electroslag remelting process by a monofilar scheme alter the mechanism of the electrode remelting and thus, affect the solidification of a highspeed steel and its structure. About the electro slag remelting process vacuum furnace. The premelted slag possessing electrical conductivity is located on the watercooled mold base connected to a power supply.
Behavior of alloying elements during electroslag remelting. Esrrefined material is free from shrink holes and isotropic and is characterized by high purity. This work aims at the suitability of electroslag process on production of high technological steels such as maraging steel, modified high speed tool steel niobium, high nitrogen, and free nitrogen has been investigated. Table 1 depicts the histori cal development of the process. Free energy changes on freezing and melting ductile metals 1.
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