Abstract: A method of manufacturing titanium electrodes in a vacuum arc remelting furnace as well as a reusable header for use in the remelting process is disclosed. An electrode may be attached to the reusable header and remelted in the furnace a number of times until a final ingot of the desired metallurgical quality is produced. The header and electrode are provided with a complimentarily shaped interlocking recess and projection to secure them together. The electrode may alternatively be integrally formed with a starter stub that includes a recess or projection that interlocks with a complimentarily shaped projection or recess on the header. At least a section of the header is made of the same metal as the electrode to be melted to reduce contamination of the ingot being formed in the furnace. Alternatively the starter stub is made from the same metal as the electrode.

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: 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 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: Method for recognition of noble metals otherwise not recognizable in base material clusters includes using an electric arc furnace in which base material clusters are disintegrated to free atoms or are alloyed with other components of the base materials, and are able to be recovered by conventional recovery techniques once they are recognized. The base material includes the products of smelting processes, pellets of compacted raw material, like anode mud or waste material, and the base materials are melted utilizing the heat from a dc electric arc furnace.

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 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: A remelting furnace has a crucible and a raisable pot placed thereon. An electrode rod leads into the pot through a passage sealed by means of a seal carried by a lower platform. The lower platform is connected to the pot by a hitch having free play, and can be raised together with the electrode rod by a lift means supported on a weighing platform. In this manner weighing of the electrode rod uninfluenced by the friction forces of the seal is possible. Also, it is possible to lift the pot without increasing the structural height of the structure accommodating the remelting furnace.

Abstract: A remelting furnace has a crucible (2) and a raisable pot (3) placed thereon. An electrode rod (6) leads into the pot (3) through a stuffing box (8) borne by a lower platform (9). The lower platform (9) is carried by rods (12, 13) which are fastened each at its upper end to a weighing platform (14). The connection of the lower platform (9) to the particular rod (12, 13) is performed in each case through a releasable clutch (10,11 ). Consequently, a lifter (17) can lift the pot (3) such that it shifts upwardly with the bottom platform (9) relative to the rods (12, 13).

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 closed remelting furnace 1 includes a vertical furnace axis A-A, an electrode supporting rod 15 for a consumable electrode 23, a furnace body 29 which has a driving mechanism for the electrode supporting rod and several furnace lower portions 6, 7 each of which has an ingot mold 9 including an ingot mold axis K-K. A furnace upper portion 11 and the furnace lower portions can individually, if desired, be aligned by means of a lateral relative movement. Through a sealed passage the electrode supporting rod is passed through a top limiting wall 16 of the furnace upper portion 11. In order to reduce the total height and labor and cost involved in design and construction the furnace upper portion 11 is subdivided in two partial segments 13, 19 along a horizontal separating groove.

Abstract: Apparatus for producing crystalline ribbons of a material from a "crucible-less" configuration of bodies of the material including possible deposition on a substrate. Means for capacitively coupling electromagnetic energy into a source body of material are provided to appropriately induce electrical current gradients in order to control and restrict the molten zone and supress net loss of the heat of fusion from the balance of the ribbon-like body. The melt zone is replenished from any direction with ribbon or a bulk source to sustain the shape and size of the growing ribbon-like body. The heat of crystallization is selectively removed by a heat sink from one end of the melt zone in a direction substantially perpendicular to the direction of pulling.

Abstract: A paint or coating composition which contains only pure Ziroconium containing compounds, and a small amount of NH.sub.4 (OH).sub.2 and acid is applied to the vertical walls of a vacuum arc furnace Copper crucible to form a stable, substantially uniform, coating thereon. The Zirconium coating composition of the present invention is free of Aluminum and Aluminum compounds and consists essentially of Zirconium Oxide suspended in a water-based Zirconyl Nitrate gel, to which small amounts of base and acid have been sequentially added. This coating eliminates the introduction of spurious impurities into the surface of the zirconium ingot formed during vacuum are melting of a zirconium compact.

Abstract: This is an improved electrode for consumable vacuum arc melting of zirconium and titanium alloys, for alloys containing a low melting point alloying material or for very low oxygen zirconium. Electrodes of this type use a low resistance spar extending substantiallly the length of the electrode, with this spar being substantially free of any unalloyed low melting point material. The improvement utilizes attachment by wedging of the external members to the spar core. Preferably the wedging is accomplished by rotation of the external member with respect to the spar core.

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.

Abstract: This is an electrode for consumable arc melting of zirconium and titanium alloys containing a low melting point alloy constituent. The electrode uses a low resistance spar extending substantially the length of the electrode and being substantially free of any unalloyed low melting point alloy constituent. The external member containing unalloyed low melting point constituent is attached to the spar member in a manner to provide a relatively high resistance through the external member in an axial direction of the electrode. During operation, this minimizes resistance heating of the external member away from the arc and thus premature melting of unalloyed low melting point constituent is generally avoided.