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Vacuum Induction Melting :: Total Materia Article
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Vacuum melting, casting and re-melting equipment have been implemented in huge numbers over te recent years mainly with an intention to try and eradicate impurities from te process wherever possible.
Vacuum induction melting (VIM) has some specific advantages including, gas elimination, chemical composition control, process control and more.
In recent years te world of metallurgy has seen a massive growth in installations of new melting, re-melting and casting equipment under vacuum. This development is driven by various factors, but mainly by te increasing demand from te aerospace and power turbine industries, which pursue te simple philosophy: “Impurities that are not generated do not have to be removed.”
This means, especially for materials which are used in rotating parts under high thermal stress, that cleanliness is very important and influences te lifetime of such parts. For example, low cycle fatigue (LCF) properties of turbine disks can be directly related to both non-metallic inclusion content and inclusion size of te material. In aircraft and land based gas turbines, most parts and components (eg, turbine blades and vanes, turbine disks, cases, shafts, bolts and combustors) that undergo high thermal stress during operation, are made of superalloys with different amounts of alloying elements.
Most of these alloying elements have a high affinity for oxygen, nitrogen and hydrogen, therefore, during melting of such alloys under air, formation of oxides and/or nitrides will occur. These oxides have a dramatic influence on mechanical properties of te materials. To minimize or avoid te formation of inclusions, it is therefore necessary to protect te melt from contact with air.
Vaccum Induction Melting (VIM) is te melting of metals by induction done under a vacuum. This process first became important in te1950s; As a result of VIM, te jet engine made te great advance in performance and durability which has been so important to both military and commercial aviation.
Te specific advantages of vacuum induction melting include:
Elimination of gases - under te very low pressures obtained, .000001 atmosphere, undesirable gases and potentially harmful volatile elements are eliminated from te charged raw materials as melting occurs
Close control of chemical analysis - exceptional and reproducible control of reactive element containing compositions is possible because of te lack of atmosphere
Superior process control – independent control of pressure, temperature and inductive stirring provides an exceptional opportunity for developing melt practices specifically tailored to alloy composition and desired properties
Slag free melting - melting in a vacuum eliminates te need for a protective slag cover and decreases te potential of accidental slag contamination or inclusions in te ingot
Melt protection - high vacuum prevents deleterious contaminating reactions with atmospheric gases
What is Vacuum Induction Melting Used For?
Some applications of vacuum induction melting are:
Refining of high purity metal and alloys
Master alloy stick for processes such as investment casting
Casting of aircraft engine components
Figure 1: Processing routes for superalloys and high quality steels
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