Electroslag Remelting brochure
Electroslag Remelting brochure
The Electroslag Remelting (ESR) process involves melting the lower end of an electrode through a layer of molten slag into a water-cooled copper mold. The slag, composed of calcium fluoride and other oxides, becomes electrically conductive and superheated, facilitating the melting of the electrode. This process purifies the metal and forms a structurally sound ingot.
Consarc's Generation 7 Automatic Melt Controls utilize a SCADA system with a PLC and PC interface to automate furnace operations. This system maintains electrode immersion and melt rate through voltage swing control, allowing for detailed data logging and process optimization.
Innovations include a high fill ratio electrode and a coaxial conductor system, which reduce power consumption and improve ingot quality. Their proprietary AC power supply technology, featuring saturable core reactors, offers efficient and reliable current control.
Consarc's ESR furnaces can operate under inert gas conditions, beneficial for melting oxygen and nitrogen-sensitive alloys. This prevents oxidation, allows the use of different slags, and reduces inclusions in ingots.
Consarc offers various standard and custom-sized static ESR furnaces capable of producing large ingots. The inert gas system includes features like sealed slag feeders and oxygen monitoring to maintain low oxygen levels during the melt.
The document outlines various models of inert gas furnaces with specifications such as maximum ingot weight, crucible diameter, baseplate dimension, power supply rating, and maximum ram travel. Models range from 900 mm to 1200 mm with ingot weights from 4,000 kg to 35,000 kg and power supplies from 15,000 amps to 40,000 amps.
Consarc's engineers developed a unique approach to ESR in the 1960s, focusing on a high fill ratio electrode and a coaxial conductor system. This design reduces power consumption, improves ingot quality, and minimizes magnetic stirring and stray field eddy current heating.
Consarc designs its own AC power supplies using saturable core reactor technology. These systems are water-cooled, reducing footprint and maintenance costs, and are enclosed in a NEMA 12 steel enclosure for maintenance access.
The ESR process involves melting an electrode through molten slag into a water-cooled mold. The slag acts as a resistance heating element, purifying the metal as it solidifies. The process can occur in an inert gas environment to prevent oxidation.
Consarc's Generation 7 Automatic Melt Controls use a SCADA system with a PLC and PC interface. The system manages melt rate, electrode immersion, and data logging. The remelt profile is customizable, and the process is automated through various segments.
Consarc Corporation and Consarc Engineering Limited provide contact details for further inquiries.
Catalog excerpts
For more information visit www.consarc.com. >
Open the catalog to page 1
The ESR process involves the gradual melting of the lower end of a cast or forged electrode through a layer of molten metallurgically active slag into a water-cooled copper mold. The slag is usually calcium fluoride with the addition of lime, magnesia, and other oxides.In its molten state the slag is electrically conductive and acts like a resistance heating element when a high current is passed between the electrode and the mold. With the continued passage of the electric current, the slag becomes superheated.The electrode tip is immersed in this superheated slag and begins to melt. The immersion...
Open the catalog to page 2
Consarc is the only ESR furnace supplier that designs and builds our own custom designed AC power supplies. These units are specifically designed to meet the demanding requirements of the ESR melting application. This provides Consarc ESR customers with a single source responsibility for the complete ESR and power transmission system. Consarc offers only Saturable Core Reactor based power supply technology for use in our ESR furnace systems. All systems are internally water cooled by a dedicated, dual pump, closed loop, water pumping module which substantially reduces the overall power unit footprint,...
Open the catalog to page 3
Consarc is the only ESR furnace supplier that designs and builds our own custom designed AC power supplies. These units are specifically designed to meet the demanding requirements of the ESR melting application. This provides Consarc ESR customers with a single source responsibility for the complete ESR and power transmission system. Consarc offers only Saturable Core Reactor based power supply technology for use in our ESR furnace systems. All systems are internally water cooled by a dedicated, dual pump, closed loop, water pumping module which substantially reduces the overall power unit footprint,...
Open the catalog to page 6
The ESR process involves the gradual melting of the lower end of a cast or forged electrode through a layer of molten metallurgically active slag into a water-cooled copper mold. The slag is usually calcium fluoride with the addition of lime, magnesia, and other oxides.In its molten state the slag is electrically conductive and acts like a resistance heating element when a high current is passed between the electrode and the mold. With the continued passage of the electric current, the slag becomes superheated.The electrode tip is immersed in this superheated slag and begins to melt. The immersion...
Open the catalog to page 7
For more information visit www.consarc.com. >
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