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Rendering of electro-slag remelting apparatus and cross-sections. Electroslag remelting (ESR), also known as electro-flux remelting, is a process of remelting and refining steel and other alloys for mission-critical applications in aircraft, thermal power stations, nuclear power plants, military technology and others. [1]
Limestone is added to act as a flux. As the heat rises within the stack the metal is melted. It drips down through the coke bed to collect in a pool at the bottom, just above the bottom doors. During the melting process a chemical reaction takes place between the fuel, the blast air, and the metal.
Vacuum arc remelting (VAR) is a secondary melting process for production of metal ingots with elevated chemical and mechanical homogeneity for highly demanding applications. [1] The VAR process has revolutionized the specialty traditional metallurgical techniques industry, and has made possible tightly controlled materials used in biomedical ...
Vacuum arc remelting (VAR) is a secondary remelting process for vacuum refining and manufacturing of ingots with improved chemical and mechanical homogeneity. In critical military and commercial aerospace applications, material engineers commonly specify VIM-VAR steels. VIM means vacuum induction melted and VAR means vacuum arc remelted.
In the electro-slag remelting (ESR) process, steel scrap is first melted using the conventional process but is then remelted in a water-cooled form. With this process, a more even microstructure can be achieved which gives completely different properties than a material produced with the conventional method.
High purity iron is also produced in dry process. VOD (vacuum oxygen decarburization), and ESR (electro-slag remelting) are known as dry process. VOD is a process of melting pure iron in a vacuum and degassing. ESR (electro-slag remelting) method is a process of dripping the molten metal refining pure iron as an electrode.
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Additional flux is added until the molten slag, reaching the tip of the electrode, extinguishes the arc. The wire is then continuously fed through a consumable guide tube (can oscillate if desired) into the surfaces of the metal workpieces and the filler metal are then melted using the electrical resistance of the molten slag to cause coalescence .