VIM
VIM
Vacuum Induction Melting (VIM) is a process that uses electromagnetic induction under vacuum conditions to melt metals. It is crucial for producing high-value alloys such as superalloys, stainless steels, and electronic alloys. The process involves charging material into an induction furnace, melting it under vacuum, refining the molten metal, and adjusting its chemistry to meet desired specifications.
VIM Process Overview:
The VIM process consists of several key steps: charging the furnace, melting the material, refining the molten metal, and pouring it into molds. Consarc VIM furnaces are designed for efficient pouring by aligning the tundish with the pour stream, reducing refractory costs, and minimizing gas inclusion in the final product.
Design Features of Consarc VIM Furnaces:
Consarc furnaces include advanced features such as rugged induction steel shell furnaces, rapid exchange features, efficient power supplies, auxiliary stirring systems, multiple chamber systems, and computerized control systems with SCADA for remote operation.
Types of VIM Systems:
Consarc offers two main types of VIM systems:
- Master Alloy Systems: Handle heat sizes from 1 to 10 tons, designed for pouring multiple small diameter ingots, featuring overmelt chargers, vibratory side feeders, and advanced vacuum pumping systems.
- Electrode Systems: Larger systems with heat sizes over 30 tons, capable of pouring long electrode molds, including large capacity overmelt chargers, custom isolation valves, and sophisticated safety systems.
Chamber Design and Operational Efficiency:
Consarc's VIM systems are designed for high productivity with static melting chambers that allow continuous operation without breaking vacuum. Features include rollaway heads for easy access and door-mounted designs for simplified maintenance.
Melting Procedure:
Materials are charged into the furnace under vacuum, and power is applied to melt them. Additional charges are added to reach the desired melt capacity. The molten metal undergoes refining under vacuum, with chemistry adjustments made to achieve precise melt chemistry. Impurities are removed through chemical reactions, disassociation, flotation, and volatilization. Once the desired chemistry is achieved, the molten metal is poured through a preheated tundish into molds.
Applications:
VIM is used to produce superalloys, stainless steels, magnetic and battery alloys, electronic alloys, and other high-value alloys.
Design Advantages:
Consarc's VIM furnaces are designed for pouring with a tundish aligned with the pour direction, eliminating the need for a launder. This design offers advantages such as reduced refractory costs, minimized gas dissolution, and the possibility of bottom filling molds (uphill casting).
Contact Information:
For more information, visit Consarc's website or contact their offices in New Jersey, USA, or North Lanarkshire, UK.
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 Phone: +44 (0)1698 730430 Fax: +44 (0)1698 730431 E-mail: [email protected] www.consarceng.com Vacuum Induction Melting Furnaces For more information visit www.consarc.com.
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VIM— The Process VIM— Pouring Design A B C D E F G H I J Vacuum Induction Melting (VIM) is the melting of metal via electromagnetic induction under vacuum. An induction furnace containing a refractory lined crucible surrounded by an induction coil is located inside a vacuum chamber. The induction furnace is connected to an AC power source at a frequency precisely correlating to the furnace size and material being melted. Material is charged into the induction furnace under vacuum and power is applied to melt the charge. Additional charges are made to bring the liquid metal volume to the desired...
Open the catalog to page 2
VIM - Chamber Design Vacuum Induction Melting Furnaces Consarc designs a static VIM melting chamber which is adequately sized and designed to operate in this harsh environment. The system is designed to operate for many consecutive melting cycles without the need to break vacuum for cleaning or furnace charging between melts. This simple design philosophy ensures that the VIM furnace offers the highest possible productivity in operation. Consarc has built the majority of the large VIM systems in production today worldwide. Companies producing the best masteralloy barstock for precision casting...
Open the catalog to page 3
Masteralloy VIM Systems Masteralloy VIM systems are generally in the range of 1-10 tons and are characterized by their ability to pour many multiples of small diameter ingots configured on a mold car or turntable. Masteralloy ingots are commonly as small as 73 mm (27/8”) and as large as 254 mm (10”) in diameter and generally about 1.2m (48”) tall. Consarc Masteralloy VIM systems commonly incorporate the following features: • Overmelt Chargers for primary bucket charging of high density charge materials like balls and briquettes, temperature probe insertion, sample taking, and late alloy additions....
Open the catalog to page 4
Masteralloy VIM Systems Masteralloy VIM systems are generally in the range of 1-10 tons and are characterized by their ability to pour many multiples of small diameter ingots configured on a mold car or turntable. Masteralloy ingots are commonly as small as 73 mm (27/8”) and as large as 254 mm (10”) in diameter and generally about 1.2m (48”) tall. Consarc Masteralloy VIM systems commonly incorporate the following features: • Overmelt Chargers for primary bucket charging of high density charge materials like balls and briquettes, temperature probe insertion, sample taking, and late alloy additions....
Open the catalog to page 5
VIM - Chamber Design Vacuum Induction Melting Furnaces Consarc designs a static VIM melting chamber which is adequately sized and designed to operate in this harsh environment. The system is designed to operate for many consecutive melting cycles without the need to break vacuum for cleaning or furnace charging between melts. This simple design philosophy ensures that the VIM furnace offers the highest possible productivity in operation. Consarc has built the majority of the large VIM systems in production today worldwide. Companies producing the best masteralloy barstock for precision casting...
Open the catalog to page 6
VIM— The Process VIM— Pouring Design A B C D E F G H I J Vacuum Induction Melting (VIM) is the melting of metal via electromagnetic induction under vacuum. An induction furnace containing a refractory lined crucible surrounded by an induction coil is located inside a vacuum chamber. The induction furnace is connected to an AC power source at a frequency precisely correlating to the furnace size and material being melted. Material is charged into the induction furnace under vacuum and power is applied to melt the charge. Additional charges are made to bring the liquid metal volume to the desired...
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 Irtductotherm Group Company For more information visit www.consarc.com. Leading Manufacturers of Melting, Thermal Processing and Production Systems for the Metals and Materials Industry Worldwic
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