Vacuum consumable electrode arc furnaces are widely used in the metallurgical industry for melting high-purity alloys, especially titanium alloys, reactive metals, and refractory metals. These furnaces operate under vacuum conditions to ensure minimal contamination during the melting process. Unlike non-consumable electrode furnaces, the consumable type uses an electrode that is gradually consumed during the process. This method allows for the production of large ingots with excellent purity, making it a preferred choice for specialized applications.
The system typically includes a furnace body, power supply, vacuum system, control electronics, cooling system, and optical monitoring components. The furnace itself consists of a shell, electrodes, electrode rods, and lifting mechanisms. Power is usually supplied through a DC generator or modern rectifier systems, with a low voltage (around 20-28V) requiring a step-down transformer before the rectification process.
One of the main advantages of this technology is its ability to produce highly pure materials by allowing impurities to rise to the surface and be removed. Additionally, the high vacuum environment helps decompose oxides and nitrides, which are then pumped out, resulting in a cleaner final product. The controlled solidification from bottom to top minimizes element segregation and avoids shrinkage, leading to a more uniform microstructure and improved mechanical properties in the final alloy.
However, controlling the exact composition of the alloy can be challenging due to the nature of the melting process. Despite this limitation, the vacuum consumable electrode arc furnace remains a crucial tool in advanced metallurgy.
Vacuum arc furnaces, specifically the shell type, are commonly used in the industrial smelting of copper and its alloys. These furnaces feature a spherical shape and rely on the molten material itself to form a solidified shell, hence the name "solidification furnace." The charge is added to a water-cooled crucible, where the metal is melted and poured into a mold. The structure of such a furnace is illustrated in Figure 4-8.
Flame reverberatory furnaces, once widely used for melting aluminum and copper alloys, have largely been replaced by more efficient technologies. These furnaces traditionally used coke, coal gas, or fuel oil as energy sources. However, due to environmental concerns and technological advancements, they have been gradually substituted by oxygen-fuel, gas-fired, or oil-fired systems. The reverberatory furnace for melting aluminum is often paired with a static furnace to allow for proper alloying and refining processes.
For copper smelting, reverberatory furnaces are still used, particularly for processing scrap materials like electrolytic copper and wire. Oxidation-reduction operations can enhance the purity of the final product. However, the harsh operating conditions require high-quality refractory materials to withstand the intense heat and prevent leakage.
Combustion boiler vortex furnaces are ideal for small-batch, multi-material smelting of non-ferrous alloys. These furnaces have evolved significantly, with traditional fuel types being replaced by more efficient and environmentally friendly alternatives. They come in various forms, including fixed, tilting, and holding types, each designed for specific applications in light alloy production.
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