Abstract: A method for producing an electrical heating device with the steps of preparing a sleeve from a first material that has a first strength; arranging an electrical heating element in the sleeve; arranging of a filler material in the sleeve, so that parts of the electrical heating element carrying current are electrically isolated from the sleeve and the position of the electrical heating element in the sleeve is fixed, and at least section-wise compression of the sleeve, of the electrical heating element is arranged in sections of the sleeve that are compressed, and of the filler material arranged in sections of the sleeve that are compressed, wherein, before the completion of the at least section-wise compression of the sleeve, in sections to be compressed, a tubular section is arranged that is made from a second material that has a second strength higher than the first strength.

Abstract: A process for directional solidification of a cast part comprises energizing a primary inductive coil coupled to a chamber having a mold containing a material; energizing a primary inductive coil within the chamber to heat the mold via radiation from a susceptor, wherein the resultant electromagnetic field partially leaks through the susceptor coupled to the chamber between the primary inductive coil and the mold; determining a magnetic flux profile of the electromagnetic field; sensing a magnetic flux leakage past the susceptor within the chamber; generating a control field from a secondary compensation coil coupled to the chamber, wherein the control field controls the magnetic flux experienced by the cast part; and casting the material within the mold under the controlled degree of flux leakage.

Abstract: A method for refining and casting metals and metal alloys includes melting and refining a metallic material and then casting the refined molten material by a nucleated casting technique. The refined molten material is provided to the atomizing nozzle of the nucleated casting apparatus through a transfer apparatus adapted to maintain the purity of the molten refined material. An apparatus including a melting and refining apparatus, a transfer apparatus, and a nucleated casting apparatus, in serial fluid communication, also is disclosed.

Abstract: An apparatus for casting metals by a nucleated casting technique to create a preform, the apparatus including a mold having a base and a side wall where the base can be moved relative to the side wall to withdraw the preform as it is being created. In various circumstances, portions of a droplet spray created by an atomizing nozzle, i.e., overspray, may accumulate on a top surface of the side wall and prevent or inhibit the preform from being moved relative to the side wall. The atomizing nozzle can be oriented such that the droplet spray passes over the top of the side wall to remelt and remove at least a portion of the overspray that has accumulated thereon. The mold can be rotated such that the overspray formed on a region of or on the entire perimeter of the top surface can pass through the droplet spray and can be removed from the side wall.

Abstract: A vacuum arc remelt furnace system that automatically monitors for electrode to crucible arcing in a VAR furnace. The vacuum arc remelt furnace system includes a crucible, an electrode provided within the crucible, and a spectrometer operatively coupled to the gap between the electrode and the crucible. The spectrometer detects the presence of one or more copper-specific light wavelengths in light that is present in the gap, and preferably generates an alarm and/or shuts the furnace down depending upon what is detected. Also, a method of operating a vacuum arc remelt furnace to automatically monitor for electrode top crucible arcing. The method includes collecting light that is present in the gap between the crucible and said electrode, and determining whether one or more copper-specific light wavelengths are present in the light. An alarm is generated and/or the furnace is shut down depending upon what is detected.

Abstract: A method for refining and casting metals and metal alloys includes melting and refining a metallic material and then casting the refined molten material by a nucleated casting technique. The refined molten material is provided to the atomizing nozzle of the nucleated casting apparatus through a transfer apparatus adapted to maintain the purity of the molten refined material. An apparatus including a melting and refining apparatus, a transfer apparatus, and a nucleated casting apparatus, in serial fluid communication, also is disclosed.

Abstract: A method for producing metal ingots or billets, especially from steels and Ni- and Co- base alloys, by melting off consumable electrode in an electroconductive slag bath using alternating or direct current in a short, downwardly opening, water-cooled mould through which a current contact can be established with the slag bath. The melting current is introduced into the slag bath through the consumable electrode and through the mould in a controlled manner in terms of regulating the distribution of the current between the electrode and the mould; and is conducted back through the mould and the block and the base plate at option; the division of the currents being adjustable in a controlled manner. The proportion of the overall melting current delivered that is delivered via the consumable electrode can be chosen from between 0 and 100%.

Abstract: An electric heater assembly suitable for heating molten metal, the electric heater assembly having a sleeve comprised of a closed end suitable for immersing in the molten metal. The sleeve is fabricated from a composite material comprised of titanium alloy and having an outside surface to be exposed to the molten metal coated with a refractory resistant to attack by the molten metal having a sealant metal applied thereto; and an electric heater located in the sleeve in heat transfer relationship therewith.

Abstract: In a special melting unit, in particular a pressure induction furnace having a copper ingot mold (6) and water cooling, in which the cooling water is circulated in a closed pressurized water circuit around the cooling crucible (2) surrounding the ingot mold, a device is provided for equalizing the pressures in the melting chamber (35) and in the cooling crucible (2), comprising a piston-type accumulator (19) which is subdividable by a piston (16) into two variable-volume chambers (17, 18), the one chamber (17) corresponding with the cooling water circuit and the other chamber (18) being connected to a vessel (30) which is approximately half filled with a hydraulic liquid, the other half of the vessel being connected via a pipe (32) to the furnace hood (3) which is under gas pressure.

Abstract: A method for refining and casting metals and metal alloys includes melting and refining a metallic material and then casting the refined molten material by a nucleated casting technique. The refined molten material is provided to the atomizing nozzle of the nucleated casting apparatus through a transfer apparatus adapted to maintain the purity of the molten refined material. An apparatus including a melting and refining apparatus, a transfer apparatus, and a nucleated casting apparatus, in serial fluid communication, also is disclosed.

Abstract: A method for refining and casting metals and metal alloys includes melting and refining a metallic material and then casting the refined molten material by a nucleated casting technique. The refined molten material is provided to the atomizing nozzle of the nucleated casting apparatus through a transfer apparatus adapted to maintain the purity of the molten refined material. An apparatus including a melting and refining apparatus, a transfer apparatus, and a nucleated casting apparatus, in serial fluid communication, also is disclosed.

Abstract: A method of magnetically-controllable, electroslag melting of titanium and titanium-based alloys is provided that includes the effect of an external radial magnetic field on the metallurgical melt. The field forms at least two adjoining melting layers which are rotated horizontally in opposite directions, and causes intralayer and meridional toroidal rotation of the melt. The uniform hydrodynamic structure of the melt over the total length of the ingot is stabilized by changing the melting voltage. The external radial magnetic field and the use of a fluoride-chloride flux improves the refinement of metal (by reducing harmful inclusions), condenses the metal structure, and provides high chemical and physical homogeneity of the metal ingot. This method is the most useful in the production of high strength titanium alloys including heavy metals (e.g., W, Mo, Cr and Fe).

Abstract: A VAR process is conducted in an apparatus characterized by a crucible wall that provides a stable shelf anchor. The VAR apparatus includes a furnace chamber, a consumable electrode formed of a material to be remelted within the furnace chamber and a crucible within the furnace chamber. The crucible has a wall that forms a vessel to collect melt material from the consumable electrode. At least part of the wall is textured to provide area for mechanical stabilization of the shelf as the underside of the shelf melts and the upperside of the shelf forms. In a vacuum arc remelting process, a consumable electrode is loaded into a furnace chamber above a cooled crucible having a textured wall that forms a vessel to collect melt material from the consumable electrode. The process includes striking a direct electric current between the electrode and a bottom of the crucible to cause melting of material from a tip of the electrode. Melt material is collected from the tip in the crucible.

Abstract: A channel arrangement for discharging molten metal from a smelting furnace, includes a channel (2) with two sidewalls (4, 5) and a channel bottom (6) made of a fireproof material. The channel (2) is arranged within a formwork trough (3) having receiving spaces (14) abutting lateral formwork walls (12, 13). A respective transversely moveable push wall (7, 8) is associated with each of the formwork walls (12, 13), while the receiving space (14) can be filled with a fireproof material, thereby providing a replacement sidewall. As soon as a channel (2) is worn, the channel is taken out of service and the bottom region is exposed. The remaining portion of the sidewalls (4, 5) together with the replacement sidewalls positioned in the receiving space (14) is displaced by a predetermined distance, and subsequently a fireproof material is poured into the channel bottom (6) as well as into the new receiving space (14) created behind the replacement sidewalls.

Abstract: A guide tube structure for flux concentration is provided. The discharge guide tube comprises a central orifice that extends from a source of metal to an outlet in the discharge guide tube for directing a stream of melt therethrough; a structure that generates an electromagnetic field in the discharge guide tube; and an interior discharge guide tube flux concentration configuration that is capable of concentrating at least one of heat, electromagnetic field, and electromagnetic flux onto the stream of melt that flows through the central orifice. The electromagnetic field is applied at a substantially constant level.

Abstract: A method of magnetically-controllable, electroslag melting of titanium and titanium-based alloys is provided that includes the effect of an external radial magnetic field on the metallurgical melt. The field forms at least two adjoining melting layers which are rotated horizontally in opposite directions, and causes intralayer and meridional toroidal rotation of the melt. The uniform hydrodynamic structure of the melt over the total length of the ingot is stabilized by changing the melting voltage. The external radial magnetic field and the use of a fluoride-chloride flux improves the refinement of metal (by reducing harmful inclusions), condenses the metal structure, and provides high chemical and physical homogeneity of the metal ingot.

Abstract: A melt guide is provided for enclosing a bottom of an electroslag refining crucible containing a melt of electroslag refined metal. The guide includes an upper plate sized to engage the crucible bottom for attachment thereto, and includes an upper orifice drain therethrough for draining by gravity the melt from the crucible. A lower plate is spaced below the upper plate to define a plenum therebetween, and includes a lower orifice drain therethrough. A downspout extends through the plenum in flow communication between the upper and lower drains, and includes a middle orifice drain. A heater surrounds the downspout for heating the melt drainable therethrough. And, a coolant is circulated through the plenum for cooling the guide.

Abstract: A method and system of heating a body of molten aluminum, for example, contained in a heating bay, the method comprising providing a body of molten aluminum; projecting an electric powered heater into the body of molten aluminum; passing electric current through the element and adding heat to the body of molten aluminum. The heater is comprised of a sleeve suitable for immersing in the molten aluminum. The sleeve may have a closed end and is comprised of a composite material comprised of an inner layer of titanium or titanium alloy having an outside surface having a refractory coating thereon exposed to the molten aluminum, the refractory coating resistant to attack by the molten aluminum. An electric heating element is located in the sleeve in heat transfer relationship therewith for adding heat to the molten aluminum.

Abstract: A method of magnetically-controllable, electroslag melting of titanium and titanium-based alloys which provides high homogeneity over substantially the total ingot length is provided. The homogeneity of the ingot is achieved by maintaining the maximum permissible values of electrode gap and consumable electrode feed rate substantially constant. The value of the melting current increases due to the decreasing melting voltage. The direction and intensity of magnetically-controllable, toroidal rotation are kept substantially constant by maintaining the melting current and electrode gap at substantially constant values. The quality of the metal was increased due to the reduction of harmful gas inclusions by using the fluoride-chloride flux. This metal purification is optimized by the toroidal rotation of melt. Smooth regulation of the melt direction is provided by using the device for stabilizing the melting current.

Abstract: A method and system of heating a body of molten aluminum, for example, contained in a heating bay, the method comprising providing a body of molten aluminum; projecting an electric powered heater into the body of molten aluminum; passing electric current through the element and adding heat to the body of molten aluminum. The heater is comprised of a sleeve suitable for immersing in the molten aluminum. The sleeve may have a closed end and is comprised of a composite material comprised of an inner layer of titanium or titanium alloy having an outside surface having a refractory coating thereon exposed to the molten aluminum, the refractory coating resistant to attack by the molten aluminum. An electric heating element is located in the sleeve in heat transfer relationship therewith for adding heat to the molten aluminum.

Abstract: A process for producing a turbine rotor using an ingot in which segregation is prevented effectively when ESR is used to produce a large-sized ingot. A hole is formed along an axial direction in the core of an electrode. The molten pool is made shallow and flat and segregation is prevented from occurring. Consequently, an ESR ingot of good quality offering an excellent surface is obtainable as it is free from segregation. Moreover, an electrode melting rate is increased and efficiency is improved so that a high quality turbine can be manufactured from the ingot.

Abstract: A roller for furnaces, is used with a plurality of rollers substantially parallel to each other. The roller is provided with a plurality of annular collars which are side by side and spaced apart. The annular collars are cooled by means of a flow of cooling fluid which is oriented transversely with respect to their axis and parallel to their median plane. The annular riders are made in tubular form and may be of toroidal form and are connected separately each to the supply duct and to the return duct for the cooling fluid. They may also be formed by the individual turns of a tubular spiral or by a number of successive segments of a spiral which are connected via their ends to the supply duct and to the return duct.

Abstract: An object of the present invention is to provide an ingot wherein occurrence is prevented when an electroslag remelting method is used for producing a large ingot and which a super alloy is sensitive to segragation. According to the present invention, the electrode for electroslag remelting method has a hole formed along an axial direction in the core of an electrode. Therefore, the molten pool is made shallow so that flat and segregation is prevented from occurring. Consequently, an ESR ingot of good quality is accomplished with an excellent surface and is free from segregation. Moreover, an electrode melting rate is increasing and efficiency is improved.

Abstract: An electroslag remelting plant includes an ingot mold 4 for forming a block from remolten material, at least one consumable electrode 26, a body having at least one vertically driven electrode rod 20 for the advance of the consumable electrode and a hood 33 disposed above the ingot mold which has at least one concentric opening toward the respective electrode axis. In order to limit the volume over the slag the following is provided: The hood 33 is, with respect to its vertical axis "A", subdivided into laterally movable sectors 34, 35 each of which is, at a first sealing joint 41, gas-tight connected with its lower edge 40 to top of the ingot mold 4 as far as possible and with its upper edge 39, at a second sealing joint 42, gas-tight sealed as far as possible with respect to the electrode rod. Further, the hood 33 has an interior of such cross section and height that, in its most elevated position, the top end of the at least one consumable electrode 26 is below the second sealing joint 42 of the hood 33.

Abstract: A method and apparatus is provided for controlling the atmosphere above the bath of an electroslag remelting furnace, including sealing the atmosphere of the furnace directly above the crucible by employing a shell secured to the crucible and a shroud secured between the shell and the movable furnace ram to encapsulate the atmosphere, and analyzing the oxygen content of the atmosphere and controlling the amount of oxygen therein by introducing an inert gas in the atmosphere.

Abstract: The metallurgical vessel comprises a continuous wall and a bottom plate and such vessel constitutes a mold for electrically remelting an electrode by resistance heating of an electrically conductive slag bath. The metallurgical vessel further comprises solenoids for generating an electromagnetic field which is controlled by control means operatively connected to a reference signal generator and to magnetic measuring means like Hall generators preferably arranged tangentially relative to the vessel.