Abstract: A process for casting an ingot of pre-alloyed metal from a consumable electrode. It includes the steps of: providing a consumable electrode corresponding to the desired metallurgical composition of the to-be-cast ingot; providing a second electrode; striking an arc between the consumable electrode and the second electrode to melt the consumable electrode and thereby form a molten pool; maintaining the arc between the consumable electrode and the molten pool; rotating or oscillating the consumable electrode about its axis during melting; providing a controlled atmosphere for the melting of the consumable electrode; delivering molten metal into a fluid cooled mold; and withdrawing the ingot from the mold.

Abstract: A method for fine grain casting prealloyed metal comprising the steps of providing first and second electrodes within an enclosed chamber, said first and second electrodes being spaced so as to form a gap between them, at least one of said electrodes being an ingot having a composition corresponding to the composition of a prealloyed continuous casting to be formed; and heating said electrodes to a temperature sufficient to melt said at least one electrode into molten metal which falls from said at least one electrode into a mold wherein the molten metal is at least partially solidified; wherein the improvement comprises causing said molten metal to fall directly from said at least one electrode into a mold so as to result in a casting having a fine grained structure.

Abstract: Slag which is not electrically conductive when solid or at least at temperatures below 1500.degree. F. is melted by providing a graphite covering on top of the solid slag, contacting the covering material with at least two electrodes in spaced apart relationship, and supplying electric power to the electrodes to cause the graphite to sublime and set a plasma arc of carbon dioxide between the electrodes with resulting initial melting of the slag adjacent the electrodes. This melted slag then provides a conductive electrical path between the electrodes for continued melting of the slag.