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Tertiary Metallurgy

Metallurgy
Special melting and remelting processes for unique steel properties

It's the job of tertiary metallurgical plants to create unique technological properties in ultra-pure steels, super alloys, cast alloys, and nonferrous metals. These peak-performance, heavy-duty materials are used in demanding, high-tech industries such as aviation, aerospace, power generation, and automotive. There is no alternative technology in this high-end field.

Induction melting facility vim

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Process

No oxidation

The oxygen-free atmosphere avoids oxidizing elements with an affinity to oxygen

Precise analysis

Very narrow analysis tolerances (PPM range)

No tramp elements

Removes unwanted tramp elements with high steam pressure

Effective degassing

Removes dissolved gases (O, N, H) from raw materials and the final melt

Narrow temperature range

Precisely sets the melting temperature and the homogeneity of the heat

Electrodes for remelting

Casts homogeneous electrodes for remelting process and semifinished products for further processing

Sophisticated vacuum system

Removes unwanted tramp elements with high vapour pressure

Technology

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VACUUM INDUCTION MELTING - VIM PROCESS

Designed for a wide range of capacities

VIM is a powerful process applied to melt down selected scrap and refine the resulting liquid steel. The process involves casting ingots under vacuum, which further improves final-product quality.

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VACUUM CHAMBERS

VIM works with dedicated vacuum chambers for melting and casting. They are connected by launder and tundish units.
The crucible comes with a vacuum-tight electricity supply and can be exchanged easily using the advanced lifting system.

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Mechanical pump systems

It's a special advantage that the mechanical pump
system generates extra-strong vacuums.
There is also a charger that ensures clean material feeding under vacuum.

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Deslagging machines

Finally, an integrated deslagging machine removes the slag from the crucible.

Vacuum pumps

High-performance vacuum pumps from SMS Mevac are the heart of secondary metallurgical vacuum processes. For both recirculation or tank degassing processes, our vacuum pump technologies are tuned to your specific steel conditions and to your individual plant and production requirements.

Our vacuum pump systems precisely control the rate of pressure reduction from atmospheric level to low vacuum pressure. During the various treatment steps the vacuum level is accurately controlled to match the system’s metallurgical needs.

In order to deliver optimum results high suction capacity, low energy consumption and optimal reliability are essential elements of our design.

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Vacuum induction melting & casting

Vacuum Induction Melting & Casting (VIM) is a highend process for melting down selected scrap and refining the resulting liquid steel in a powerful manner. The capability to perform ingot casting under vacuum conditions further improves the final product quality. SMS Mevac supplied a 8/18 t VIM unit to a customer in the UK. The plant is to be commissioned in 2015. VIM features dedicated vacuum chambers for melting and casting connected by launder and tundish. The crucible has vacuum-tight electrical power supply and can be exchanged easily via advanced lifting system. The mechanical pump system generates extra-deep vacuum. A charger ensures clean material addition under vacuum conditions. Direct slag removal is enabled by integrated deslagging machine.

Metallurgical functions

  • “Clean” inductive heat transfer
  • Vacuum conditions of < 0.05 mbar
  • Massive degassing of steel
  • No influence of ambient air (O2)
  • Evaporation of tramp elements
  • Narrow chemical steel analysis (in ppm range)
  • Precise setting of temperature and excellent homogeneity of melt
  • Vacuum casting of electrodes for remelting and semis for forging/rolling
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ESR and VAR X-EED®

X-eed® is the brand name of the overall SMS Mevac portfolio, expressing our continuous endeavours in development of enhanced technologies for the benefit of our worldwide customers.
X-eed® represents our pledge to meet your individual needs by means of innovative solutions, process know-how and selection of the most appropriate production routes.

Common feature of remelting processes are the melt-down of a metal electrode, the metallurgical treatment of the liquid phase and the subsequent uniquely fast solidification an ingot. The ingots produced feature superior material properties as:
 

  • Highest cleanliness (purity)
  • No macro segregation
  • Extremely homogenous structure of produced ingot for excellent material properties
  • No hydrogen flakes
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Electro Slag Remelting

These products represent the top end of technological properties in metals.

Features

  • Melt-down in liquid slag created by resistance heating
  • Inert atmosphere
  • Lowest sulfur content and excellent cleanliness
  • High yield
  • Ingot diameter from 300 to 1600 mm
  • Ingot weight from 2 to 160 t

 

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Vacuum Arc Remelting

These products represent the top end of technological properties in metals.

Features

  • Melt-down by electric arc under vacuum of 0.004 mbar
  • Evaporation of tramp elements
  • Utmost degassing
  • Excellent cleanliness
  • No risk of freckle formation
  • Extra-high accuracy of final chemistry
  • Ingot diameter from 300 to 1000 mm
  • Ingot weight from 1 to 30 t

 

Selected References

Contact

SMSgroup Schlüter, Jochen

Jochen Schlüter

SMS Mevac GmbH
CEO/Sales
Bamlerstraße 3a
45141 Essen
Germany

Phone : +49 201 6323 120
Fax : +49 201 6323 220

SMSgroup Mellinghoff, Benjamin

Benjamin Mellinghoff

SMS Mevac GmbH
Sales
Bamlerstraße 3a
45141 Essen
Germany

Phone : +49 201 6323 169
Fax : +49 201 6323 269