Abstract: A Vacuum Arc Remelting controller apparatus wherein process control is accomplished primarily through control of pool power. Pool power being defined as the total energy flux into a top ingot surface of the VAR ingot. The controller apparatus of the present invention comprises a controller computer that transmits commands to the host furnace through an ethernet connection.

Abstract: A method of model-based ingot solidification control for the vacuum arc remelting process is presented. Specifically, the model predicts the pool depth as a function of radial position from ingot centerline and time, given melting current, and electrode melting efficiency. The analysis leading to the model assumes that the electrode gap is being accurately controlled during the melting process. The controller has both 2-dimensional and 3-dimensional embodiments.

Abstract: A Vacuum Arc Remelting controller apparatus wherein process control is accomplished primarily through control of pool power. Pool power being defined as the total energy flux into a top ingot surface of the VAR ingot. The controller apparatus of the present invention comprises a controller computer that transmits commands to the host furnance through an ethernet connection.

Abstract: The present application describes and claims an integrated remelting manager for the VAR and ESR remelting processes comprising the following three integrated components: a pre-process manager, a real-time process manager and a post-process manager. The present application also describes and claims a method of using the integrated remelting manager.

Abstract: An apparatus for controlling a vacuum remelting furnace comprising a controller capable of adjusting electrical current to an electrode and a controller capable of adjusting the electrode's drive speed. The controllers adjust the current and drive speed based on a predetermined pool power reference value. The apparatus may also comprise a third controller that receives the adjusted current and drive speed as inputs and sends estimated electrode drive speed bias as output to the drive speed controller and estimated current bias as output to the current controller.

Abstract: An apparatus for and method of controlling a remelting furnace comprising adjusting current supplied to an electrode based upon a predetermined pool power reference value and adjusting the electrode drive speed based upon the predetermined pool power reference value.

Abstract: A method of producing three-dimensional particle structures with enhanced magnetic susceptibility in three dimensions by applying a triaxial energetic field to a magnetic particle suspension and subsequently stabilizing said particle structure. Combinations of direct current and alternating current fields in three dimensions produce particle gel structures, honeycomb structures, and foam-like structures.

Abstract: An apparatus and method of controlling a remelting process by providing measured process variable values to a process controller; estimating process variable values using a process model of a remelting process; and outputting estimated process variable values from the process controller. Feedback and feedforward control devices receive the estimated process variable values and adjust inputs to the remelting process. Electrode weight, electrode mass, electrode gap, process current, process voltage, electrode position, electrode temperature, electrode thermal boundary layer thickness, electrode velocity, electrode acceleration, slag temperature, melting efficiency, cooling water temperature, cooling water flow rate, crucible temperature profile, slag skin temperature, and/or drip short events are employed, as are parameters representing physical constraints of electroslag remelting or vacuum arc remelting, as applicable.

Abstract: A method and apparatus for controlling vacuum arc remelting (VAR) furnaces by estimation of electrode gap based on a plurality of secondary estimates derived from furnace outputs. The estimation is preferably performed by Kalman filter. Adaptive gain techniques may be employed, as well as detection of process anomalies such as glows.

Abstract: The electrode gap of a VAR is monitored by determining the skewness of a distribution of gap voltage measurements. A decrease in skewness indicates an increase in gap and may be used to control the gap.

Abstract: An apparatus and method for controlling electrode gap in a vacuum arc remelting furnace, particularly at low melting currents. Spectrographic analysis is performed of the metal vapor plasma, from which estimates of electrode gap are derived.

Abstract: The invention relates to improved apparatuses and methods for remelting metal alloys in furnaces, particularly consumable electrode vacuum arc furnaces. Excited reactive gas is injected into a stationary furnace arc zone, thus accelerating the reduction reactions which purify the metal being melted. Additionally, a cooled condensation surface is disposed within the furnace to reduce the partial pressure of water in the furnace, which also fosters the reduction reactions which result in a purer produced ingot. Methods and means are provided for maintaining the stationary arc zone, thereby reducing the opportunity for contaminants evaporated from the arc zone to be reintroduced into the produced ingot.