Note: Descriptions are shown in the official language in which they were submitted.
1(~88~58
~TL~ FOR ~l~D l~HOD O~ C~R9SLAG L~I~ir~ G
O~ ~i~VllAIS ~LTD AILOYS
rrhe -present invention relates to pl~lts ~or and me~thods
olD elec-trosla~ remelti1lg olD Irletals and allo~s. It is partic~-
larly use~ul lor producing ingots and slag ingots ~or subse-
quen-t metallurgical collversion and for manufac-turing sound
shaped cas-tings ~or machine-building indus-tr~, sai~ castings
being less expensive than welded-and-~`orged or extruded-and-
-welded struc-tures and being not onl-~ not inferior in terms
of their qualit~ but on certain occasions even superior to
those.
In many industriall~ developed coun-tries o~ the world
the engineering and technology o~ electIoslag remelting o~
metals and alloys are s-triding vigorously.
~ his has created a problem o~ providing such plants and
methods which would o~fer, ~irstly, a higher e~iciency, that -
is heretofore low on prior-art installations, along wit~ a
high qualit~ of metal, and would enable, secondly, the produc-
tion of various products: ingots, slab ingots, shaped cast- -
ings, tubes, tube skelps, etc., on -the same e~uipment and1
thirdly, t~1e-y would allow simpli~ying bot`n the ~aintenance
a~d operation o~ metallurgical equipment~
At present known in the art is a pl~rlt ~or electroslag
- remelting o~ metals in a cooled rnould with two consumable
electrodes or two groups of consumable~etrodes comlected in
seriss to an electric circuit. Both consumable electrodes or
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~088758
'ooth groul)s oi` consui~a'ole ~lec-tL~des are mounted in a ~ingle
electrode holder, `oeing carried vertically at t~-le same rate
by ole cor~lon vertical -tr~ls~er gear. Now said plant is em-
plo~ed 'or roducin~ slab ingots.
Hcwever, the above plan-t is no-t deprived of di~advantag-
es, of which tihe main consists in that it is unfeasi'ole for
producing hollow shaped castings with projecting parts, a
~eature liL~ii-ting the field o~ its applica-tion. iiloreover, said
pla~t ~ails -to avoid considerable heat losses in the slag
bath owing to high-rate cooling of -the mould in the slag bath
zone.
Also k~own in the art is an installation for alectroslag
remelting o~ metals and alloys, comprising an auxiliar~ ele-
ctrode for sustaining the requisite tempera-ture of liquid
slag a~d metal in a mould at the instan-t when a new electro-
de is fitted upon melting the proceding one.
However, at the above installation said auxiliar~ ele-
ctrode operates only at short-time duty during -the replace-
ment o~ the melted consw~ble electIode, whilst its applica-
tion in said installation complicates both its design and
attendance. Moreover, in view o~ interruption in the electro-
slag remelting process needed to replace the consumable ele-
ctrode, an ingot sur~ace is rough and, i~spite of the auxi-
liary elect~ode operating during the replacement period, it
adversely a~ects the quality of metal obtained.
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1088758
~ lOWIl as well ill the art is a l~ethod oi elect~oslag re-
meltillg o~ etals ancl alloys in which an electric current is
fed t~ough a consumable electm de ~nd slag to a copper mouldc
~he above method intensifies -the melting of the electrode,
i.e. provides a higher elficiency o~ the elec~ro lag remelt-
ing process~
However, said method suffers from a serious disadvan-
tage which resides in electrolytic attack on the working sur-
face of the copper mould and its erosion owing to the passage
of the electric current from the consumable electrode through
the slag to the mould which causes rapid failure of the lat-
ter (mould).
~ lso known in the art is a plant for producing hollow -
metal ingots by the electroslag remelting technique, wherein
said hollow ingot is shaped by a mould and a mandrel5 a power
supply source being connected to said l~andrel and to a consu-
mable electrode. In service an electric current is passed
through the consumable electrode, a slag ba-th and -the mandreL
A disadvantage of said plant lies in rapid failure of
the mandrel owing to electrolytic deterioration and erosion
of the mandrel surface caused by the passage of the electric
current through the slag and said mandrel.
Enown in the art is a method of the electroslag remelt-
ing o~ a consumable electrode in a cooled mould by carrying
both the electrode and the mould during said remelting to
provide -the socalled method with an opposite motion of an
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electrode and mould. With sai~ ~ethod the cross-section oiR
the con~umable elec-trode ~ust be smaller tllan -that of an
ingot being melted, the height o~ the melted ingot being
therefore always smaller -than the length of -the consumable
electrode. ~ome-times, particularly v~nen producing tube skelps
and slab ingots the cas-tings being melted must have a consi-
derable heigh-t. However, the above method fails to provide
such castings.
Also known in -the art is a plant for producing ingots
in metal allo~s, especially in steel, by the elec-troslag re-
melting technique, said plant comprising a mould whose bot-
tom part determines external dimensions of an ing~ot being
moulded, said bottom mould part passing into a flaring, pre-
ferably, conical intermediate part which in turn Fasses into
a spreading out top part. ~oth the mould and the ingot move -
relative to each o-ther. Said plan-t is superior to -the prior-
-o~e~s in that it is adaptable for remel-ting electrodes with
a cross-section greater -than that o~ the ingot being melted-
However, said plant suffers from a low efficiency and
fa~s to produce shaped castings with projecting parts. ~he
flared -top part o~ the mould serves either as a collector
of liquid slag and metal or as a bath for melting metal and
increases the cooled surface of the mould walls coming in
contact with the mol-ten slag bath during electroslag remelt-
ing, which in turn increases heat reinoval from the slag bath
diminishing thereby the plant efiiciency.
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" 1088758
1'~nV~Jn as well is a r~ t ~or electrosla~ neltir)~ ofshaped cas-tin~s with concurrent ~usin~ OI cer-bain ii~emberS~
said plan-t co~prisin~ a ~ould mounted on a bass plate with
an openin~, into which a member beiIlg fused is introduced,
and an electric current switch with connects one of the po-
les of a power supply source either to the mould or to a
consumable electrode.
A disad~antage of said plant resides in that as &n ele-
ctric current passes throug~ the ~ould and fused member,
power losses are -too high owing to slag accretions built-up
on the working surface of the mould; moreover, mould walls
and a base plate can break down upon spreading of a i~etal
pool &nd making an electric 'imould-fused member" circuit by
said metal pool.
~ he main object of the presen-t invention is to overcome
the aoove disadvantages peculiar to prior-ar-t pl~l-ts and
methods of electroslag remelting oP metals and alloys.
A~o-ther object of the invention is -to provide a plant
for &~d a method of electroslag remeltin~ of metals &nd al-
loys which would o~fer not onl~ a considerably higher effi-
ciency, as compared with the prior-ar-t plants of the t~pe
described, but would allow producing various pro~ucts on the
same plant, i.e~ would extend the ~ield of application of
the electroslag remelting facilities and si~plify concurren-
tl~ both the mainten&nce al~d operation of said pla-nt.
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~ aid aLl~ o-ther obj C-C-G5 are achieved iLl a Qlant l`or ele-
ctroslag rer~ltinO ol ~letals a~d ~lloys, co~,rising a slag
bath contained in a cooled mould set u~ on a base plate,
with ~the bottom end o~ a consu~able electrode bein~ submerged
in-to said slag bath, said electrode being co~1ected -to o-ne
of the poles of an electric current supply source ~ld beirlg
carried by a vertical traasfer gear, said pl~nt, according
to the irverltio~, comprising a-t least one non-cons~nable ele-
ctrode co~ ected to the o-ther pole of the electric current
supply source in series with the co~sumable electrode, the
non-consumable electrode and base plate being movable rela-
tive to each o-ther in a vertical direction.
; ~he application of said plant accelerates the melting
o~ the coIlslLmable electrode with -the same power input, in
other words, a higher plan-t efficiency and b~tter qualit~ of
an ingot are provided owing to ~ore efficient an/complete
utilization o~ heat power of the slag bath. Moreover, this
eliminates the necessity ~or dumr4y bars which are unavoidable
in prior-art plallts~ this si~lplifying the elec-troslag remelt-
ing techn;que and providing a be-tter design of the base plate~
Xelative advance of the non-consu~able electrode and
base plate can be effected since the non-consumable electrode-
is fitted with a vertical transfer gear, or the base plate
can be provided with a gear for vertical transfer of the
ingot bei~g melted. In this case the non-consu~able electrQde
and the mould are immovahle during the electroslag remelti~g
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process ~vhich siIlpli~ies both -the main-tenance and operation
o~` the plarlt.
~ he non-consumable electrode is advisable to be made
hollow, fixed on asl interrlal wall of the mould and insulated
electrically there~rom, while the consumable elec-trode must
bearranged inside the non-consumable one and i~mersed with
its bottom end in the slag bath; it is expedient that the
mould and non-consumable electrode be carried upwards by one
vertical tra~is~er gear, the ingot remaining sta-tionary.
Said plant is well adaptable for e~fecting the method
b~sed on an opposite motion of a consumable elec-trode and a
mould, the plan-t ef~iciency being in this case considerably
higher than in prior-art installations owing to a rational
electric circuitry e~lployed for connecting both the consuma- -
ble and non-consumable electrodes -to the power supply source
and because the hollow non-consumable electrode ~ed into the
slag bath acts at the same time as a heat-insulating element,
dirninishing heat losses o~ the slag bath owing to heat trans- -
~er to the rnould wall, insofar as said wall happens to be
heat-insulated by the non-coilsuTmable electrode.
The base plate can be equipped ~ th a gear ~or vertical -
~trans~er o~ the ingot being melted, the mould and non-consu-
mable electrode being stationary in that case.
Sornetimes it is convenient in terms of design to make
t~e non-consumable electrode as current-carrying pla-tes en-
1~887S8
colnpassial~ tne consun~ble electrode, said non-consumable
elec-trode (plates) being moul~ed on the in-te~nal surI'ace of
the mould and insulated e~ ctrically therei`rom.
~ he current-carryiIlg plates can 'be set up alon~ the
entire perirleter of the internal mould surface.
~ he noll-consuma'ole electrode can be rnade hollo~s, a man-
drel being fixed therein and insulated electricall~7 there-
from, the consumable electrode in this case encompassing at
least partly the non-consumable one and being submerged with
its bottom end into the slag bath, the non-consumable ele-
ctrode, mandrel and mould are advisable to be carried up-
wards by one vertical transfer gear ensuring the production
of a hollo-7l casting. -'
~ he proposed plant makes it possible to produce tube
skelps ~yelectroslag remelting of metals and alloys, hea-t
losses of the sl'ag bath owing to heat transfer -to -the mandrel-
diminishing in this case as the mandrel happens to be heat-
-insulated by the non-consumable electrode.
~ he base pl~-te can be fitted with a vertical -transfer
gear for carrying -the melted tube skelp.
~ o produce a hollow casting with a bottom the plant for `
electroslag remelting of metals and allo~7s, according to the
invention is advisable to be fitted with a current s~tch
connected from one side to one of the poles of the current
supply source and from the other to the base plate or to the
non-consumable electrode.
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1088758
_ g _
Such an embodiment makes it possible at the initial
mome~t, whe~ melti~g the bottom o~ a preset thickness, to
operate on the proposed plant according to a co~ventional
circuit passing`an electric current through the consumable
electrode, slag bath, ingot and the base plate.
It is sound practice, when producing -tube skelps on the
plant ~or electroslag remel-ti~ of mstals a~d alloys, that
the non-consumable electrode be made as two hollow rods of
any desirable cross-section, concentric with each other, one
of said rods accommodating the mandrel i~sulated electrically
therefrom and the other rod bei~g disposed on the internal `-
surface of the mould and bei~g also insulated ~lectrically
therefrom, the consumable electrode that is made hollow being
advisable to be set up intermediate of the hollow rods, con-
ce~tric therewith and submerged with its bottom end into the
slag bath, the non-consumable electrode and the mould being
carried upwards by one vertical tranafer gear relative to the
melted tube skelp.
Such a plant enables the production of diversi~ied hol-
low castings and is noted for low heat losses o~ its slag
bath owing to the no~-consumable electrode insulating thermal-
ly said slag bath ~rom both the cooled mould walls and the
mandrel, a ~eature which enhances the plant ef~iciency.
On said pl~nt -the base plate can be equipped with a
gear for vertical transfer of the melted tube skelp.
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1(~887S8
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In case a plant for elec-troslag remelting of metals and
alloys is furnished with a base plate having an opening whe-
rein a member, being fused, is fed, and with a curren-t switch
connected from one side to o~e of the poles of the current
supply source and from the other tv the fused member or con-
sumable electrode, said plant is adapted f~r produci~g shaped
castings by the electroslag remelting tecimique with concur-
rent fusing of certain parts, ensuring a guar~nteed quality
of joining the member being fused with a casting body.
~ he above plant provided with the current switch co~ne-
cted from one side -~o one of -the poles of the current supply
source and from the other to the consumable electrode or base
plate enables the consumable el~ctrodes to be replaced in the
course o~ electroslag remelting, providing sound castingsO
It is expedient that in said plant ~or electroslag re-
melting of metals and alloys the no~-consumabls electrode be
made of graphite.
Graphite is a good conduc-tor of electricity, i-t features
a high heat resistance and owing to its great affinity to
oxy~en it is a good deoxidizer during electroslag remelting,
this being especially important when remelting steels con-
taining such easily o~idizable eleme~ts as titanium, silicon
aluminum, etc.
~ he method of electroslag remelting of metals and alloys
on the proposed plant, according to the invention, consists
in that during the entire alectroslag remelting process an
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electric c~rre.r.t is passed through a consumable electrode,
slag~ bath alld non-consumable electrode.
It is good practice if during the entire electroslag
remelting process the non-consumable electrode is carried
upwards b~ the vertical trans~er gear at a rate equal to that
o~ motion of the slag bath, keeping thereby the end o~ the -
non-consumable electrode submerged into the slag bath, with
the consumable electrode being carried downwards, as it melts,~
to obtain an ingot of remelted metal.
In case the plant for electroslag remelting o~ metals
and alloys comprises a base plate fitted with a vertical
transfer gear, the ingot set up on said base plate is carried .
downwards, as it is being built up, so that the level of said
slag bath remains stant relative to a stationary non-consuma-
ble electrode and mould.
If the plant ~or electroslag remelting of metals and
allogs employs a hollow non-consumable electrode fi~ed on the-
internal surface of a mould, according to the in~ention, said .
non-consumable electrode is carried u~wards together with the
mould by one vertical transfer gear with respect to the ingot
bein$ melted, realizing thereby an electroslag remelting
method with an opposite motion of the mould and consumable
electrode.
In case the.plant is fitted with a gear for vertical
transfer of a base plate, the ingot being melted is carried
10~87S8
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downwar~s by said vertical transIer gear, a non-consumable
electrode and a mould being immovable in this case.
According to the invention, to produce on said plant
for electroslag remelting o~ metals and alloys a tube skelp
the no~-consumable electrode is carried upwardæ by ~he verti-
cal tran~fer gear together with the mandrel, the tube skelp
being immovable.
When moulding a tube skelp on a plant with a base pla-te
provided with a vertical transfer gear, said tube skelp is
carried downwards, a non-consumable electrode, ma~drel and
mould being stationary ~o that the level o~` a slag bath is
kept constant ensuring the shaping of the tube skelp. -~
~ or producing by the method of the invention an ingot of
remelted metal with a greater length than that of the melted
electrode, the consumable elec-trode, non-consumable electrode
and the mould are transferred upwards, the consumable electro- -
de being carri.ed at a rate o~ 0.05 - 0.95 the rate o~ motion
of the slag bath whilts the non-cons~mable electrode and the
mould travel at a rate of transfer o~ said slag bath, mainta-
ining the ends of both the consumable and no~-consumable ele-
ctrodes immersed in the slag bath.
From the equality o~ volumes of remel~ed electrode metal -
and that obtainable upon remelti~g it ~ollows that the height
of the melted ingot will be as much greater than the length
of the consumable electrode, as the cross-section o~ said
consumable electrode is greater than that o~ the melted ingot,
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1088758
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i.e. l2sl1 = S1 S2, where 12 and 11 is -the length accor~ingly
of the in~ot being melted and consumabl~ ~lectrode, and S2
and S~ - their cross-sec-tions.
By selecting the ratio S2:S1 within (0.95 - C 05) the
rate of transfer of -the coils~nable electrode, i.e. the ele-
ctrode melting ra-te will vary within (0.05 - 0.95) of the
slag bath transfer, i.e. of the ingot building-up rate.
Thus, by choosing consumable electrodes of appropriate
cross-section and leng-ths it is possible to obtain the melt-
ed ingot of a maxi~um height. l~oreover, the use of low-height
electrodes with large cross-sections decreases power consu-
mption owing to a lower electric resistance of the consuma-
ble electrode.
If the plant is provided with a gear for vertical trans-
~er o~ a base plate, then, according to the invention, said
gear carries an ingot downwards so that the level of a slag
bat~ is kept constant relative to a stationary non-consumable~
electrode and mould, with a consumable electrode being car-
ried downwards, as it melts.
To enable the production of ingots of a still greater
height according to the invention, from the beginning of the
remelting process t~e ingot is carried downwards by the ver-
tical trans~er gear -to an exte~t of possible gear transfer
so that the level of the slag bath is constant with respect
to the immovable ~on-consumable electrode and mould, the
oonsumable electrode of a cross-section ($1~ greater than -
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108~758
- 14 -
that (S2) of -the l1lelted ingo-t ~eing carried downwards, as
said conswnable electrodes melts, whereupon the gear discon-
-tinues the ingo-t transfer and up to the end of the re~lelting
process the consumable electrods, non-consumable electrode
and the mould are carried upwards, the consumable electrode
being moved at a rate of 0.05 - 0.95 the rate of the slag
bath, whilst the non-consumable electrode and mould travel
at a rate of transfer of the slag ba-th, keeping the ends of
both -the consumable and non-consumable electrodes submerged
into the slag bath and ensuring the production of the ingot
superior in height to a plant mas-t.
~ o produce a tube skelp with a wall -thickness smaller
than the cross-section of the remelted electrode, according
to the învention, the consumable and non-consumable electro- ~-
des, mould and mandrel are carried upwards, the consumable
electrode being transferred at a rate of 0.05 - 0.95 the rate -
of the slag bath, whilst the non-consumable electrode, mould .. .
and the mandrel are shifted at a rate of the slag bath, with
the ends of both the consumable and non-consumable electrodes
being i~mersed in said slag bath~
In case the plant comprises a gear for vertical transfer
of a base plate, -then, according to the iIlvention, said gear .:.
is employed for carr~ing the tube skelp downwards so that the
level of a slag bath remains constant relative to an immova-
ble non-consumable electrode, mould and mandrel, the consu-
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~088758
~ 17
mable elec-t-rode wi-th a c~oss-sec-tional area (S1) greater than
that (S2) of the mel-ted -tube skelp being carried downwards,
as said consumable electrode Inelts~ keeping the ends of bot~
the consurJIQble and non-consumable electrodes immersed in the
slag bath and ensuring the production OL -the tube skelp with
the wall s~aller in thickness than the cross-section of the
remel-ted electrode.
'~o enable the manufacture of` a tube skelp superior in
height to the plant mast, according to the i.-nvention, from
the beginning of the remeltin~ process the vertical transfer
gear carries the tube skelp being melted ~ownwards so that
the level of the slag bath is kept constan-t relative to the
immovable non-consumable electrode, mould and mandrel, with
said consumable electrode ha~ing a cross-sectional area ~S1)
greater than that (S2) of the melted tube skelp being trans-
ferred downwards, as said electrode melts, whereupon ~urther
trans~er of the tube skelp is discontinued, the consumable
electrode be:ing trans~erred up to -the end of the process at
a rate of 0005 - 0.95 the rate of the slag bath, whilst the
non-consumable electrode,mould and mandrel are shifted at a
rate of the slag bath, with -the ends of both the consumable
and non-consumable electrodes being immersed in said slag
bath.
When producing hollow shaped castings ~.vith a bottom by
the method of the invention at first -the consu~able electrode
is remelted by passing an electric curren-t -through said ele-
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1088758
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ctrode, tlle slag b~th. all~ base plate with -the non-co~lsumable
elec~ro~e, ~i.andrel and mould being i~J~ovable until -the bot-
to~ ol` a ~iven thick-ness is built-up and un-til the end of
the consumable elec-trode submerges into -the slag bath, vlhe-
reupon and up to the end of the process the currer~t is passed
tl~ou~h the consumable electrode, slag bath and non-consuma- ~:
ble electrode, the mandrel and the non-consumable electIode ~-
being carried upwards a-t a rate e~ual to tha~ o~ the slag ~ -
b~th, sustaining the end of the non-consumable electrode in ..
said slag bath and moulding the interior of -the casting being
melted. .......
~ or producing hollow castings by using a movable mould,
upon moulding the bottom of a given thickness, both the man- -
drel and non-consumable electrode are transferred together
wit~ the mould by one vertical trans~er gear.
If the pl~nt is fitted with a gear for vertical trans~er
of the base plate, then. upon moulding the bottom, the hollow
casting is carried downwards b~ said vertical transfer gear
relative to the ir~movable mandrel, non-consumable electrode
and ~ld.
It is expedient that during electroslag remelting of
metala and alloys, according to the inventioIl, upon melting . -.
of one consumable electrode the curre~t supply.source be -~.
discor~Lected from the consumable electrode and connected to . .: -
the base plate to maintain the slag bat~ in hot ~luid state, - ..
whereupon the melted consumable electrode is replaced~ with
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the end of said new consuinable ~l~ctrode bein~ qubmer~ed
into the slag ba-th, said consumable electrode is a~ain con-
.nected to th- current supply source aLld electrosla~ remeltirlg
o~ said i-le~ corisumable elac-trode continues.
Thus, a plu~alit~ of low-heigh-t consumable electrodes
can be remelted one after another in-to heavy i~gots. This is
converlient and profitable for the manufacturing of consuma-
ble electrodes and enables the arrangeme~t o~ an electroslag
remelting plant in the premises of a limited height, this
being of prime importance when organizing a new p~oduction.
In electroslag remelting o~ metals and alloys it is sound
practice, according to the invelltion, upon establishing a
slag bath -to pass an electric current through a non-consuma-
ble electrode, slag bath and a fused member until the top
end ~ace of said fused member starts melting, with a consu-
mable electrode being withdra~m from the slag bath to be t~e-
reupo~l submerged with its end in-to said slag bath, following
~ich the electric currerlt is passed throu~h the consumable
elec~Dde, slag bath and non-consumable electrode un-til the --
completion of the electroslag remelting process, er~suring a :.
guaranteed jointing of the ~used member to a casti~g body.
The nature o~ the in~ention will be clear from the fol- ~ :
lowing detailed description OI` particular embodiments of a
plant for and a method of electroslag remelti~g of metals
and alloys to be had in conjunction with accompanyingd draw- .-
ing, in which-
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~088758
Fig. 1 shows a plarlt Yor electroslag rel~lelting of metals
and alloys;
~ ig. 2 depic-ts a plant for electroslag remelting of me-
tals and alloys with an ingot vertical transfer gear;
Fig. 3 represents a plant for electroslag remelting of
metals and alloys with a consumable electrode set up on an
internal surface of a mould;
Fig. 4 shows -the same plant with the ingot ~ertical
transfer gear;
Fig. 5 - section V-V of Fig. 3;
Fig. 6 shows a possible embodiment of the consumable
electrode;
Fig. 7 depicts a plant with a mould flaring in its top
portion and an insertion piece shaped as a non-consumable
electrode;
Fig. 8 - section VIII-VXII of Fig. 7;
Fig. 9 - section IX - IX of Fig. 7;
Fig. ~0 illustrates the calculation of the rate of trans- ~ --
fer of a consumable electrode;
Fig. 11 illustrates the operation of the plant, as shown
in Fig. 7 and fitted with an ingot vertical transfer gear;
Fig. 12 shows a plant for electroslag remelting of metals
and alloys while producing a tube skelp, said plant being
provided with a non-consumable electrode and a mandrel intro~
duced therein; - -
. - . - .
...... ~.. . ., . , -
~. .
: ' ' : . .
.
-
: :
10887S8
- 19 -
Fig. 13 - section XIII-XIII of ~ig. 12;
Fig. 14 shows an embodiment of the non-consumable ele-
ctrode;
Fig. 15 illustrates the operation of a plant for ele-
ctroslag remelting of metals and alloJs, as shown in ~ig. 12,
with a tube skelp vertical transfer gear;
Fig. 16 depicts a plant for electroslag remelting of me-
tals and alloys while producing a tube skelp by using a non-
-consumable electrode set up on a mandrel and a mould;
~ ig. 17 illustrates the operation of the plant shown in
Fig 16 and fitted with a tube skelp vertical transfer gear;
~ ig. 18 shows a part of the plant illustrating its func-
ti~ng with a mould ~laring and a mandrel narrowing in their -
top portions; -
~ ig. 19 - section XIX-XIX of ~ig. 18;
~ ig. 20 - section ~X-XX of ~ig. 18;
Fig. 21 illustrates operation o~` a pla~t, as shown in
~ig. 18, provided with a tube skelp vertical transfer gear;
~ ig. 22 depicts a plant for electroslag remel-ting of
metals and allo~s while producing a hollow casting wi-th a
bottom in it8 lower portion, said plant having a movable
external mould; ~ -
~ ig. 23 s~ows a plant for electroslag remelting of me-
tals and alloys while producing a hollow casting with a bot-
tom in its lower por-tion, said plant having a base plant ~ -
movin downwards;
;; ,.'
-
~ .
-: ,~: .- ............... . .
. .
- :. . . ~ ~
- .
1088758
-- CO _
~ . 24 shows relative posi-tion o~ -tlle ~arts o~ a plan-t
for electroslag remel-ti~O of me-tals and alloys a-t ~the begin-
ning of the process o~ producing a hollow shaped cas-ting ~ith
a bottom iIl its lower portion;
Fig. 25 shows relative position of the parts of a plant
for electroslag remelting of metals and alloys at the end of
the process o~ manufacturing a hollow shaped cas-ting with a
bottom in its lower portion;
~ ig. 26 depicts a plant ~or electroslag rernelting of
metals and alloys at the moment of replac~ment OI' a consuma- ~
ble electrode; :
Fig. 27 shows relative posi-tion OI` plant parts upon melt- -
ing several low-height consumable electrodes with a descend-
ing ingot; -
Fig. 28 shows relative position of plant parts at the
begi~ning of -the electroslag remelting process with concur-
rent fusing of a member;
Fig. 29 shows relative position of the plant parts upon .
fusing æaid member~
Fig. 30 shows relative positio~ of -the plant parts upon
fusi~g said~member and remelting a plurality o~ consumable
eleotrodes with a descending ingot. ,
Conaidered hereinbelow are several sxamples illustrating
the application of the present invention while:
a) producing ingotæ;
b) producing tube skelps;
,~
, ~
., . , ~. . . .
.
' ~ - , ~ . - . -: '-
: .. ' ,- ~- ., .: .
., . . ~
- : . . -
. . : .
1088~S8
c) producing hollow castings with a bottom;
d) replacing~ consumable electrodes durin~ melting;
e) producing castings with concurren-t ~usi~g of cer-tain
me~bers.
A plant for electroslag remelting o~ me-tals and alloys
comprises a bearin~ mast 1 (~'ig. 1) and a top carriage 2
travelling -the realong, said carriage 2 mounting an electrode
holder 3 with a consumable electrode 4 ~ixed therein. ~o
shape an e~ternal surface of ingots use is ~ade of a cooled
mould 5 set up on a cooled base plate 6. Prior -to the begin- ~ -
ning of the electroslag remelting process a slag bath 7 is
established in the mould 5 (molte~ slag starti~b~)~ the con- -
sumable electrode 4 a~d a non-consumable electrode 8 being
submerged into said slag bath 7. ~he non-consumable elec-trode
8 is secured by means of a stand 9 to a bo-t-tom carria~e 10
mounted on the mast 1 and adapted for vertical -transfer of
said non-consumable electrode 8 along the mast i. ~oth the
consumable electrode 4 and non-consumable electrode 8 are
connected to unlike poles of an a.c. supply source ~, an
electric current passing thereb~ -through the consumable ele-
ctrode 4. slag bath 7 and non-consumabla electrode 8. lo ena-
~ble the ends o~ the consumable electrode 4 a~d non-consumable
electrode 8 to be always ;~mersed in the slag bath 7 during
the entire electroslag remel-ting~ process the non-consumable
electrode 8 is transferred upwards a-t a rate equal to that
.
~ of tne slag bath 7, whilst the consumable electrode 4 is lo-
-, .
~ wered into said slag bath 7, as it melts.
.. . , . .. .. ~ . . . ~ . . - : . .
. -. ~ , - -~ . . .
~088758
- 22 -
An in~ot 12 beinO ~ lted is s~laped by the base i~late 6
a~d mould 5. 'L'O ,preclude the passage of tl--e electric curren~
to an in-ternal wall 13 o~ -the mould 5 'both -the consumable ele-
ctrode 4 and non-consumable electrode 8 are not electrically
associated with t11e mould 5, said mould 5 together with the
base plate 6 bein~ not co~nec-ted into t..,he electric circuit.
Insofar as the mould 5 and base plate 6 are d~ad, their walls
are therefore protected against electrochemical attack.
Ic case the plan-t base plate 6 (~ig. 2) is fitted wi-th a '
gear 14 for vertical -transfer of -the ingo-t 12, there is no
need to carry the non-consumable electrode ~. In this case
the vertical transfer gear 14 carries the ingot 12 downwards,
as it is built up, so that the level of the slag bath 7 is
kept constant wi-th respect to tne irnmovable non-consumable
electrode 8 and mould 5~ ,
Said plant is more collvenient in service because the
mould is stationary during -the melting process, however, it ~'
requires a ver-tical shaft for its arrangernen-t ~vith a depth
sufficient to accommodate the melted ingot 12.
Fig. 3 shows a plan-t ~or electroslag remelting of metals
and alloys in which a non-consumable elec-trode 15 is made
hollow and is rigidly ~'ixed on the in-ternal wall 13 of a mould
16 having a low height as compared with -the above plant. To
preclude the passage of an electric current to the m~uld 16
a l~yer 17 of electric insulation is placed between the non-
consumable electrode 15 a~d mould 16.
:' . ': " ' ,' , .
,, .
';
1088758
2~
O~in~ tv said desi~n tl~e low-height mould 16 can be used
for producinJ in~ots 12 oi` considexable height ~ecause bo-th
the mould 16 and non-consurnable electrode 15 are carried up-
~ards b~r one vertical transfer O~ear 10.
In operation -the non-cons~-nable electrode 1~ is carried
upwards to~e-ther with ~the mould 6 by one vertical transfer
geal 10 relative to the mel-ted in~ot 12.
If the base pla-te 6 of the plant (~ig. 4) is equipped
wi-th -the gear 14 for ver-tical transler of the ingot 12, the
melted ingo-t 12 is carried downwards b~ said vertical -tran~- -
~er ~ear 14 wi-th -the non-consumable elec-trode 15 and mould
16 being s-ta-tionary.
Shown in ~ig. 5 is a cross-sec-tional view of a non-con- -
sumable electrode 15 which is made as a hollow rod.
However, someti~es in -terms o~ design it is more conve- ~
nien-t to emplo~ a non-consurnable electrode made as plates 18 -- -
(~ig. 6) encompassing partly or completely a consumable ele-
ctrode 4, said plates 1~ being mounted on -the internal surfa-
ce 13 OI' a mould 16 and insula-ted elec-trically therefrom.
Fig. 7 shows the func-tioning of a plant ~or electroslag
remelting of stesl and alloys when producing a slag ingot 19.
~ mould 20 of said plan-t flares in i-ts top portion to accom-
modate a slag ba-th 7 in which -the consumable electrode 4
melts. A non-consumable elec-trode 21 is an ir~ertion piece
arranged on tha ~lared top portion OL -the mould 20. '~he slab
ingot 19 is bei~g shaped in the bottom narrowing par-t of the -
mould 20.
- ' -
- , - ~ : . :
. .
- - .
1088758
- 24 -
Said desi~ll ol' the ~larl-t allo~s, firs-tly, remelting the
elec-trodes 4 v~ith a cross-sectioll S~ `ig. ~) grea-ter than
the cross-sec-tion S2 (~ o. ~) of the melted ingot 19, crea~-
in~, secondly, more favourable conditions for fusinO OI the
consumable elec-trodes 4 and snaping of the slab in~ot 19, a
feature which renders the plant more compact and efficient.
By melting the consumable electrode 4 with the cross-
-section ~1 greater than the cross-sec-tion S2 of the melted
slab ingot 19, with -the consumable electrode 4, non-consuma-
bie electrode 21 and the mould 20 being carried upwards,
ingo-ts of a large heigh-t can be produced.
Said examples are considered hereinaf'ter in detail.
If the electroslag remeltin~ process is conducted with
a constan~ rate, uniformly, and -the volume of a slag bath 7
does not change, the rate of transfer of the consumable ele-
ctrode 4 (Fig. 10) will 'be~
Vl ~ 2 411 (1)
where Vl is -the rate of transfer of' the consumable electro-
de 4;
~11 is -the length of a fused part of the consumable
electrode 4;
12 is the height of` a buil-t-up par-t of -the slab in~ot
~: 19; `
t is a time interval under consideration.
'' " ~
:::
.: ~ . . ~ . . . -
.
: . . - - : -
~ ',' '' ' .. , ' '', ~
108~58
l'he buildin~-up rate (V2) of the slab in~o-t 19 or that
with which the slag -ba-th 7, mould 20 and ~on-co~sumable ele-
ctrode 21 mo~e will become equal accordinOly:
V2 = 12 (2)
at
~rorn -t~e equations (1) and (2) it c~n be ~ound;
Vl 1 A
V2 ~` 12
~ rom the equali-ty of volumes of remelted metal of the
consumable elec-trode and -that of tile obtained slab ingot 19:
~1- a 1l = S2- ~12 (4)~
or
1 = S2 (5).
~ 12 Sl
Substitutin$ ~quation (~) into ~qua-tion (3)
~2
Vl = V2 ~1 - - ) (6)
Subs-tituting practically possible limi5s 0~ 2
= 0.95 - 0.05 in-to Equa-tion (6), i-t is possible -to find out
the rate (Vl) of transfer of the consumable electrode 4
which amou~ts -to 0.05 - 0.95 the rate (V2) of travel of the `~
slag ba~th 7.
r~he foregoing is illustrated below by an example.
rlhe cross-section S1 of the consumable elec-trode 4 is
twice as ~reat as the cross-section S2 of a slab ingot 19
- ., ,. -
. . - :- . .
.- . . ~
.
- ~ - ' ' '-
10887S8
_ 26 --
bein~ melted. L'he~ by mo~mtin~ tl-le consumable electrode 4 in
the middle oI` a rnaqt 1, its ~e~lel-ting in -the slag ba'~h 7 is
ini-tia-ted. In this case the building-up rate (V2) o~' the slab
ingo-t 19 will be twice as great as the rate of ~'usi~g (Vl)
of -the electrode 4, according -to ~`quation (6), both rates
being directed upwards. 'i'he non-consumable electrode 21 and
mould 20 are carried upwards at the ra-te of travel of said
slag bath 7 by which virtue the ends oi' the consumable ele-
ctrode 4 and non-co~sumable elec-trode 21 are immersed in said
slag bath 7.
In the above exarnple as the elec-trode remel-ting process
comes to an end, the electrode 4 will reach the top end of
the mast 1, in other words, i-t will pass the distance equal
to one half` o~ the height of -the mas-t 1. At the same time the
height increment of the slab ingo-t 19 will be twice as great
as said path passed by the electrode 4, i.e. the height o~ the
slab ingot 19 will be equal to tha-t of` the mast 1.
I~aturally, the electrodes and ingots may di~f'er in shape.
~ he present invention rnay prove to be most advan-tageous
in producing slab ingots. In this case owing tc a large ingot
height a cas-ting (a slab ingot) can approach to a maximum ex-
tent a rolled sheet, diminishing thereby the reouisite reduc-
tion degree and cutting down the rolli~g cycle. I~oreover~ the
use of low-height consurnable electrodes 4 o~' a large cross-
-section, as well as the ~act that -the remel-ti~g process is
conducted in -the slag bath 7, heat-insulated f'rorn the cooled
'
. ' . ,
1088758
~ ~7 ~
Wa11S OI tii6` i~ould 2~ by an ilsertion piece shaped as a non-
-co~lsw-~able elec-trode 21, oiI`ars ~1 abrupt decrease in ele-
ctric energy collsu~lption, i.e. e~lances tfle plan-t e~ficien~
All ~tL~e ~ore~oin~ cuts ~o~n botfl-the cost o-f rle-tallurgi-
cal produc-tion and me-tal conversion expenditures.
~ `ig. 11 shows -the prvduc-tion o~ a slab in~o-t 19 on a
plant wi-th a base plate 6 being ~`i-tted Wi-tfl a g-ear 14 for
vertical transfer o~ said slab ingot 19. Durin~ electroslag
remelting on said plant -the slab ingo-t 19 is carried down-
wards by the vertical trans~er gear 14 so -that tne level o~
a slag bath 7 remains constant relati~e -to the i~movable non-
-consumable elec-trode 21 and mould 20, the consurna'ole electro-
de 4 being carried downwards, as it melts.
Said method o~' electrosla~ rel~leltin~ in combination with
the above-outlined p~ocedure (with a consurnable elec-trode
being shif`ted upwards) ~akes i-t possible to melt slag ingo-ts
19 o~ a height equal to -the surn o~ dis-tances passed by the
gears 10 and 14, i.e. practicall-~ the slab ingot 19 can ex-
ceed in height -that OL the fnast 1 ~ or a value of possible
descend of the base plate 6.
Owing to such large dimensions the slab ingo-t 19 can be `-
employed as a plate even wi-thou-t rolling, mee-ting the requi-
rel~ents as to i-ts quality. '~he present invention is of parti-
cular advantage i~ ship-building when manu-~acturing ships'
hulls. Economic expediency OI` -this applica-tion is quite ob-
vious.
.~
~, .
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.
' - ~ .. , . - .- ~ : -
1088758
Considare~ hereil1below is -ti1e produc-tion o~ -~ube sk~lps.
~ ig. 1~ shows one of the embodiments o~' a plan-t ~'or ele-
ctroslag ram~1-ting o~ metals and alloys for producingj a tu~e
skelp 22. On said plant a non-consumable electrode is made
hollow -to accommodaie a mandrel 24 ~'ixed therein. Placed be-t-
ween a non~consumable elec-trode 23 and an external surf~ace o~'
the mandrel 24 is a layer ol ~lec-tric insulation 25 preclud-
in~ the passage of an electxic current through the mandrel 24.
A consumable electrode 26 is ~ade as a tube or of separate
rolled bars and encompasses a-t least partly the non-consuma-
ble electrode 23.
'~he non-consumable elec-trode 2~ may consti-tute a hollow
cylinder 2~ (Fig. 13) or it can be made as separate plates 27 ;
(~ig. 14) arranged around the mandrel 24 and encompassing it ~ -
par-tly or completely. -
, The plant ~unctions in the ~ollowing manner.
Upon mou~ting a low-height mould 28 on a base pla-te 6
(~ig~12), with -the mandrel 24 being fixed on the upper part
of said mould 28, said mandrel being fitted with a hollow
non-consumable electrode 2~, molten slag s-tart is provided by
pouring a preliminary heated slag bath 7 in a mould 28 reach-
ing such a level that the end o~ the non-consumable electrode -
23 happens to be submerged therein-to. ~ollowing that a consu- -
m~ble electrode 26 is immersed in said slag bath 7 and by --
,
passing an eleotric curren-t from the a.c. supply souxce 11
through the consumable electrode 26, slag bath 7 and non-con-
. ~ ,
~ ~ .
~ '
, . ,. , ,,.. ,... - - - - ,
.
.
,
10887S8
_ ~9 _
sumable electrode 23 the electrosla~ remel-ting ~rocess is
ini-tial,ed.
As the me-tal of the consumable el~c-trode 26 start melt-
ing~ the ~ear 10 carries -the norl-consumable elec~trode 23
-toget~er with the mandrel 24 and -the mould 28, -the tube skelp
22 remainillæ i~movable. The movinO internal surface 1~ of t~e .
mould 28 shapes an external surface oi` the tube skelp 22,
while an external sur~ace 25 o~`-the mandrel 24, on being
-transferred upwards, shapes the internal sur~`ace of -the tube
skelp 22.
'~he inherent design of -the mandrel 24 with the hollow
non-consumable electrode 23 fixed on i-ts upper portion is
favourable in that it reduces heat losses of the slag bath 7, .
provides better conditions for ~elting the consumable electro-
de 26 by ensuring better current distribution in the slag bath
and precludes elec-tric erosion of tha mandrel 24.
~ ig. 15 illustrates the operation o~ a plant ~or elec-tro-
slag re~lelting when p~oducing the tube skelp 22 by using the
~ertical transfer gear 14. In this case ~the tube skelp 22 is .~ :
carried downwards -by the ver-tical -transfer gear 14, non-consu-
mable electrode 23, mandrel 24 and mould 28 bein~ s-tationary ..
so that the level of -the slag ba-th 7 remains cons-tan-t. -~ ;- -
Said plant provides better servicin~ conditions.
~ ig. 16 illustrates the operation of a plant when .ro- -
~ducing the -tube skelp 22 with a non-consumable electrode 30
made as two hollow cylinders of any desired cross-section,
'
.. ...
' . :: ~ - -
. . . . , . . . ~
- ' . - .
, . - : ' ,
~088758
-- 30
o:E wllich one is fixed on the inteInal surL~ace 13 of the mould
16 and the other ore on the ~1andrel 24.
Said desi&~n o~ the non-consumable electrode creates
optimum conditions ~`or current dis-tribution in the slag bath
7 around the consumable electrode 26, ensuring i-ts melting.
ItIoreover, in this case the non-consumable electrode 30 ac-ts
as a heat ins~lator o~ cooled walls of -the mould 16 and man-
drel 24 in the zone o~ the slag bath 7, a ~eature which dimi-
hishes materially hea-t losses in -the slag ba-th 7. ~verything
taken -together enhances the plant ef~iciency, i.e. decreases
the specific consumption of electric power as compared with
prior-ar-t installations ~or electroslag remel-ting o~ metals
and alloys. .-
The tube skslp is shaped similarly to the above-outli-
ned, i.e. with the tube skelp 22 being stationary a~d with -
~-the gear 10 moving upwards the mould 16 together wi-th the
ma~drel 24 and non-cons~mable elec-trode 30.
In another embodiment the mould 16 (~'ig. 17), mandrel 24
and non-consu~able elec-trode 30 are immovable and the tube
skelp 22 mounted on the base plate 6 is carried downwards by
the gear 14.
~ his creates bet-ter conditions for plant servicing, in-
so~ar as the mould 16, mandrel 24 and the non-consumable ele-
ctrode 30 are stationary a~d can be easily obssrved during
the entire process.
.
108~7S~
-- 31 --
l~'ig. 1~ illus~ates tiLe ol)eration of a plant when pro-
ducing the ~ube skelps ~2 ~ith a wall thick~ess smaller -than
tile Cl'OSS-SeC tiOn OI cons~-,lable electrodes 31.
~ `ixed on tlle mould 20 with the ~lared -~op portion is a
hollo~v non-consumable elec-trode ~2 irlsulated electrically by
the layer 17 of elec-tric insula-tion from -the walls of -the
mould 20. Arrar~ed on -the top paxt of the mandrel 24, narrow-
ingr towards its -top portion, is -the hollo~v--I~on-consumable
elec-trode 23 insula-ted -through -the layer 25 o~ elec-tric in-
sulation fro~ the walls o~ the mandrel 24. ~`he consumable
elec-trodes 31 made up of individual bars ~Jith a ~otal cross-
-sectional area of Sl (~i~. 19) greater than -the sec-tional
area S2 (~ig. 20) of the tube skelp 22 bein~ melted are re-
melted in -the flared portion bstween the non-consurnable ele-
ctrodes 32 and 23.
~ he tube skelp 22 (~ig. 1~) is shaped sirnilarly -to the
above-described procedure of producing a slab ingot, i.e. by
carrying the consumable electrode 31, mould 20 and non-consu- -
~mable electrodes 23 and 32 upwards.
Both non-consumable electrodes 23 and 32 and the mould
20 are trans~erred at a ra-te V2 that is equal to that o~ -the
slag bath 7 which corresponds to the building-up rate of the - -
tube skelp 22. ~he consumable electrode 31 is carried upwards
a-t a ~ate of `0.05 - 0.95 -the rate o~ the slag ba-th 7 depen-
ding on the ratio o~ cross-sectional areas o~ the consumable
electrode 31 (Sl) and tha -tube skelp 22 (S2) being ob-tained.
.. '' - . . ~ , " ` '
.. : . . . . - .
.
. . - ~ . . .
:.: , .- . ~ ,
- . . .
1088758
'~hus, it is possi~le ~ produce high ~hin-walled tube
skelp 22. ~he inven-tio1l is par-ticula~ly efLicient economi-
cally when producinO -tu~bes in hard-to-work alld non-delor~aole:~
steels. At presen-t such tubes are usually pro(luced by ~orgring
and drilli~
l~ig. 21 ~hows t-he operation of a plan-t provided with
-the gear 14 ~or vertical -trans~er of -t~le base pl~-te 6. Wi-th
the help of said gear 14 the tube s~elp 22 is lowered, as i~
is built-up, so tha-t the level o~ the slag bath 7 remains
cons-tan-t with respect -to -the stationary non-consumable ele-
c-trode 31 beingr carried down~-vards, as it melts.
As the tube skelp 22 is carried down~ards, i-ts atten-
dance becomes more convenien-t, since the mould 20, non-consu-
mable electrodes 23 and 32 and slag bath 7 are immovable
during the en-tire process simplifying supervision and car-
rying out of the requisite produc-tion operations.
Moreover, the down~ard motion o~ -the -tube skelp 22 and
consumable electrode 31, with the mould 20 and non-consu~ab- -
le electrodes 2~ and 32 beingr stationary, and in combination
with an upward mo-tion of the consumable electrode 31, mould
.20 and non-consumable electrodes 23 and 32 e~ables the pro-
duc-tion o~ still higher tube skelps 22.
The latter is o~ prime importance when producin~ tubes,
since it is quite eviden-t -tha~ the larger -the length o~ a
tube being -produced, -the smaller is -the a~uunt o~ as~mbly
welds, this being proLitable ~or a tube consu~er, renders
,
- '- ~ . : .
~088758
tlle l~ ~`aturer l)roclucts Lilore competitive by cutting down the
produc-tion cost, as com~ared ~ th the -tube-makin~i ~roced~es
in curren-t use~ and ensures ~ioh quali-ty of material.
Considered hereinaf-ter is the fabrica-tion of hollo1;~
castings with a bo-t-tom in --~heir lowe~ portion.
~ ig. 22 illustrates -the prod~c-tiorl ol' a hollo-~i casting
33 ~7i-th a bottom 34 in its lower por-tion.
Upon es-tablishing -ti-le slaO ba-th 7 an elec-tric current
is passed by rneaIls OI a Swi-tCi1 35 -ti~ouOh -the consumable
elec-trode 26, sla~ bath 7 and base pla-te 6, with -bhe non-con-
sumable elec-trode 2~, mandrel 2L~ arld a mould 2~ beinO statio-
nary. Under the effec-t of the elec-tric c~rren-b the end of -the
consumable electrode 26 m~l-ts~ me-tal drople-ts collec-ting in
-the bo-ttorll part of -the ~nould 28 and solidifyinO on the base
plate 6 -to form the bottom ~4~ Gradually bo-th the slag bath '~
7 and a metal pool 36 climb upwards alon~ -the ~enera-trix of ,
the mandrel 24. UPO1L coming in con-tac-t ~ith -the surface of
the cooled mandrel 24 liquid me-tal of the metal pool ~6 soli- --
difies formillg walls of tl-le interior 37, while the slag bath
7 reaches the end of the non-consumable electrode 23. As soon
as the end o~ the non-consumable electrode 23 is immersed in ,
the slag bath 7 the switch 35 disconnects -the pole of the
current supply source 11 from the base plate 6 connec-ting it -
-to the non-consu~able electrode 23. Af'ter t~a-t -the elec-tric
current is passed through the consumable electrode 26, slag
bath 7 and the non-consumable electrode 2~. ~t -the same -time
.. , .. -:
. . - . .
'' ' :, ,: -
1088758
_ 3L~ _
-til~ ~an~rel c4 Wit~l the non-con~lablQ electrode 23 and mould
28 are carried upwards and u~ to -the end of -the process -the
rerilaining pOItiOll o~ the hollow cas-ting is Lrloulded similarly
to -the above-outlined procedure user~ when producing the tube
skelp.
Shown in ~i~. 2~ is an errlbodimen-t illus-trating the pro-
duction of the same hollow cas-ting by using -the vertical
-transfer gear 14.
Wi-th the plant opera-tin~ in the above maI~er upon shap
ing the bot-tom 34, -the hollow casting ~ is carried downwards,
the mandrel 24 non-consurQable electrode 23 and the mould 28
being sta-tionar~. Said method is particular~ly efIicient eco-
nomically for producing variou6 high-pressure vessels: pump
bodies, hydraulic (oil) plants and compressor bodies.
~ 'igs 24 and 25 show rela-tive position o~ -the plant pa~ts
at -the begLnning and at the end of -the electroslag remel-ting
process when producing a hollow shaped casting 38 with a bot-
tom 39 in its lower portion.
Projecting parts of the shaped casting 38, made as bos-
ses (of the branch pipe, flange or some other type), do nob
enable the transfer of an external mould 40 during the melt-
ing process; therefore upon producing -the bottom ~9 of a gi-
ven thickness, tha-t is effected similarly -to the preceding
case, and upon co~necting -the pole of tne curren-t supply
source 11 to the non-consumable electrode 23, -the mandrel 24
~ith said non-consumable electrode 2~ is carried upwards at
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a r.lGe e~ual ~o -tha~ OI ~,lle sl.~g bath 7~ t'le mould 40 bein,-
~statioll.ry. ~t the end o~ the .)r~cess, upon ascer-taining the
exac-t instan-t the formi1lg shrink nole -legulation mus-t be
started, and UpOll disconnecGin~ -the curren-t supply source 11
the ra-te of wi-thdrawal o~ -the ~andrel 24 is increased so as
to provide i-ts free remo~al ~ithou-G being jar~ed by the f'or-
ces arisin~ on -the side OL' the casting ~ durin~ its shrin-
kage.
~ 'hus, said method can be successfully employed f'or pro-
ducin~ various shaped cas-tings, such as -the bodies o~' power
fittings and gates, reactor vessels ~or atomic power s-tatio-~s
e-tc. ' "'
Considered hereinbelow is the operation of a plant, ac-
cording to -the in~ention, with -the consumable electrode 4
bein~ replaced during melting (~ig. 26)o
In contra~t to the above plant a current swi-tch 41 is
connected from one side -to one of -the poles of -the current
supply source 11 and from the other -to -the consurirlable electr~
de 4 o~ the base plate 6.
Elec-trosla~ remelting o~ the consumable electrode 4 is
effected si~ilarl~ to -the abo~e-outlined procedure, until
said electrode melts. ~ext the current supply source 11 is
disconnec-ted from the co~sumable electrode 4 and connected
to the base plate 6. In -this case the elec-tric current pas-
' sing through -the non-consumable electrode 15, slag bath 7, .:
ingo-t 12 and -the base pla-te 6 maintains tile slag ba~th 7 and
the metal pool 36 in hot fluid s-ta-te.
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-- 36 --
At this tilile ~lle co~unla~le electrode 4 i~ replaced,
~ith -the end of~ a new consu~able electrode being iI~roduced
in-to ~he slag ba-th 7. After that the new consumable electrode
4 is co~lec-ted -to -the cur~ent suppl~ source 11 by -the swi-tch
41 and electroslag remelting of` said new consumable elec-trode
4 continues.
Evidently, said replacel-nen~ o~ consu~able electrodes
can be eff'ected as many -ti~es as it i~ re~uired, enabling -t e
production of heavy ingo-ts 12 b-y relnel-ting small elec-trodes.
Hence, when replacing the electrode 4, the meral pool 36
is sus-tained in hot fluid state which ensures a homogenous
ingot structure and a high-quali-ty surface. ~'he plant is con-
venient in ~ervice, does not require additional devices and
gears, is noted for its low height and a comparatively low
power input when producing ingo-ts of' various weight.
~ ig. 27 shows the operation of said plant f'itted wi-th
the gear 14 f'or vertical trans~er o~` the ingot 12 a-t the in-
stant of' ~itting the next consumable electrode 4.
It is obvious that in all the above-outlined cases the
proposed plant can opera-te by replacin~ the consumable ele-
ctrodes in the cowrse of' melting and these cases will not be --
considered in detail.
~ o summarize considered hereinbelow will be the functio-
nin~ of an electroslag remeltin~ plant ~ en producing shaped
castings wi-th concurrent fusing of a member which can be made
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108~758
-- 37 --
oi rolled products, ~orOinOs or prefabrica-ted by the electro-
slag remeltiIlg -technique.
Relative position OL` -the ~lant par-ts a-t the beginninO of
electroslag remelting with concurrent joinin~ of a fused mem-.-
ber 42 is shown in l~i~. 28.
A base plate 43 has an opening into v~hich -the member 42 -~- -
-to be ~used is int-roduced before -the ~rocess is initia-ted.
~he plant is fi-tted with a current switch 44 connected from
one side to one of the poles oi` the curxent suppl~J source 11
and ~rom the o-ther -to the ~used rnember 42 or to the consuma-
ble electrode 4.
'~he plant operates in the follo~in~ rnanner.
U-pon es-tablishing -the slag ba-th 7 (molten slag starting)
the switch 44 connec-ts one pole of the current supply source
11 -to the fused member 42. Hence, a~ elec-tric current is pas-
sed through ~he non-consumable electrode 15, the slag bath 7
and fused member 42 until i-ts -top end face 45 fuses, with the ~ :
consumable e:Lec-trode 4 being withdrawn from the slag bath 7. -.
'~hen the end of the consumable electrode 4 is submerged into - --
the slag bath 7 and the pole o~ -th~ current supply source 11
is disconnected by -the swi-tch 44 from -the fused member 42 and
connected to the consumable electrode 4. '~hus, the electro- -
sla~ remelting of the consumable electrode 4 (~'ig, 29) is
carried out by passing the electric curren-t thro~gh said con-
sumable electrode 4, the slag bath 7 and non-consumable ele-
ctrode 15.
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10~758
Preli!~in~ry fusing ol~ tilt'i top end face 45 of tLle fused
member 4~ ens~ues a guarallteed high-quali-ty joint 46 betvJeen
the ~used me~ber 42 and a casting body 470
Said ~ethod is particularly useful ,or Droducin~ shaped
combination castings with various cross-section, such as,
cold rolls, covers for power fi-ttin~ bodies, e-tc., and for
IUSi~g finished mernbers of an ar-ticle to one of its par-ts~
in the course o~ electrosla~ remel-ting, ob7~iating thereby
welding, cut-ting down ultimately the produc-tion cost and en-
s~ring hi~h quali-ty of the ~inished produc-t.
~ ig. 30 shows allother possible e~bodimen-t of a plant
when producing a cold roll 48 by fusing in -the course of ele-
ctroslag remelting its neck 49 which may be made by rolling,
by remelti~g a plurality of -the electrodes 4 one after ano-
ther and carrying -the base plate 43 downwards by the vertical ;
transfer gear 14.
It stands to reason that -the present inven-tion is not
limited to -the disclosed par-ticular embodimen-ts which must
be considered by way of illustrations only. ~articularly such
are all the devices w~ich cons-ti-tute technical equivalents
of said devices disclosed hereinbefore, as well as their com-
~binations, in case they are made without departing from the
spirit and scope of the in~ention as set forth in the appen-
ded claims.
