VAR
VAR
Consarc Corporation specializes in producing specialty steel, superalloys, and reactive metals using advanced Vacuum Arc Remelting (VAR) technology. Their furnaces feature state-of-the-art computerized controls and robust DC power supplies.
The VAR process involves melting an electrode in a vacuum furnace to create a high-quality ingot. Key steps include loading the electrode, creating a vacuum environment, striking a high current arc to form a molten metal pool, and maintaining precise control over the arc gap and melt rate for quality assurance. The molten pool is solidified directionally to enhance material properties.
Consarc's Generation 7 Automatic Melt Controls use a SCADA system for precise control and data acquisition. Features include a PLC for furnace logic, a dripshort processor for monitoring short circuits, a PC interface for control and analysis, and customizable remelt profiles.
Consarc designs its own DC power supplies, offering Variable Reactance Transformer (VRT) and Thyristor SCR based units. These are water-cooled, enclosed in NEMA 12 steel enclosures, and equipped with features for stable power delivery.
Consarc VAR furnaces address issues like uncontrolled metal stirring and alloy segregation. Features include coaxial design for melt uniformity, X-Y axis electrode positioning, load cell-based precision melt control, automated hot topping, and proprietary power supply.
Designed for reactive metals like titanium, RVAR furnaces include safety measures such as argon gas purging and overpressure relief valves, and a Vacuum Stub Welder for efficient electrode preparation.
Consarc offers VAR furnaces in various sizes to meet specific needs, with specifications for maximum ingot weight, crucible diameter, and power supply ratings.
- Precision Melt Control: High-accuracy load cells monitor electrode weight for optimal melting conditions.
- Automation: Fully automated process enhances operation ease and consistency.
- Power Supply: Proprietary power supplies ensure reliability and efficiency.
- Primary Melt Furnaces: For long, low-density electrodes requiring extensive ram travel and head lift.
- Secondary/Tertiary Melt Furnaces: For previously melted electrodes, focusing on safety due to titanium's explosive nature.
Includes argon gas purged valves, emergency argon backfill, and protective concrete bunkers for safe operation.
The Vacuum Stub Welder optimizes furnace time by welding electrode stubs under vacuum.
The VAR process involves loading the electrode, creating a vacuum, and striking a high current arc to form a molten metal pool, with controlled directional solidification to enhance material properties.
The Generation 7 Automatic Melt Controls system uses SCADA technology for precise control and data logging, allowing detailed process analysis and optimization.
Consarc Corporation and Consarc Engineering Limited provide contact details for further inquiries.
Catalog excerpts
CONSARC CORPORATION 100 Indel Avenue P.O. Box 156 Rancocas, New Jersey 08073 Phone: +1 (609) 267-8000 Fax: +1 (609) 267-1366 E-Mail: [email protected] www.consarc.com CONSARC ENGINEERING LIMITED 9 Woodside Eurocentral Holytown, North Lanarkshire ML14XL Scotland,United Kingdom Telephone : +44 (0)1698 730430 Fax : +44 (0)1698 730431 E-mail : [email protected] www.consarceng.com Vacuum Arc Remelting Furnaces For more information visit www.consarc.com.
Open the catalog to page 1
VAR — The Process F A (-) E G B C H (+) Automatic Melt Controls Prior to start up, the electrode to be melted is loaded into the furnace. For specialty steels and superalloys, the electrode is previously cast in air or vacuum. For primary reactive metals like titanium, the electrode is fabricated from compacted sponge and/or scrap, or from a hearth melt process like Plasma or Electron Beam. Consarc pioneered in Automatic Melt Controls in the early 1970’s. At that time, before personal computers, melt rate was maintained using programmable calculators while operators adjusted the arc gap by changing...
Open the catalog to page 2
Proprietary High Current DC power supply (Reactor or Thyristor based): Consarc is the only VAR furnace supplier that designs and builds our own custom designed DC power supplies. These units are specifically designed to meet the demanding requirements of the VAR melting application. This provides Consarc VAR customers with a single source responsibility for the complete VAR and power transmission system. Consarc offers both its signature Variable Reactance Transformer (VRT) power supply as well as Thyristor SCR based units. Both systems are internally water cooled by a dedicated, dual pump, closed...
Open the catalog to page 3
Vacuum Arc Remelting Furnaces Reactive Vacuum Arc Remelting Furnaces ‘RVAR’ Advantages of Consarc VAR furnaces A Consarc Reactive Metals Vacuum Arc Remelting (R-VAR) Furnace is a precision machine specifically designed and built for the remelting of reactive metals such as Titanium. The Consarc VAR process overcomes serious problems that have been historically associated with conventional VAR operations. Problems such as strong magnetic fields in the electrode melt area that cause uncontrolled metal stirring, uneven solidification, and alloy segregation. Imprecise positioning of the electrode...
Open the catalog to page 4
Vacuum Arc Remelting Furnaces Reactive Vacuum Arc Remelting Furnaces ‘RVAR’ Advantages of Consarc VAR furnaces A Consarc Reactive Metals Vacuum Arc Remelting (R-VAR) Furnace is a precision machine specifically designed and built for the remelting of reactive metals such as Titanium. The Consarc VAR process overcomes serious problems that have been historically associated with conventional VAR operations. Problems such as strong magnetic fields in the electrode melt area that cause uncontrolled metal stirring, uneven solidification, and alloy segregation. Imprecise positioning of the electrode...
Open the catalog to page 5
Proprietary High Current DC power supply (Reactor or Thyristor based): Consarc is the only VAR furnace supplier that designs and builds our own custom designed DC power supplies. These units are specifically designed to meet the demanding requirements of the VAR melting application. This provides Consarc VAR customers with a single source responsibility for the complete VAR and power transmission system. Consarc offers both its signature Variable Reactance Transformer (VRT) power supply as well as Thyristor SCR based units. Both systems are internally water cooled by a dedicated, dual pump, closed...
Open the catalog to page 6
VAR — The Process F A (-) E G B C H (+) Automatic Melt Controls Prior to start up, the electrode to be melted is loaded into the furnace. For specialty steels and superalloys, the electrode is previously cast in air or vacuum. For primary reactive metals like titanium, the electrode is fabricated from compacted sponge and/or scrap, or from a hearth melt process like Plasma or Electron Beam. Consarc pioneered in Automatic Melt Controls in the early 1970’s. At that time, before personal computers, melt rate was maintained using programmable calculators while operators adjusted the arc gap by changing...
Open the catalog to page 7
CONSARC CORPORATION E-Mail: [email protected] CONSARC ENGINEERING LIMITED Holytown, North Lanarkshire ML14XL Scotland,United Kingdom E-mail : [email protected] An inductatherm Croup Company For more information visit www.consarc.com. Leading Manufacturers of Melting, Thermal Processing & Production Systems for the Metals & Materials Industry Worldwide.
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