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In the 1960s Consarc’s engineers conceived a new approach to electroslag remelting, quite different from others in use at the time. The resulting improvements in the efficiency and performance of the process established Consarc as the leading manufacturer of ESR systems worldwide.
What Consarc’s engineers did was to combine the use of a “high fill ratio” electrode (an electrode whose diameter approaches that of the crucible) with an AC line frequency furnace design in which the main power conductors were arranged coaxially around the melt zone. The high fill ratio electrode provides significant benefits, including reduced power consumption, increased ingot quality, and improved ingot surfaces.
The coaxial conductor system allowed the use of smaller, more efficient power supplies and decreased undesirable magnetic stirring of the melt. Moreover, it virtually eliminated the stray field eddy current heating of surrounding steelwork which had characterized all prior ESR furnace designs and allowed magnetic interaction between adjacent melts.
The principles of this coaxial design are incorporated in all ESR furnaces produced by Consarc.
Features
Consarc electrode exchange ESR furnaces utilize multiple electrodes, one at a time in series, to form a single larger ingot. Electrode exchange furnaces always utilize two ESR furnace heads, and can be designed to exchange into either a static melt station or a withdrawal melt station that is located between the two heads.
Frequently these furnaces will have one or two “side” melting stations as well, which can allow for higher productivity when melting more standard product in a single electrode to single ingot configuration.
Features
Consarc has built the world’s largest single electrode static ESR with a final ingot weight of 150,000 kg. This furnace is also capable of using multiple electrodes to melt that same 150,000 kg ingot via electrode exchange into a static crucible.
Consarc’s ESR furnaces are available in custom sizes to meet any customer requirements for both round and slab electrodes.
Features
| Inductotherm Group | |
|---|---|
| Product Category | Furnaces (industrial) |
| Product Number | ElectroSlag |
| Product Name | Remelting Furnace |
| Application | Foundry or Melting Furnace; Industrial |
