100 Indel Avenue
P.O. Box 156
Rancocas, NJ 08073
Ph.: +1(609) 267-8000
Background - Pioneers in VAR Technology
Consarc is well known to primary producers of speciality
steel, superalloys, and reactive metals. We pioneered
commercial ingot production using automated Vacuum
Arc Remelting (VAR) furnaces. We were the first to
apply load cell weighing of electrodes to improve process control. We developed coaxial furnace designs to minimize uncontrolled stirring. And we fully computerized the controls
to optimize reproducibility and ease of operation. Users
of Consarc VAR furnaces get proven process technology,
state-of-the-art control and fully computerized controls to optimize reproducibility and ease of operation from the industry's most innovative and experienced resource.
Consarc essentially makes two types of VAR furnaces.
The first is for speciality steels and superalloys and the
second is reactive furnaces for titanium and other highly
reactive metals. Both types are available in many sizes
and production capacities to around 30,000 kg ingot weights.
Materials to be melted are loaded into the furnace. For speciality steels and superalloys, an electrode is used, previously cast in air or vacuum. For primary reactive metals like titanium, it is material fabricated from compacted sponge and/or scrap. Two major mechanical assemblies combine to form the vacuum vessel in which melting occurs - the movable furnace head and the fixed melt station.
The movable furnace head is the upper section of the vessel. An integral, highly sophisticated ram drive assembly supports and controls the movement of the electrode. The water-cooled ram extends through
a vacuum seal in the head; the electrode clamps to its lower end thus becoming the cathode of the arc melting operation.
The fixed melt station, the lower half of the vacuum vessel, consists of a removable copper crucible that
is placed into a fixed stainless steel water jacket and guide. Design and construction of the crucible are critical to the successful solidification of the restructured metal ingot.
Once the furnace head with electrode is lowered and secured onto the melt station, a vacuum is established. A controlled, high dc current is applied to the electrode (cathode) and arcing between it
and the ingot (anode) remelts the electrode material at a pre-determined rate. The entire melting cycle
and all the key operating parameters (Current, Voltage , Melt Rate and Arc Length) are automatically monitored and controlled to a pre-defined melt recipe from start to finish.
Advantages of Consarc VAR furnaces
The Consarc VAR process overcomes serious problems that have been historically associated with conventional VAR operations. Problems such as strong magnetic fields in the electrode melt area that caused uncontrolled metal stirring, uneven solidification, and alloy segregation. Imprecise positioning of
the electrode that compromised ingot reproducibility and in the case of titanium, system safety. Consarc has developed and implemented solutions to all of these problems. Solutions that have proven their worth through years of field use.