The arc melting method is an electrothermal metallurgical process that utilizes electric energy to generate an electric arc between electrodes or between an electrode and the material to be melted.
This method is characterized by its ability to achieve extremely high temperatures, typically up to 3000℃, which is sufficient to melt a variety of metals, including reactive and refractory ones.
1. Principle and Operation
The arc melting process begins with the conversion of a high voltage into a low voltage but high current by a transformer, typically using 220V or 380V input.
The instantaneous short circuit of the positive and negative poles triggers the arc, which is a self-sustaining discharge phenomenon that maintains stable combustion without the need for continuous high voltage.
This arc, with temperatures reaching nearly 5000K, is used to melt the metal electrode or material.
2. Types of Arc Melting
2.1 Vacuum Arc Remelting (VAR)
This method is conducted under slag-free and vacuum conditions.
The metal electrode is rapidly melted by the DC arc and then re-solidified in a water-cooled copper mold.
This process refines the metal, purifying it and improving its crystal structure and performance.
2.2 Plasma Arc Melting
This technique uses electrically excited gas, such as helium or argon, to melt metals in a sealed chamber under an inert atmosphere.
It is particularly effective for reactive and refractory metals and offers significant improvements in the properties of conventional alloys.
2.3 Non-self-consuming Vacuum Arc Melting
This method uses a water-cooled copper electrode instead of a consumable one, which helps in industrial pollution control.
It is widely used for melting titanium and titanium alloys, eliminating the need for pressing and welding electrodes.
3. Applications and Advantages
Arc melting is used in various metallurgical processes, including hearth melting, scrap consolidation, and the production of ingots, slabs, and powders.
The advantages of arc melting include the ability to melt high melting point metals, the production of clean, as-cast metal by removing inclusions, and the potential for recycling materials.
Additionally, the non-self-consuming method allows for longer arc dwell times on the material, leading to better homogenization of the ingot composition and the use of raw materials of different sizes and shapes.
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