Abstract: Superalloy component castings, such as turbine blades and vanes, are fabricated or repaired by an electroslag or electrogas welding process that at least partially replicates the crystal structure of the original cast substrate in a cast-in-place substrate extension. The process re-melts the base substrate surface and grows it with new molten filler material. As the base substrate and the filler material solidify, the newly formed “re-cast” component has a directionally solidified uniaxial substrate extension portion that at least in part replicates the crystalline structure of the base substrate. The “re-cast” component can be fabricated with a unified single crystal structure, including the extension portion. In other applications, a substrate extension can replicate a directionally solidified uniaxial crystal structure of an original base substrate casting.

Abstract: There is described a method for producing ultrahigh-purity Fe-base, Ni-base, and Co-base alloying materials to achieve impurity levels of (C+O+N+S+P)<100 ppm, and Ca<10 ppm, in the form of a large ingot, using a refining flux while forcibly cooling the crucible. A refining flux selected from the group consisting of metal elements of the Groups IA, IIA, and IIIA of the Periodic Table, oxides thereof, halides thereof, and mixtures thereof, is added to the molten metal during primary melting and the molten metal is held in contact with the refining flux for at least 5 minutes before tapping. Thereafter, the molten metal is caused to undergo solidification inside a mold, thereby producing a primary ingot.

Abstract: Proposed is a zirconium crucible used for melting an analytical sample in the pretreatment of the analytical sample, wherein the purity of the zirconium crucible is 99.99 wt % or higher. In light of the recent analytical technology demanded of fast and accurate measurement of high purity materials, the present invention provides a zirconium crucible for melting an analytical sample, a method of preparing such analytical sample, and a method of analysis that enables the analysis of high purity materials by inhibiting the inclusion of impurities from the crucible regardless of difference in the analysts and their skill.

Abstract: The energy consumption during electroslag remelting is determined to a considerable extent by the heat losses of a slag bath on the wall of a water-cooled ingot mould. A process and an ingot mould suitable for carrying it out wherein these heat losses may be avoided for the most part. Remelting thus takes place in a short, two-part sliding ingot mould known per se, except in the start-up phase, during normal block construction, the metal surface is always kept in the lower, water-cooled part of the ingot mould- that is below the line of separation between water-cooled part and insulated part of the same—by corresponding control of the relative movement between ingot mould and remelting block, so that the distance between the surface area of the metal surface on the one hand and the planes determined by the line of separation between cooled part and insulated part on the other hand, is at least 5 mm, but 100 mm at the most.

Abstract: In a method of producing substantially segregation-free and in particular freckle-free castings of metal—in particular high-alloyed steels and Ni- and Co-based alloys of large dimensions in accordance with an electroslag melting or casting method—using a short electrically conductive water-cooled chill mold (10), in the wall of which current-conducting elements (6) which are not directly water-cooled are installed in electrically insulated relationship with the part of the chill mold (10) forming the casting, a substantially segregation-free and freckle-free bloom (24) of a cross-sectional area which is at most 90% of the part of the chill mold (10) forming the casting is arranged therein and connected to the supplied metal, using a slag bath (31) which is heated by the flow of current and which is disposed in the region of the current-conducting elements (16) by continually quantitatively controlledly pouring in liquid metal (34)—or by the supply of solid metal in the form of for example gr

Abstract: The invention relates to a method and the apparatus required for carrying out the method for the continuous production of billets or ingots of metals, in particular steels and Ni- and Co-base alloys using the method of electroslag remelting and electroslag continuous casting in downwardly open water-cooled ingot molds, in which the billet issuing downwardly from the ingot mold is pressed against at least one guide element arranged rigidly in respect of its position with respect to the ingot mold axis, by at least one clamping element arranged opposite the guide element, in such a way that the regions of the billet surface which are in contact with the guide or clamping elements change within short intervals of time, wherein at least one of the elements is driven to withdraw the billet while the others move with the billet and a contact with a current source can be made by way of at least one of the elements.

Abstract: Nucleated casting systems and methods comprise the addition of powders into a liquidus portion of the casting. The casting system forms a casting comprising a liquidus portion that receives the refined liquid metal and a solidified portion, the casting further comprising a fine-grain, homogeneous microstructure that is essentially oxide- and sulfide-free and segregation defect free. The casting system comprises a source of refined liquid metal, the refined liquid metal having oxides and sulfides refined out of the metal; a solid metal particle addition system that adds solid metal particles to a surface of the liquidus portion of the casting; and a nucleated casting system for forming the casting. The solid metal particle addition system adds solid metal particles that serve as nucleation centers during solidification of the casting.

Abstract: A casting system with auxiliary cooling onto a liquidus portion of the casting can produce a metal casting that comprises a fine-grain, homogeneous microstructure. The microstructure is essentially oxide- and sulfide-free, segregation defect free, and essentially free of voids caused by air entrapped during solidification of the metal from a liquidus state to a solid state. The casting system with auxiliary cooling onto a liquidus portion of the casting can comprises an electroslag refining system as a source of liquid metal; a nucleated casting system; and at least one cooling system that supplies coolant onto a liquidus portion of the casting. The liquidus portion of the casting is cooled in a manner sufficient to provide a casting microstructure that comprises a fine-grain, homogeneous microstructure that is essentially oxide- and sulfide-free, segregation defect free, and essentially free of voids caused by air entrapped during solidification from a liquidus state to a solid state.

Abstract: Device and corresponding method for the continuous casting of molten materials, comprising a vertical duct having the shape of a funnel made of refractory material for receiving molten material, and a second duct where the molten material is cooled off, the two ducts being set one on top of the other and being axially aligned. The molten material is injected into the channel, around a stretch of which electromagnetic means are set for generating magnetic forces on the molten material, the said means consisting of a plurality of windings of electrically conductive material and of a ferromagnetic core and may be electrically supplied to produce a magnetic flux along the direction of the channel, thus producing a set of forces acting on the molten material which are directed orthogonally with respect to the direction of the said magnetic flux so as to maintain detachment of the outer surface of the molten material from the walls of the channel.

Abstract: The disclosed process consists in filling the gap between a billet and the wall of a sectional mould with a molten slag in at least two stages. When the first portion is poured in, the gaps between the sections of the mould are filled. Once the slag in the gaps is solidified completely, voltage is supplied and the second and next portions of the slag are added. The creation of an electromagnetic field inside the mould takes place following the starting of the cladding process. The liquid metal is then added for the cladding process, which is carried out by means of the stable rotation of the slag and metal. The process can be carried out with varying levels of slag inside the current-carrying part of the mould. The billet can be preheated at the short-circuiting conditions prior to the cladding process.

Abstract: A system and method of electroslag refining of metal is taught. The system and method includes the introduction of unrefined metal into an electroslag refining process in which the unrefined metal is first melted at the upper surface of the refining slag. The molten metal is refined as it passes through the molten slag. The refined metal is collected in a cold hearth apparatus having a skull of refined metal formed on the surface of the cold hearth for protecting the cold hearth from the leaching action of the refined molten metal. A cold finger bottom pour spout is formed at the bottom of the cold hearth to permit dispensing of molten refined metal from the cold hearth. The dimensions of the cold finger apparatus pour spout are controlled by positioning a retaining means around the outer surface of the pour spout thereby controlling the flow rate of molten metal through the cold finger apparatus.

Abstract: In a process for producing blocks of metals, in particular steels and nickel-base and cobalt-base alloys, by remelting self-consumable electrodes under electrically conductive slag in an atmosphere of controlled composition, the operation of melting down the self-consuming electrode is effected in a space which is gas-tightly delimited by the slag bath surface, the wall of a chill mold and a hood which is disposed on the chill mold, wherein for opening the closed-off space for effecting the electrode-change operation the gas-tight connection between the hood and the chill mold is separated, with the hood raised the residual electrode portion is removed from the melting region and a new electrode is moved into the melting position.

Abstract: For the continuous remelting of metals--in particular steels and Ni-- Co-base alloys--in a short, downwardly open water-cooled chill mold (20) for producing an elongate casting portion (26) the latter is produced either by continuous or stepwise withdrawal from the chill mold (20) or when the elongate casting portion (26) is stationary by corresponding lifting movement of the chill mold (20). In order to ensure on the one hand a sufficiently high and thus economical smelting rate and on the other hand a high level of quality in respect of the remelted elongate casting portions (26), the cross-sectional area of the smelting-off electrode (16) should be at least 0.5 times the cross-sectional area of the remelted elongate casting portion (26) and the smelting-off rate should be so adjusted that it corresponds to between 1.5 and 30 times the equivalent elongate casting portion diameter (D.sub.eq) calculated from the circumference (U) of the casting cross-section, in accordance with the relationship:D.sub.eq =U/.

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: The method consists in that molten metal and slag are obtained in a reservoir and then are poured into a mold and kept there till crystallization of the metal takes place and a shaped casting is produced. Prior to the process of pouring, the mold is moved towards the reservoir so that their upper end faces adjoin each other to form a closed integrated unit, which is turned in a vertical plane to transfer the metal and slag into the mold. The joint of the mold with the reservoir in the process of pouring is tightened by providing a time delay for this process from the moment of covering the joint with a slag layer till the moment of solidification of this layer. In the device for producing the castings, the mold and reservoir are provided with individual drives rotating them in a vertical plane, the drives moving the mold to form a closed integrated unit with the reservoir and rotating this unit in the process of pouring the molten metal and slag into the mold.

Abstract: A process of manufacturing a roll suitable for use in a rolling mill, the roll having a cylindrical barrel middle section and a neck at each end of the barrel, wherein the barrel and necks are of different material compositions, by remelting an electrode having a central region corresponding in mass and composition of materials to that desired for the barrel of the roll, two end regions corresponding in mass and composition of materials to that desired for the necks of the roll and a transition region disposed between the central region and each end region, each transition region including the material of the barrel and at least one further material. An electroslag remelting process is used in a water cooled mold. The mold is composed of at least two parts and defines a cavity approximating the final outlines of the roll. The mold has tapered transition regions between a part of the cavity corresponding to the barrel and the constricted cavity regions corresponding to the necks.

Abstract: Apparatus for the production of a metal article comprises means for maintaining a reservoir of molten metal with a free surface, means for rotating the free surface of the reservoir about an axis such that the molten metal is atomized and thrown outwardly away from the said surface by centrifugal action, and a substrate in the path of the atomized particles of said molten metal, whereby a solid article may be built up on the substrate by solidifying the atomized particles thereon. The molten metal may be produced by melting an electrode or otherwise.An annular solid metal article is disclosed having excellent mechanical properties. The solid metal article is produced in a single step by a spray deposition process. Molten metal is centrifugally atomized to splat and build up on a cooled mold surface disposed around the centrifuge means. Controlled relative reciprocatory movement in the direction of the rotational axis of the centrifuge is provided.

Abstract: A method of producing a composite steel body shaft by using at least one cooling metal mold having a cavity of a diameter and a steel body having another cavity of another diameter both of which cavities are coaxially disposed to define a through-hole in which the remelting and solidifying of electrode is effected to provide a shaft portion connected to the hollow body. At a contact position defined by both the metal mold and the hollow steel body at which contact position the diameter of the through-hole is reduced step-wise, a space is provided so that the diameter of the through hole is reduced gradually without the step-wise reduction of diameter of the through hole so as to prevent the confining of slag from occurring at the contact position.

Abstract: A method and apparatus for building an axially symmetrical workpiece of desired geometry by deposit welding which uses a translatable welding head for depositing molten weld material and a rotatable, reusable shoe which translates with the welding head. The rotatable, reusable shoe forms, supports and cools the deposited molten weld material puddle while the weld material is solidifying thereby eliminating the need for a conventional preform.

Abstract: Process and apparatus for the production of metal blocks, castings or profile material (14) during which molten metal (S3) in a chill (K) is moved from a heating zone (HZ) into a cooling zone according to the solidification speed of the molten metal (S3) and during which cooling time hard material grains are continuously fed through the heating zone (HZ), preferably being electrical heated molten slag (12), the temperature of which is above the melting point of the hard material, into the molten metal (S3), the temperature of which is lower than the melting point of the hard material. The temperature of the molten slag, the height (h) of it and the height of the molten metal is controlled by the control device (ST) controlling the electrical current and dosing of the materials currents. Control methods and devices as well as material selections for matrix and doping materials are described.

Abstract: A method of nucleating highly alloyed metals is provided in which the metal alloy is melted, a metal alloy powder is added to the molten metal under conditions such that the powder enters the metal substantially free of surface impurities and the metal is then cooled to solidification.

Abstract: This invention is in a method of manufacturing a composite steel ingot wherein a consumable electrode is inserted into an empty space positioned concentrically with said steel ingot, and electric power is fed to said consumable electrode to effect electroslag remelting under a slag bath and then to solidify the molten metal, while taking out an electric current through a plurality of collecting electrodes which are electrically connected to said steel ingot placed on a surface plate, the improvement in that a flow path of the electric current passing from said consumable electrode to said collecting electrodes is moved in the circumferential direction of said steel ingot during said electroslag remelting.

Abstract: A method for rotary refining and casting comprising the remelting of an alloy electrode suspended within an essentially cylindrical mold wherein said electrode and said mold are both rotated about their coincident axes of symmetry; heating the tip of said electrode to a sufficiently high temperature to cause melting, with the metal droplets formed at said tip of said electrode descending into said mold under the combined effect of gravitational and centrifugal forces, wherein said droplets form a liquid pool, the free surface of said pool assuming the configuration of a paraboloid of revolution about said axis of rotation, resulting in a shallow pool with high surface area; said pool progressively solidifying into a fine-grain ingot exhibiting high homogeneity and cleanliness; the energy for melting said tip of said electrode and for maintaining said pool molten provided by converting electrical energy to thermal energy at a gap maintained between said electrode and said molten pool.

Abstract: A method of fabricating a structural member such as a wicket gate for water turbines by electro slag forming comprises the steps of mounting a water-cooled metal mold on a part of a previously formed structural member, such as a stem; melting electrodes inserted in the water-cooled metal mold to form the other part of the structural member such as a vane portion of the wicket gate on the previously formed structural member. The previously formed structural member has a concave portion which is exposed in the water-cooled metal mold and the water-cooled metal mold is mounted so as to contact with the previously formed structural member at the lower portion than the top of the concave portion. The previously formed structural member is melted gradually from the central portion of the concave to the outer periphery and then such a portion as the vane portion is formed by molten metal of the electrode.

Abstract: An improved method is disclosed for electroslag remelting an electrode of an alloy containing at least one oxide forming ingredient, including melting such electrode in a novel flux composition containing about 1-35% boron oxide, by weight.