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... .. ... .. ... .. ... .. ..... ..... ..... ..... ..... ..... ..... .....
. . . . . . . . . . . .. .. .. .. .. .. .

VOl. 3,NO. 3, 1987 Published by the Center for Metals Production - An EPRl Sponsored R&D Appllcatlons Center

Vacuum Induction Melting

Technology
A unique electrical methodfor production
of hiah aualitv and reliable alloys needed
in critical applications.
Vacuum induction melting (VIM)is the been so important to both.,militaryand
melting of metals by induction done
under a vacuum. This process first
commercial aviation(Figwe 1). The Advantages
success in theproductlon of superal-
The specific advantagesof vacuum
became important in the1950s; when loys byVIM for the gas turbine indus-
induction meltmg include:
heat resisting alloys or superalloys, try stimulated interestin VIM for the
which contam large amountsof reac- manufacture of other crltical applica-
tlve elements such as alumlnum or tion alloysfor use in nuclear reactors Elimination of gases under the . -
titanium, were found to have superior and electronics. Inaddition, the low very low pressures obtained,
service life and rellabllity when melted material lossesof this process made it torr or .000001 atmosphere, unde-
in a vacuum. As a result of VIM, the jet the economic melting technique for sirable gases and potentially harm-
englne made the great advance in some high-valuealloys which did not ful volatile elements are eliminated
performance and durability which has require superior cleanliness. from the charged raw materials as
melting occurs.
LOW PRESSURE
FAN COMPRESSOR H Close control of chemical analysis
- exceptlonal and reproducible
control of reactive element contain-
Ing compositionsis possible be-
cause of the lack of atmosphere.

Superior process control - inde-

pendent controlof pressure, tem-
perature and inductive stirring
provides an exceptionalopportu-
nity for developing melt practices
specifically tailoredto alloy compo-
sition and desired properties.

Slag free melting - melting in a

vacuum eliminates the need for a
protective slag coverand de-
creases the potentialof accidental
slag contamination or inclusionsin
the ingot.

IN'LET Melt protection - high vacuum

CASE
prevents deleterious contaminating
Figure 1 Vacuum melted titanium fan blades and superalloy turbne blades are essentral to the high reactions with atmospheric gases.
performance of modern jet engines. This Prattand Whitney PW 4000 is used to power some recent
models of the Boeing 747.

Process Description
Although the VIM process is rather
simple, the equipmentis quite sophisti-
cated when compared to other melting
installations. All components require
careful maintenance,testmg and Cali-
bration to assure optimum production.
A plan view schematic of a typical
commercial VIM facility is given in
Fiaure 2.
Heater
Samplecup 0 Mold
Chamber
Ceramics
Furnace Primary
and
Secondary
Tundishes
Molds -
rn
Furnace
I 1
Flgure 2 Vacuum mducf/on melbnglacrl,t/es requlres elecfrrury/of melfmg, vacuum pumpmg. rnPrt
gas genefar/on. and usuallymold preheafmg.
As shown, the furnace consistsof a
melt chamber, mold chamber, pump-
ing system, power supplyand a con-
trol station.
The melt chamber contains the refrac-
tory melt crucible surrounded by the
induction coil which supplies both
melting and stirring energy. Bulk
charging, containers for late additions,
charged while ingots cool at the end of
a cycle. An argon system is also at-
tached to the melt chamber to permit
any back-fill operations required or for
emergency conditions.
The pumping system design
considerably, depending upon the
furnace volume, typeof alloys to be
Control Statlon
Purnplng
System
melted, pumping speed deisred, and
the ultimate vacuum required ina typi-
cal system; mechanicalforepumps,
blowers, and vapor pumps are com-
bined in sequence to develop the de-
sired vacuum at reasonable speeds
withthelowest operating costs, Cham-
ber pressureduring a typical melt
cycle is shown in Figure 3.
¶
The power supply for most largefur-
naces IS a motor generator system
capable of dellvering about4.2 mega-
watts at 180 hertz.
The control statlon contains all valve
actuators, sensor instruments and
recorders for control of the process.
Melt observationis conducted directly
through shielded sights or by video
cameras and recorders.
The major power-consumingancil-
laries are furnaces forheating molds,
tundishes, other ceramlcs, and sample
cups. These furnaces can be heated
by oil, gas, or electricity. However,
electricity offers a dlstinct advantage In
freedom from chemical deposits. For
example, minute tracesof sulfur or
carbon deposited on sample takers
can give false chemlstry Indications.
Specific melt cyclesand related proce-
dures are considered proprietary by
alloy producers. However, the following
general process steps usually occur.
Step One.After raw materials are
charged, leak rates are takenperiodi-
cally during the pump down to assure
system Integrity. Melting poweris then
applied.
Step WO.Pressure usually is erratic
during the melt down, increasing and
decreasing as various materials melt.
At times it is necessary to partially
backfill the melt chamber with argon to
control boilingif it becomes too vigor-
ous. When the charge becomesall
molten the pumprng continues untilit is
 In the
order of to torr and a
nearly constant leak rateIS attained.
The constant leak rate lmpiles near
completion of deoxidation.
Step Three. Reactive alloy additions
are made at this point. A small pres-
sure rise IS always notlced as the reac-
tive elements outgasand melt.
Step Four. Samples are takenand
analyzed to assure the melt is within
specification.
Step Five. After chemlstry approval
the pour chamber is opened. A pri-
mary tundish is positioned to allow
metal to flow from the melt chamber
Into the mold chamber. The primary
tundish contains ceramic damsto
control metal flow and to hold back
pieces of furnace skullor ceramics that
may breakfree from the meltcrucible.
Metal flows through the primary nozzle
Into the secondary tundish whichcon-
tains additional flow control dams,
weirs, and pour nozzles and directs
the metal Into the series of molds in the
chamber. A slight pressure rise is ob-
served as the pouring system out-
gasses.
Step Six. Upon completion of the
pour, the tundishes are dralned and
repositioned in themold chamber. The
air lock is closedand the next cycle
can be started in the melt chamber.
When the metal is frozen, the mold
chamber vacuum is broken and the
chamber is opened. At this time the
filled molds are removed and the .
chamber is prepared for the next cy-
cle.
Related Technologies
Other premium melting processes
often used in conjunction with vacuum
induction melting include vacuum arc
remelting (VAR). Inthisprocessan . aseffectivewith somealloycomposi-estqualitymaterials.
ingot isselectively zone melted from
the bottom to top to remove impurities. melting is done by passing an electron
This is a common practice in both
superalloy and titanium production.
Electroslag remelting(ESR) is selective “dam” which traps heavyhigh density
L
Vacuum induction meltmg mainly is About 80% of all superalloys are used
used in the manufactureof superal- in aircraft and aerospaceapplcatlons.
loys. These are usually nickel, cobalt The next largest useis in power gener-
or iron-based alloys offeringhigh ation, 13%. The petrochemcal Indus-
strength at elevated temperatures. VIM try and miscellaneous applicatlons
is also used to melt specialcopper account for the remaining 7%.
base, uranium,and other unique ma- Total electric power consumption per
terials. Often it is combined with other unit of product is high for vacuum
processes inproducing premium high induction melting becauseof the small
performance parts. Figure4 shows the quantities produced and the energy
variety of process steps that can be required to produce a vacuum. While
followed after vacuum induction melt- no exact figures are available, knowl-
ing.
edgeable individualsestimate the con-
Superalloys comprlse the majorityof sumption rate istwice thatof normal
VIM production. About 60 to 100 mil- Induction meltingor about 1200 kwh
lion pounds are produced per year Der ton.
mainly dueto the demand for aircraft
engines.
I
I I
Vacuum
Induction
Melting
Production
Investment of Parts
Precision Forging Casting From Powder
r
WW””I”””]
I
I I I
Elecrroslas E!ec:ron Beam
Finlshmg
Flguro 4 Metals fhafare vacuum mduc:.cn me:!su are formed !nto parts byprecwon forgmg
mesfmen1 casrmg. or powder metallurgy : e c n n m e s
remelting similar to VAR but done us- Inclusion particles. Light low density
ing a slag father than under a vacuum. inclusions are vaporized. This tech-
While less expensive than VAR, it is not nique IS useful for obtaining the high-
tions. Electron beamcold hearth re-
beam in a vacuum over a charge to be
melted. The molten metal flows overa

The Electric Power Research
Institute (EPRI)conducts a tech-
nical research and development
program for the US. electric
utility industry. Through planning,
selection, funding,and manage-
ment of research projects carried
out by contracting organizations,
EPRl promotes the development
of new and improved technolo-
gies to help the utility industry
meet presentand future electric
energy needsin environmentally
and economically acceptable
ways. EPEl conducts research
on all aspects of electric power
production and use, including
fuels, generation, delivery, en-
ergy management and conser-
vation, environmentaleffects,
and energy analysis.
CMP-1087-008
01987 Center for Metals Production
TheCenter for Metals Production
(CMP) IS an R&D applcation center
sponsored by the Electrlc Power Re-
searchInstitute(EPRI) and adminis-
teredthroughMellon Institute of
Carnegle Mellon University. CMPS
goal IS to develop and transfer techni-
cal mformation that improves the pro-
ductlvlty and energy efficiency of
US. primary metals producing com-
panles (SIC 33). Areas of concentra-
tion are reductlonlsmelting;
reflntng/remelting;thermal & me-
chanical processing; and surface
condltloninglprotection.
EPRl
Robert Jeffress, Project Manager
CMP
Joseph E. Goodwill, Director
Richard M. Hurd, Chairman
Steelmaking Processes
James M. Hensler, Manager of
Technical Projects
John Kollar, Manager of
Communications
W. J. Boesch, Consultant
References:
“Vacuum Melting of Metals: State-of-
the-Art Assessment” EPRl ReportNO.
EM-4132,July 1985.
“Induction Melting of Metals: State-of-
the-Aft Assessment” EPRl Report No.
EM-4508, April 1936.
LEGAL NOTICE
This report was prepared and sponsored by the
Center tor Metals Productlon (CMP) Nelther
members of CMP nor any person actlng on
thelr behalf (1) makes any warranty expressed
or implled. wlth respectto the useof any
mtormatlon. apparatus. method. or process
disclosed In thls report or that such use may not
infringe privately owned rights; or(b) assumes
any habilltles wlth respectto the use of, or tor
damages resultlng from the use of. any Informa
tion, apparatus. method. or processdisclosed
In thls report
Center for Metals Production
Mellon Institute
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Pittsburgh, PA 15213
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