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Te Pressure Electroslag Remelting Process (PESR) :: Total Materia Article
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Te Pressure Electroslag Remelting Process (PESR)
Te pressure electroslag remelting process is a recent advancement and allows for te manufacture of new high nitrogen alloys with unique properties under pressures of several atmospheres.
Much higher levels of nitrogen can be achieved due to te pressure applied above te slag which can be increased significantly above normal atmospheric pressure levels.
Te ESR is te metallurgic process for te production of steel with high purity and a controlled solidified and respectively faultless structure. It is well known as a refining method used mainly in te steel and superalloy industry. Te main goal of this process is te inclusion, removal, desulphurization and te adjustment of a uniform microstructure. Te fundamentals of this process are described elsewhere and are not further outlined in this paper.
Many alloys contain elements like aluminum and titanium which, when heated, react with oxygen to form oxides. Oxides are detrimental to premium quality melted alloys. Premium grade alloys, such as those required by te aerospace, energy, medical and automotive industries, can be protected from te atmosphere and residuals by melting inside a vacuum container. This approach gives te metals producer more control over alloy chemistry. Te result is a cleaner, more uniform product with te superior properties required for critical service applications.
On te other hand, te investments in state-of-the-art technology such as Pressure Electro Slag Remelting (PESR), Vacuum Induction Melting (VIM) and Vacuum Arc Remelting (VAR) are te result of research showing a real need for a new generation of steels.
Electroslag Remelting (ESR) is a secondary refining process used to further refine many alloys. As a feedstock it uses consumable electrodes produced either by VIM or conventional air melting. Conventional ESR improves te microstructure and cleanliness of te VIM, or arc melted alloy, by removing inclusions as te metal passes through te slag and controlling te solidification rate in te refined metal ingot to minimize chemical segregation. Melting through te slag permits very close compositional control.
A more recent advancement is Pressurized ESR (P-ESR) furnaces, which have te ability to melt alloys under nitrogen pressures of several atmospheres and produce very high nitrogen steel compositions that cannot be achieved via standard air melting techniques. This capability allows te manufacture of new and novel high-nitrogen alloys with unique mechanical properties.
Pressure ESR (P-ESR) is an even more advanced process than standard ESR. With pressure ESR te metal is melted under elevated nitrogen pressure, permitting te production of alloys with high levels of nitrogen. For P-ESR, te standard ESR crucible is enclosed and becomes a pressure vessel melt chamber. With this design, te pressure above te slag can be increased to levels that are significantly above normal atmospheric pressure levels, enabling much higher levels of nitrogen to be achieved. Te P-ESR furnace can also melt at atmospheric pressure, in an air atmosphere or with an inert gas cover of argon over te slag. Having an inert gas cover over te slag enables enhanced compositional control of reactive elements, such as aluminum and titanium, during melting. Te high-nitrogen compositions from te P-ESR process cannot be achieved through either conventional ESR or VAR melting techniques.
Figure 1: Schematic design of a pressure electro slag remelting furnace (PESR)
Today’s biggest PESR unit is located at Energietechnik Essen GmbH, Germany. Its operating pressure is max. 40 bars and can achieve ingot weights up to 20 tons and 1030 mm diameter. Te functional principle is shown schematically in Figure 2. Basically, te PESR process is a conventional remelting facility that works in a pressure tank. Te process is designed to meet both, an ESR refining and nitrogen pick up. Te metallurgical approach is similar to a standard ESR-process, i.e. refining, low segregation, no porosity or shrinkage, defined microstructure and solidification.
Figure 2: View of te industrialized PESR –process at Energietechnik Essen GmbH for ingot weight up to 20 t and ∅1030 mm
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