text: The alloy to undergo VAR is formed into a cylinder typically by vacuum induction melting (VIM) or ladle refining (airmelt).  This cylinder, referred to as an electrode is then put into a large cylindrical enclosed crucible and brought to a metallurgical vacuum ().  At the bottom of the crucible is a small amount of the alloy to be remelted, which the top electrode is brought close to prior to starting the melt.  Several kiloamperes of DC current are used to start an arc between the two pieces, thus a continuous melt is derived.  The crucible (typically made of copper) is surrounded by a water jacket to cool the melt and control the solidification rate.  To prevent arcing between the electrode and the crucible walls, the diameter of the crucible is larger than the electrode.  As a result, the electrode must be lowered as the melt consumes it.  Control of the current, cooling water, and electrode gap is essential to effective control of the process and production of defect-free material.
  Ideally, the melt rate stays constant throughout the process cycle, but monitoring and control of the vacuum arc remelting process is not simple.  This is because there is a complex heat transfer occurring involving conduction, radiation, convection within the liquid metal, and advection caused by the Lorentz force.  Ensuring the consistency of the melt process in terms of pool geometry, and melt rate is crucial in ensuring the best possible properties of the alloy.