US3670089A - Apparatus for electroslag remelting of metals with molten slag introduction - Google Patents

Apparatus for electroslag remelting of metals with molten slag introduction Download PDF

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Publication number
US3670089A
US3670089A US68637A US3670089DA US3670089A US 3670089 A US3670089 A US 3670089A US 68637 A US68637 A US 68637A US 3670089D A US3670089D A US 3670089DA US 3670089 A US3670089 A US 3670089A
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Prior art keywords
crucible
furnace
electrode
bottom plate
slag
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Boris Evgenievich Paton
Jury Vadimovich Latash
Boris Izrailevich Medovar
July Georgievich Emelianenko
Mikhail Markovich Kljuev
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PATON INSTITUTE
Institut Elektrosvarki Imeni E O Patona Akademii Nauk Ukrainskoi Ssr
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Institut Elektrosvarki Imeni E O Patona Akademii Nauk Ukrainskoi Ssr
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    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/60—Heating arrangements wherein the heating current flows through granular powdered or fluid material, e.g. for salt-bath furnace, electrolytic heating
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B9/00—General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals
    • C22B9/16—Remelting metals
    • C22B9/18—Electroslag remelting
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D11/00—Arrangement of elements for electric heating in or on furnaces
    • F27D11/02—Ohmic resistance heating
    • F27D11/04—Ohmic resistance heating with direct passage of current through the material being heated
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D3/00—Charging; Discharging; Manipulation of charge
    • F27D3/18—Charging particulate material using a fluid carrier
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/0004—Devices wherein the heating current flows through the material to be heated
    • H05B3/0009—Devices wherein the heating current flows through the material to be heated the material to be heated being in motion

Definitions

  • Electroslag Refining in the U.K. Steel Times, pp. 92-97, July 15, 1966 Primary Examiner-Hemard A. Gilheany Assistant Examiner-R. N. Envall, Jr. Anomey-Strauch, Nolan, Neale, Nies & Kurz ABSTRACT
  • the plant can can use sin le or plural consumable electrodes and in some embodiments as a bottom plate weld lug to enhance efficient current flow.
  • the achievement of the predetennined depth is signalled when current flows as a result of the bottom introduced slag contacting and closing a circuit through an energized electrode pre-positioned in the remelting zone.
  • the present invention relates to an apparatus for electroslag remelting of metal from consumable electrode means, and particularly to such an apparatus having provision for introduction of molten slag at the bottom portion of the remelting crucible.
  • a bath of molten slag is obtained in a remelting zone, for example, a crucible or a mold (often referred to as a crystallizer).
  • At least one consumable electrode is disposed in said zone with its lowermost end immersed in said molten slag bath. Electric current is caused to flow from the electrode to and through the slag bath. The passage of the current through the slag bath produces heat which causes the electrode to melt. As the electrode melts, the remainder of theelectrode is lowered into the slag bath so that all of the electrode is progressively melted. Because the metal in the electrode has a density greater than that of the slag bath, a molten pool of metal is formed below the slag bath. This molten pool of metal progressively solidifies into an ingot of refined metal.
  • the molten slag pool is obtained in the crucible in one case due to the melting of a solid flux or a mixture of its charge constituents during the remelting of a consumable electrode directly in the crucible.
  • non-consumable electrodes carbon or graphite, are employed for these purposes. This method is known as the dry start" method.
  • top pouring There is also employed a flux premelted in a separate unit or a mixture of its charge constituents, followed by top pouring the molten slag thus obtained into the crucible. This method is referred to herein as top pouring.
  • the time as required for obtaining an ingot is increased by as much as to percent, since the melting of slag is carried out directly in the crucible, which is likely to decrease the production rate of the plant by as much as 10 to 20 percent.
  • the gap therebetween is small, and the pouring of the molten slag therein presents difficulties.
  • the molten slag gets on the crucible walls and consumable electrode, and is likely to produce slag sows or lumps thereon.
  • the falling off of the slag sows into the slag pool during the melting process may result in marked variations of electrical conditions of the melting process.
  • a voltage is applied to the installation, and the consumable electrode is lowered at a maximum speed into the crucible until it is brought into contact with the slag.
  • a crust or lining of the solid slag may form on the crucible walls and on the cooled bottom plate or a dummy bar, if it is to be placed on the bottom plate, which crust is likely to insulate the molten slag pool from the bottom plate and crucible, which results in a breaking occurring in the current circuit, and the melting process may not start.
  • Disadvantages of the existing plants employed for effecting the electroslag remelting of metal according to said method consist in their excessive height, which is connected with a necessity of pouring the molten slag with the consumable electrode being raised, and with considerable losses of time as required for effecting auxiliary operation. Besides, there are required dummy bars or sacrificial plates for protecting the bottom plate against the burning through.
  • the apparatus enables the slag pool to be introduced into the crucible by pouring the molten slag into its bottom part or lower portion.
  • the consumable electrode (or electrodes) is inserted into the crucible until its lower end is at a predetermined distance from the bottom plate, and a voltage is applied to the plant simultaneously with the pouring of slag into the bottom portion of the crucible.
  • the level of slag in the crucible reaches the electrode, there occurs the completion (closing) of the electric circuit of the plant, and the process of remelting the consumable electrode beings.
  • a novel electroslag remelting plant includes an electrode holder complete with one or more consumable electrodes, adjustably depending into a crucible placed on a bottom plate, in the lower part or portion of the plant there is disposed a pouring device for supplying the molten slag into the crucible through a channel (access port).
  • the access port or channel for introduction of the slag can be constructed in many ways such as a bore or aperture adjacent the lower portion of the crucible through either or both of the crucible wall or the crucible bottom plate.
  • a channel can be made separable, e.g., it can be formed by the linking of the bottom plate with the crucible.
  • the channel, through which the pouring device communicates with the crucible is formed by an external boring (elongated recess) in the bottom plate, covered from above by the end surfaces of the crucible wall and syphon pouring device.
  • the channel or passage for supplying the molten slag is formed in the lower end portion of the crucible wall by a radial boring or groove, covered from below by the bottom plate of the crucible.
  • the channel or passage for supplying the molten slag may be also formed by two borings or grooves facing each other, said borings or grooves being located in the lower end portion of the crucible wall and in and to the outside of the bottom plate of the crucible, respectively.
  • the engineering solutions set forth herein allow manufacturing a plant for electroslag remelting of metal, said plant being simple in operation and design.
  • the base plate is provided with a recess in which a piece of metal of the same composition as the ingot is fitted.
  • This piece of metal is referred to as a weld lug.
  • the weld lug extends up above the top surface of the base plate and sideways pressure is exerted against the bottom of the lug in the recess to press it firmly against the bottom plate.
  • the top of the weld lug extending into the bottom of the mold will melt and weld to the ingot.
  • excellent electrical contact will be obtained between the base plate and the ingot.
  • An object of the present invention is to provide unique apparatus which eliminates the above-said disadvantages of the existing plants for carrying into effect electroslag remelting. This object is achieved by providing novel apparatus enabling supplying molten slag to a remelting zone from the bottom part of the crucible whereby the above disadvantages are overcome or minimized.
  • FIG. 4 is a cross-section view, taken along line B-B of FIG. 1;
  • FIG. 5 is a vertical section view of a second embodiment of a bottom pouring device according to the present invention.
  • FIG. 6 is a cross-section view showing the bottom of a furnace similar to that illustrated in FIG. 4 and shows the use of a weld lug;
  • FIG. 7 is a vertical section taken along line C-C of FIG. 6 showing details of the device for clamping the welding lug;
  • FIG. 8 is an elevation view partially in section schematically illustrating the system of the present invention as applied to a bifilar furnace.
  • FIG. 9 is a sectional view taken horizontally through the mold shown in FIG. 8, illustrating the spaced apart arrange ment of the electrodes in the mold.
  • the proposed plant for electroslag remelting of metal has a supporting column 1 (FIGS. 1 and 2) complete with carriages 2 and 3 disposed thereon, said carriages being displaced progressively relative to columns 1 along guides 4 by the aid of drives 5 and 6.
  • Attached to the carriage 2 is an electrode holder 7 of the clamp type complete with a drive 8, designed to secure a consumable electrode 9 moving relative to a crucible 10 during the progressive motion of the carriage 2.
  • the crucible part 10 to be placed on its bottom plate ll, is connected by a bracket 12 to the carriage 3 and during the displacement thereof it can rise relative to the bottom plate 11, placed, in its turn, on acarriage 13. i
  • a pouring device 14 communicating with the crucible 10and intended for supplying therein the molten slag which is premelted in a separate unit, for example, in an arc furnace.
  • the pouring device 14 communicates with the crucible 10 through a channel or passage 15 (FIGS. 3 and 4) which terminates in an access port, as formed by the linking of the bottom plate 11 with the crucible 10.
  • a channel or passage 15 (FIGS. 3 and 4) which terminates in an access port, as formed by the linking of the bottom plate 11 with the crucible 10.
  • the channel 15 has boundaries determined by the top surface of bottom plate 11 and the end surface of the sidewalls of crucible l0.
  • the access port in channel 15 is formed by an external boring or aperture provided in the bottom plate 11, and is covered from above by the lower end surfaces of the crucible l0 and pouring device 14.
  • This channel 15 has its upper surface determined by the lower end surfaces of crucible l0 and pouring device 14 and its lower surface determined by an extension of bottom plate 11.
  • the boring provided in the bottom plate 11 should have 'in its cross section a trapezoidal or segment-shaped form. That is, for ease of removalof the slag from channel 15 after completion of remelting, it is desirable that the longitudinal and transverse cross section of the channel should be trapezoidal or segment shaped, as is apparent in FIGS. 3 and 4.
  • the channel or passage 15 into the lower portion of the crucible may be formed by a radial boring or aperture (which is not shown in the drawing) provided on the lower end of the crucible 10 and covered from below by the bottom plate 1 1 or by borings or grooves (not shown in the drawing) provided on the lower end of the crucible 10 and the bottom plate 11 facing each other.
  • the access into the crucible can also be formed by spaced apart apertures (not shown in the drawing), in one or the other or both of the bottom plate 11 and the sidewall of crucible 10. All these embodiments of the channel 15 provide for a rapid access thereto for cleaning it from the slag after the completion of the melting process.
  • the pouring device 14 is provided in its upper part with a receiving funnel 16, which may be made as a single piece integral with it or detachable therefrom. It is expedient to make the pouring device 14 detachable along the plane of its channel 17, if the cleaning operation is to be effected immediately after the pouring of the molten slag into the crucible 10.
  • the pouring device 14 may be made non-detachable, if the clean? ing of the channel 17 from the slag is effected after the completion of the melting process;'in this case, however, the
  • channel 17 should have a slight taper, as seen in FIG. 5, for instance, from I to 3 percent, with the big end down.
  • the top end of receiving funnel 16 ordinarily is at a distance above bottom plate 11 sufficient to insure an adequate head of slag in funnel 16 so that the slag reaches its predetermined depth inside crucible and contacts the lowermost end of electrode 9. It is desirable that the lateral end of the pouring device 14 should repeat the shape of the lateral surface of the lower flange 18 of the crucible 10.
  • the pouring device 14 may be fastened to the lower part of the crucible 10 or to the bottom plate 11, and may be made of metal or with a lining of the internal channel 17 and receiving funnel 16. Thus, when pouring device 14 has the same shape as flange 18 of the crucible 10, the pouring device 14 can be fastened to the flange 18 of crucible 10 or to bottom plate 11 or to both flange l8 and plate 1 1.
  • pouring device 14 can be made of metal, part or all of the inside of channel 17, receiving funnel l6 and channel 15 can be lined as at in FIG. 5, to resist heat.
  • heating elements can be placed on the receiving funnel 16 and/or channel 17 in order to maintain or to increase the temperature of the molten slag as it flows therethrough.
  • the plant or apparatus is also provided with a system for supplying a cooling liquid to the crucible l0 and bottom plate 11; a system for electric supply (a transformer, bus bars, and flexible cables); a system for exhausting gases evolving from the crucible during the melting process; apparatus for controlling an adjusting the melting operation, that are not described here in detail as being not relevant to the essence of the present invention.
  • a system for supplying a cooling liquid to the crucible l0 and bottom plate 11 a system for electric supply (a transformer, bus bars, and flexible cables); a system for exhausting gases evolving from the crucible during the melting process; apparatus for controlling an adjusting the melting operation, that are not described here in detail as being not relevant to the essence of the present invention.
  • the proposed installation operates as follows.
  • the consumable electrode 9 (or electrodes) is introduced into the electrode holder 7 and is clamped there by the aid of drive 8. Then, due to a displacement of the carriage 2, the electrode 7 is adjusted down into the crucible so that its lower end is disposed at a distance from the bottom plate 11 somewhat smaller than the thickness of layer of the molten slag to be poured into the crucible 10. Hence, when the layer of slag in the crucible is equal to, for example, 200 mm, the lower end of the electrode 9 should be spaced from the bottom plate 11 at a distance of 190 mm.
  • the voltage is applied to the crucible by switching in the transformer.
  • the molten slag is poured from a ladle into the receiving funnel 16 of the pouring device 14, and is supplied into the crucible 10 through channels 17 and 15.
  • the pouring of the slag is discontinued at the moment the level of the molten slag in the crucible reaches the lower end of the electrode 9, which is evidenced by the current flowing through the plant circuit.
  • desirable electrical conditions of the melting process are preset by the aid of an appropriate apparatus, said electrical conditions being maintained constant throughout the melting process involving the building up of the ingot, or may vary according to the present program, which is effected due to a variation in the speed of feeding the electrode 9 by adjusting the rotational speed of the drive 5, and to a variation of the voltage of the secondary winding of the transformer intended to supply the plant.
  • the electrode is lowered to a depth of immersion to obtain the desired current flow to maintain the desired slag temperature. As the electrode melts, it is fed into the mold to maintain the end of the electrode immersed in the molten slag.
  • the melting process is discontinued, for which purpose feeding of the electrode is stopped, the transformer switched off, and the carriage 2 then raised into its upper position.
  • the remaining stub of the electrode 9 is thereafter removed from the electrode holder 7.
  • the crucible part 10 is raised by the aid of the carriage 3 until the built-up ingot is made to leave it completely, whereupon the carriage 13 complete with the bottom plate 11 and ingot are rolled out aside from the crucible part 10.
  • the ingot is then removed and the channels 15 and 17 are cleaned from the solidified slag.
  • the pouring device 14 is to be cleaned from the slag in the course of the melting process.
  • the proposed plant may be made use of to manufacture ingots of a round, oval, square, rectangular or any other cross section depending upon the crucible shape.
  • the method and plant, realized according to the present invention provide for a maximum possible coefficient of utilization of the working time; allow obtaining ingots with the bottom portion thereof of a high quality, which permits practically to avoid cropping the bottom discard; facilitate the rapid performance of the operation of pouring the molten slag into the crucible and the preparation of the plant before starting the subsequent melting process.
  • the proposed plant is of a comparatively small height.
  • the proposed plant provides for canying out the process of electroslag remelting without the use of metallic dummy bars that are to be placed in the existing units on the bottom plate with a view of preventing its damage during the beginning of the melting process.
  • this access port and the radial cross section of channel 15 ordinarily have the same area. These areas ordinarily range from 6 to 120 sq. cm. for circular ingots of 65-l,500 mm diameter (or equivalent non-round cross sections). The use of these cross sections assures that the back pressure in channel 15 will not be excessive and that slag will solidify in channel 15 blocking backflow through the access port from the crucible and the remelting proceeds.
  • the above-described lining of the internal channel 17 and receiving funnel 16, if desired, can be extended into channel 15, using shields 20 of refractory material such as graphite as shown in FIG. 5, to prevent the molten flux from burning through the funnel wall.
  • the graphite shields may be 8-10 mm in thickness in a typical installation.
  • electrode 9 (see FIG. 1), is clamped in electrode holder 7, it is adjustably lowered by means of carriage 2 so that its lower portion moves into the crucible 10 until its lowermost end is spaced above the bottom plate 11 a distance from 4 to 20 percent less than the thickness (that is, the
  • FIGS. 6 and 7 there is an exemplary use of a weld lug.
  • a circular recess 22 is provided extending down into the bottom plate 21 from its top surface which forms the bottom of the mold.
  • a circular piece of metal 23 of the same composition as the ingot which is to be formed in the mold by the electroslag remelting process is fitted in recess 22.
  • FIG. 6 shows a pouring device 14 with a receiving funnel 16 and a connecting channel 17 attached to the mold in a manner similar to that hereinbefore described for FIG. 4.
  • a cylindrical passage or bore 24 is defined in the bottom plate 21 extending horizontally from recess 22 to the outer side of the wall of bottom plate 21.
  • Cylindrical passage 24 slidably mounts a spring biased clamp pin 25, the inner end of which engages the weld lug 23.
  • the outer end of pin 25 is slidably guided through a U-shaped bracket 26 mounted on the sidewall of bottom plate 21.
  • Pin 25 is provided with an abutment collar 27 on the portion disposed between bracket 26 and the bottom plate sidewall.
  • a coil compression spring 28 surrounds the pin 25 between the collar 27 and the U- shaped bracket 26 and applies a force against the collar 27 which urges the pin 25 against the weld lug 23 which presses the weld lug 23 against the side of the recess 22.
  • a system in accord with the present invention may comprise a mold 30 including a bottom plate 32 and sidewalls 34.
  • mold 80 is water cooled by conventional techniques, such as has been hereinbefore described.
  • a pair of electrodes 36 are positioned over the mold 30 extending down into the open top of the mold.
  • the electrodes are supported by an electrode holder 38 mounted on a carriage 40.
  • Carriage 40 can be moved up and down a supporting tower 42 to feed the electrodes 36 together as a unit into the mold 30 as the electrodes melt.
  • the sidewalls 34 of the mold are mounted on a second carriage 44 which also is movable up and down the tower 42.
  • Drive motors similar to drives 5 and 6 in FIG. 1 can provide the motive force for the carriages 40 and 44.
  • a channel 46 is defined by a groove in the top surface of the bottom plate 32 extending from inside of the mold sidewalls to outside thereof and extending into a tongue 48 formed on the bottom plate.
  • the channel 46 is preferably positioned as shown in FIG. 9 at a point half way between the two electrodes.
  • a funnel 50 provided with a base plate 52 rests on the tongue 48 of the bottom plate and closes the top of the portion of the channel 46 which extends out into the tongue 48.
  • the sidewalls are formed with a flange 54 which abuts against the plate 52 so that the portion of the channel 46 extending outside of the sidewalls 34 is completely covered.
  • the passage of funnel 50 connects with the channel 46.
  • a closed channel is provided between the bottom of the interior of the mold and the mouth of the funnel 50.
  • Each of the two electrodes 36 is connected to an opposite side of the secondary winding 56 of a transformer 58.
  • the seconding winding has a center tap to which the mold bottom plate 32 is connected, preferably by means of a weld lug as hereinbefore described, but not shown in this embodiment.
  • the assembly of electrodes 36 is first lowered into the mold 30 to a position determined by the desired depth of I the bath of molten slag to be formed in the mold. AC power is applied between the electrodes from the transformer 58. Then superheated molten slag is poured into the bottom of the mold 30 through the funnel 50 and the channel 46.
  • the slag will be poured to a depth a little above the ends of the electrodes in the mold.
  • the desired amount of slag is nevertheless precisely obtained by initially positioning the bottom ends of the electrodes just below thedesired level of slag in the mold.
  • the electrodes 36 are fed into the molten slag by the carriage 40 moving on the tower 42 to maintain the electrodes immersed at the desired depth in the molten slag.
  • the electrodes melt, they will form a molten pool beneath the bath of molten slagwhich will solidify into an ingot starting from the bottom of the mold with a pool of molten metal being maintained between the bath of molten slag and the solidified ingot.
  • the solidified ingot in the mold is designated by the reference number 62
  • the bath of molten slag is designated by the reference number 64
  • the pool of molten metal is designated by the reference number 66.
  • the connection between the bottom plate 32 and the center tap of the secondary winding 56 serves to maintain the melting rates of the two electrodes equal. Should one of the electrodes melt slower than the other it will become more deeply immersed in the molten slag. The resistance between this electrode and the bottom plate 32 will be reduced relative to that between the other electrode and the bottom plate. As a result, some current will flow between the center tap and the more deeply immersed electrode, thus increasing the current flow through the more deeply immersed electrode relative to the other electrode. This action results in the more deeply immersed electrode melting at a greater rate until its immersion becomes less, the current decreases and melting rate decreases. In this manner, the melting rates of the electrodes tend to equalize. As the ingot is formed, the bath of molten slag will rise in the mold 30.
  • the melting of the electrodes is ended and the molten pool of metal at the top of the ingot and the bath of molten slag is allowed to solidify.
  • the sidewalls 34 are stripped from the ingot by moving the carriage 44 up on the tower 42.
  • the sidewalls 34 are'conical shaped with the large end down as shown in FIG. 8 to facilitate stripping.
  • a high quality ingot is produced by an electroslag remelting system with a relatively high power factor.
  • the ingot. can be produced by remelting of ferrous or nonferrous metals from the consumable electrodes.
  • the dry start" method of obtaining a molten slag bath is time consuming and increases the time for producing finished product ingots by as much as 20 percent compared to the time required when the slag is melted outside of the remelting zone.
  • the dry start method has the disadvantage that the aforementioned arcing leads to oxygen release from the slag whereby the first portion of the metal melted from an electrode is out of specification.
  • such arcing ordinarily does not melt the slag at the periphery of the remelting zone and as a result the heat produced by the current passing through the slag at the beginning of the remelting process is not sufficient to adequately refine the metal being produced.
  • the bottom portion of the formed ingot is of inferior quality and is ordinarily trimmed or cropped from the rest of the ingot and reprocessed or discarded. This bottom portion can amount to up to 10 percent of the entire ingot.
  • the prior art top puring method overcomes the aforementioned disadvantages of the dry start" method but has disadvantages of its own as follows.
  • top pouring is carried out with the electrode removed from the remelting zone, a crust of molten slag is often formed at the bottom of the remelting zone during the time the electrode is being lowered into the zone after pouring has been completed.
  • This crust insulates the bottom of the remelting zone so as to block current flow whereby the electroslag remelting process is prevented from starting.
  • the crust-containing slag must be removed from the remelting zone and a new batch of slag poured. This phenomenon is referred to as a false start.
  • the apparatus is designed so that the electrode can be positioned above the remelting zone, the apparatus is required to be of greater height than otherwise, requiring more factory space, and the lead attached to the electrode is required to be longer whereby inductance is increased so that the power factor is lowered requiring more power per pound of metal produced.
  • top pouring is carried out with the electrode in place in the remelting zone, then a long electrode of small cross-section must be used in order to provide a sufficient gap between the electrode and the sidewalls of the remelting zone so that the slag stream does not contact and coat either the electrode or the walls with a scale of solid slag. Moreover, such scale falls in solid form into the molten slag during the remelting process and either can cause marked variation in the current applied during remelting thereby causing non-uniform results or else can be trapped within the metal melted from the electrode so as to form undesirable inclusions in the formed ingot.
  • the length of the electrode utilized in this method results in high inductance and a lower power factor thereby raising production costs.
  • a tall tower must be provided for supporting and feeding the electrode. Such a tower adds significantly to the cost of the installation.
  • the pouring stream In order to ensure that the slag being top poured does not contact either the electrode or the remelting zone walls, the pouring stream must be of relatively small cross-section. As a result, pouring of the slag to a required depth in the remelting zone takes a significant amount of time so that often a crust of solidified slag forms at the bottom of the remelting zone whereby a false start occurs.
  • top pouring techniques have the very important disadvantage that the electrode cannot be energized previous to the completion of pouring.
  • the electrode In top pouring with the electrode outside the remelting zone, the electrode cannot be energized previous to its insertion into the remelting zone for reasons of safety.
  • the electrode or electrodes In top pouring with the electrode in place, depending into the mold, the electrode or electrodes cannot be energized because slag splashing against them during pouring causes short circuiting resulting in explosion. Energizing of the electrode current circuit previous to the completion of pouring would result in a significant time savings so that the apparatus can be used more efficiently.
  • top pouring techniques have the disadvantage of requiring special measuring equipment to determine the slag level in the remelting zone at any particular time during top pouring.
  • the slag pool is produced by pouring the molten slag into the bottom part of the crucible 10.
  • This bottom part of the crucible as defined by the crucible sidewalls and its separate bottom plate 11, forms a remelting zone in which the electrode or electrodes, such as shown in the embodiment of FIG. 8, are melted by the electrical current as soon as the slag reaches its predetermined depth by rising to contact the electrode (2).
  • the pouring is sufficiently fast and current flow begins sufiiciently quickly after the pouring is started that the formation of a slag crust on the bottom of the remelting zone isprevented and thus false starts are eliminated.
  • the time required for obtaining molten slag in the remelting zone with an energized electrode in place is minimized to a matter of a few minutes or less.
  • the gap between the electrode and the remelting zone walls i.e., the sidewalls of the crucible, can be made very small thus permitting a large diameter electrode to be used.
  • a significantly shorter electrode can be used and the height of the tower required is accordingly reduced.
  • the inductance of the circuit is reduced and the power factor of the system is'accordingly increased. Since the slag is poured into the bottom of the remelting zone, the possibility of formation of slag scale on the remelting zone walls is entirely eliminated. 1
  • the operator controlling the pouring can determine very precisely when to stop pouring the molten slag.
  • the molten slag reaches the electrode, current begins to flow in the electrode and that current flow provides a condition indicating to the operator that the slag bath has reached the predetermined depth. Accordingly, pouring of the slag is discontinued when current starts to flow through the electrode. Because the slag can be poured quickly through a closed channel into the bottom of the remelting zone, there is little opportunity for the slag to react with nitrogen in the air or to dissolve moisture from the air. Furthermore, because slag is poured into the bottom of the remelting zone, the ladle is positioned near the base of the furnace thus greatly reducing the danger to personnel.
  • the initial predetermined distance between the consumable electrode and the bottom plate is essentially the same as the predetermined initial depth which the slag achieves in the remelting zone. These are not exactly the same because slight additional molten slag will enter the remelting zone between the time when the circuit completion is signalled and the time when the discontinuance of the-slag pouring is actually implemented. Accordingly, the bottom of the electrode is positioned just below the desired slag level as the molten slag is poured.
  • the predetermined initial depth of slag in the remelting zone preferably ranges from one-fourth the transverse sectional dimension of the ingot to be formed to twice the transverse sectional dimension of the ingot to be formed.
  • the transverse sectional dimension is: the diameter, if the ingot crosssection is circular; the length of a side, if the ingot cross-section is square; the length of the shortest side, if the ingot crosssection is rectangular; or the length of the shortest dimension across the center of the ingot, if the ingot is any other shape.
  • the initial slag depth is less than one-fourth the transverse sectional dimension of the ingot to be formed, arcing can occur whereby electroslag remelting no longer takes place. If the initial slag depth is more than twice the transverse sectional dimension of the ingot to be formed, a crust of solid slag can form interfering with the current flow. As an illustrative example, for a rectangular slab ingot of 9-15 tons whose smallest cross-sectional dimension is 630 mm, the initial slag depth may advantageously be 250: 15 mm.
  • the molten slag be introduced (that is, poured) into the remelting zone at a rate sufficiently fast and under such conditions that no crust of solid slag is formed on the bottom plate in the remelting zone.
  • the rate of slag introduction so that such a crust will not form is dependent upon the amount of slag being utilized which in turn is dependent upon the size of the ingot to be formed.
  • slag pouring rates ranging from to 1,500 Kg/minute are usually utilized.
  • a pour rate of 750 Kg/minute may be advantageously used.
  • the rate of slag introduction should be sufficient so that the mass of molten slag in the remelting zone at any time has sufficient superheat to remelt any of the previously added slag that has solidified or to prevent any slag from solidifying that has lost its superheat.
  • the achievement of the aforementioned flow rates is aided by the utilization of molten slag superheated to possess a viscosity of no greater than the viscosity of water at the. standard reference temperature of 68 F. and preferably much less than this viscosity. It is especially preferred that the slag be superheated to possess a viscosity ranging from 0.1 to 0.5 centipoises. In order to achieve such a viscosity, the slag for the bottom pour is at a temperature at least 100 C. higher than its meltingpoint but no higher than 100 C. below the boiling point of the slag. For the slags normally used for electroslag remelting such as ANF-6 the acceptable temperature range is approximately 1,440 to 2,l00 C. I v
  • the molten slag is advantageously introduced into the bottom of the remelting zone utilizing a reservoir which interconnects via a closed channel or conduit with the bottom of said remelting zone.
  • the head of slag in the reservoir is utilized to obtain the desired depth of slag in the remelting zone.
  • the electrode is initially positioned in the remelting zone with its lowermost portion below the top of the reservoir so that the slag can be poured to a level tolcontact the electrode.
  • the reservoir extends above the level ultimately desired for the slag so that there will be no overflow of slag from the reservoir.
  • the slag is conveniently introduced into the reservoir utilizing a ladle.
  • the cross-sectional area of the stream of slag entering the remelting zone that is the cross-sectional diameter of the conduit interconnecting the reservoir with the bottom of the remelting zone, ranges from 6 to 120 sq. cm. for circular ingots of 65-l,500 mm diameter (or the equivalent rectangular or square ingots).
  • the back pressure on the stream being introduced can be so great that introduction rate will ordinarily be too slow and a false start may occur.
  • All slag compositions used for electroslag remelting or refining processes can be poured into the crucible according to the present invention.
  • Representative slag compositions are set out in B. I. Medovar et a1, Electroslag Remelting, N64-1 1419 US Department of Commerce, Office of Technical Services, Joint Publications Research Service on Table 10, page 53.
  • EXAMPLE The remelting of an electrode to produce a 4 ton ingot was carried out by lowering an electrode into a mold or crucible of 4 ton capacity of the type as shown in FIG. 1. Next, 300 kg. of ANF-6 flux from the above-referred to Table 10 is placed into a heated, carbon-lined crucible ladle and heated by means of nonconsumable carbon electrodes to a temperature of not less than about 1,750 C. For this production cycle the diameter of the crucible cavity was about 500 mm and the depth was 800 Simultaneously with the heating of the slag, cooling water is circulated through the crucible sidewalls and the base plate. The power transformer is then turned on to energize the electrode and the base plate with a voltage of 70 to v.
  • the pouring lip of the crucible ladle is then aligned with the receiving funnel l6 and the ladle tilted to pour the molten slag into the remelting crucible in approximately 0.5 to 1.0 minute.
  • the pouring is terminated immediately upon the appearance of a current, 1 kiloamp, in the transformer electrode line. At such time the level of the molten slag is 5-10 mm above the end of the electrode.
  • the electric current then maintains the temperature of the molten slag and the consumable electrode commences remelting.
  • the access port through which the pouring device communicates with the crucible'or mold is formed by an aperture in the bottom plate.
  • the channel communicating with the access port has its top surface defined by a flange extending from the crucible sidewall and an end surface of the pouring device and its bottom surface defined by an extension of said bottom plate.
  • the access port for supplying molten slag is formed by a radial aperture in the crucible sidewall just above the bottom plate.
  • the access port for supplying the molten slag can also be formed by two apertures adjoining each other, one of these apertures being located in the bottom plate and one in the crucible sidewall.
  • a plant for electroslag remelting of metal from consumable electrodes comprising: crucible means including a bottom plate and a separable crucible placed on said bottom plate; means for disposing portions of consumable electrodes in said crucible means with lower ends thereof located adjacent the bottom of said crucible means; and means located in the lower part of said crucible means enabling introduction of molten slag from outside of said crucible means directly into the bottom portion of said crucible means through a channel means having at least a portion thereof formed by said separable crucible.
  • a plant for electroslag remelting of metal from at least one consumable electrode comprising: a crucible means including a bottom plate and a crucible device placed on said bottom platej a holder for said consumable electrode enabling the insertion of portions of said electrode into said crucible device; a pouring device for supplying molten slag into the lower part of said crucible means; said pouring device communicating therewith through a channel formed due to linking of said bottom plate with said crucible device.
  • crucible means which comprises a bottom plate and a separable crucible placed on said bottom plate and a conduit means adjacent the lower portion of said crucible means for the introduction of molten slag from outside said crucible means into the bottom portion of said crucible means, said conduit means having at least a portion thereof formed by said separable crucible.
  • conduit means extending into the lower portion of said crucible means and having at least a portion thereof formed by said base plate and said separable crucible, and said conduit means extending outwardly and upwardly thereof whereby sag poured into the outer and upper portions of said conduit means is introduced into the lower portion of said crucible means.
  • conduit means enters said crucible means at such a point to permit introduction of slag into said crucible means at a point below the lowermost end of said electrode.
  • said crucible means comprises a sidewall having an outwardly extending flange at the bottom thereof mounted on said bottom plate and wherein at least a portion of said conduit means comprises a recess in said bottom plate extending beneath said flange.
  • conduit means extends into said crucible means a distance ranging from once to twice the depth dimension of said conduit means.
  • funnel means extends upwardly sufficiently to hold molten slag at a level higher than the lowermost end of said electrode.
  • An electroslag refining furnace system comprising: a water cooled crucible means including a bottom plate and a crucible device, said crucible means having consumable electrode means extending into the top thereof and current supply means connected into a circuit with said electrode means to initiate flow of current when electrically conducting slag contacts said electrode means; and fluid communicating means from exterior to interior of said crucible means comprising conduit means in the lower portion of said crucible means, said conduit means having at least a portion thereof formed by said base plate and said crucible device, whereby molten slag poured into said upwardly extending conduit means flows by gravity through said conduit means into the bottom of said crucible means to create in said crucible means a rising pool of molten slag that reaches a level to contact said electrode means whereby said current flow commences.
  • a furnace for electroslag remelting of metal having a crucible with wall means defining a furnace start-up remelting zone by the lower portion thereof and at least one consumable electrode adapted to depend into said crucible with its lowermost end in said remelting zone and having means for applying electrical power to said electrode to melt the same
  • the improvement comprising: conduit means through said lower portion of said crucible communicating with said remelting zone and including a slag conducting aperture opening into said remelting zone; recess means formed in said wall means of said crucible in the remelting zone thereof; and weld lug means in and pressed against at least a portion of said recess means to provide electrical contact between said weld lug means and said crucible.
  • a furnace as defined in claim 32 including upwardly extending funnel means connected to said slag conducting aperture, said funnel means being constructed to receive molten slag poured thereinto outside said crucible wall means and to deliver said slag by gravity flow through said aperture into said remelting zone.
  • a furnace as defined in claim 32 wherein a plurality of consumable electrodes are adapted to depend into said crucible and wherein said crucible has at its lowermost end a bottom plate, and said means for applying electrical power comprises an AC power circuit including said electrodes and a current balancing line connected to said bottom plate whereby current flowing through said electrodes can be increased or decreased by said circuit in order to maintain equal rates of melting of said electrodes.
  • a furnace as defined in claim 40 wherein said AC power circuit includes the secondary winding of a transformer and wherein there are two consumable electrodes, each connected to an opposite side of said secondary winding and wherein said balancing line is connected as a center tap from said secondary winding.
  • conduit means extending into said remelting zone of said crucible and including a slag conducting aperture communicating with said remelting zone, weld lug means pressed against a recess formed in the wall means of said crucible in the remelting zone thereof to provide electrical contact between said weld lug and said crucible, and an AC Power circuit including said electrodes, said power circuit having a current balancing line connected to said bottom plate whereby current flowing through said electrodes is increased or decreased by said current to maintain equal rates of melting of said electrodes.
  • Electroslag refining furnace system as defined in claim 31, wherein said electrode means comprises at least two electrodes and wherein said current supply means is adapted to supply melting current between said electrodes from the time the electrically conducting slag contacts said electrode means.
  • An electroslag remelting furnace system comprising a receptacle for-forming an ingot, said receptacle including a water cooled bottom plate and a separable water cooled crucible; a support column; electrode holding and moving means disposed on said supporting column adapted to support at least one electrode extending within said crucible with the lower electrode and initially disposed a predetermined distance from said bottom plate; electrical means for supplying current to said electrode holding means and an electrode when held by the same; fluid communicating means extending from the exterior to the interior of said ingot receptacle comprising channel means in the lower portion of said ingot receptacle, at least a portion of said channel means formed by an upper portion of said base plate and a lower portion of said crucible; and an upwardly extending pouring device outside said ingot receptacle in communication with said channel and extending vertically from the base plate a relatively short distance predetermined in relation to the spacing between said bottom plate and the lower end of an electrode when held by said holding means; said construction

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US3776294A (en) * 1971-03-18 1973-12-04 B Paton Method of electroslag remelting
US3783168A (en) * 1972-07-07 1974-01-01 B Medovar Electroslag remelting plant
US3944714A (en) * 1973-04-23 1976-03-16 Jury Pavlovich Shtanko Electroslag remelting plant
US3987843A (en) * 1973-03-16 1976-10-26 Paton Boris E Apparatus for making ingots by electroslag remelting
US3990500A (en) * 1973-03-16 1976-11-09 Paton Boris E Apparatus with core for making hollow ingots by electroslag remelting
US3998265A (en) * 1976-02-20 1976-12-21 Gennady Fedorovich Skvortsov Crystallizer positioning and displacing apparatus
US4006285A (en) * 1976-01-12 1977-02-01 Cyclops Corporation Starter plate for electro slag remelting apparatus
US4108235A (en) * 1971-03-16 1978-08-22 Paton Boris E Electroslag remelting apparatus having relative mold movement and provision for introduction of slag
US4150971A (en) * 1970-09-15 1979-04-24 Institut Elektrosvarki Im.E.O. Patona Start-up method for an electroslag remelting system
US20130327743A1 (en) * 2009-08-07 2013-12-12 Radyne Corporation Heat Treatment of Helical Springs or Similarly Shaped Articles by Electric Resistance Heating
US20150174679A1 (en) * 2012-07-20 2015-06-25 Federal-Mogul Nurnberg Gmbh Method for producing a piston for an internal combustion engine
US20160136712A1 (en) * 2013-06-05 2016-05-19 Neturen Co., Ltd. Heating method, heating apparatus, and hot press molding method for plate workpiece
US10661297B2 (en) 2015-11-23 2020-05-26 United Technologies Corporation Methods for vapor deposition

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Cited By (17)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4150971A (en) * 1970-09-15 1979-04-24 Institut Elektrosvarki Im.E.O. Patona Start-up method for an electroslag remelting system
US4108235A (en) * 1971-03-16 1978-08-22 Paton Boris E Electroslag remelting apparatus having relative mold movement and provision for introduction of slag
US3776294A (en) * 1971-03-18 1973-12-04 B Paton Method of electroslag remelting
US3783168A (en) * 1972-07-07 1974-01-01 B Medovar Electroslag remelting plant
US3990500A (en) * 1973-03-16 1976-11-09 Paton Boris E Apparatus with core for making hollow ingots by electroslag remelting
US3987843A (en) * 1973-03-16 1976-10-26 Paton Boris E Apparatus for making ingots by electroslag remelting
US3944714A (en) * 1973-04-23 1976-03-16 Jury Pavlovich Shtanko Electroslag remelting plant
US4006285A (en) * 1976-01-12 1977-02-01 Cyclops Corporation Starter plate for electro slag remelting apparatus
US3998265A (en) * 1976-02-20 1976-12-21 Gennady Fedorovich Skvortsov Crystallizer positioning and displacing apparatus
US20130327743A1 (en) * 2009-08-07 2013-12-12 Radyne Corporation Heat Treatment of Helical Springs or Similarly Shaped Articles by Electric Resistance Heating
US9814100B2 (en) * 2009-08-07 2017-11-07 Radyne Corporation Heat treatment of helical springs or similarly shaped articles by electric resistance heating
US20180070409A1 (en) * 2009-08-07 2018-03-08 Radyne Corporation Heat Treatment of Helical Springs or Similarly Shaped Articles by Electric Resistance Heating
US11044788B2 (en) * 2009-08-07 2021-06-22 Radyne Corporation Heat treatment of helical springs or similarly shaped articles by electric resistance heating
US20150174679A1 (en) * 2012-07-20 2015-06-25 Federal-Mogul Nurnberg Gmbh Method for producing a piston for an internal combustion engine
US10252366B2 (en) * 2012-07-20 2019-04-09 Federal-Mogul Nurnberg Gmbh Method for producing a piston for an internal combustion engine
US20160136712A1 (en) * 2013-06-05 2016-05-19 Neturen Co., Ltd. Heating method, heating apparatus, and hot press molding method for plate workpiece
US10661297B2 (en) 2015-11-23 2020-05-26 United Technologies Corporation Methods for vapor deposition

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