ESR crucible furnaces for electroslag casting

ESR CRUCIBLE FURNACES

We design and supply for electroslag casting (ESC) whole plants that consist of a special electroslag remelting furnaces with ceramic crucible. Remelted metal is poured from the ESR crucible furnace into a mold (metal chill mold) coupled with a slag. These ESC plants can be equipped by spin cast mold, permanent and some special type molds for production of various critical parts, including shells, large size ring billets, crankshafts and other shaped castings.

Electroslag remelting process in ceramic crucible allows remelting of scraps from various steels, at those small scrapped parts and component, broken pieces, which should be assembled in a consumable electrode. Various fines and chips from nonferrous metals can be remelted as well by use of a non-consumable electrode. It is very convenient and cost-effective way if required cast parts are produced directly by remelting of the analogous scrapped ones.

We produce and supply necessary molds are made of iron or steel (metallic chill mold) and ceramics (fully or partially), graphite depending on the range of Customer products and of it cast practice. The supply of spin casting molds with drive is possible as well on your demand.

Design, maintenance, and operation of our electroslag casting plants are time-proved, simple and flexible. We supply the electroslag casting plants for manufacturing of various weight castings from ferrous and nonferrous metals taking into consideration of all requirements of your machinery or repair shops.

As an example there are following technical performances of a crucible furnace for electroslag casting of shaped parts and tools having up to 50 kg in weight.

Maximum weight of castings, kg

50

Maximum overall size of castings, mm

400×300×250

Guarantee productivity, kg/h (not less)

60

Maximum length of remelted part of an electrode, mm

950

Supplying network voltage, V

380

The total installed power capacity, kVA

145

Remelting current, kA

3

Adjustable voltage of remelting, V

31; 43; 54

Overall size of remelting unit, mm

3000×2300×1800

Furnace weight, kg

3100±50

Scope of supply:

  • Electroslag furnace with melting crucible;
  • Molds of various types on your request, including spin casting machine;
  • Crucible tilting mechanism;
  • Power supply with line-balance compensator;
  • Plant control system;
  • Necessary auxiliaries.

For field usage, the power supply is a small field power station and the whole ESC plant can be installed on a proper vehicle.

MECHANICAL PROPERTIES OF ELECTROSLAG CASTING FROM VARIOS STEELS
(after heat treatment)

Steel grade

YS,
MPa

TS,
MPa

El,
%

RA,
%

Sharpy,
Joules

20 (ES Cast product / GOST 1050-74)

 494.1/≥400  343/≥240  27/≥18 56/≥48  155/-

40Cr1 (ES Cast product / GOST 8479-70)

 825.4/≥600 664.1/≥300  18.2/≥8 29.4/≥25 67/≥60

20Cr1Ni3 (ES Cast product / GOST 8479-70)

 807.2/≥750 743.4/≥600  18/≥14 51/≥45 90/≥60