Induction melting coil power is supplied by an advanced Inductotherm VIP Power system with power and frequency proportional to high melting speed (high efficiency) and optimal agitation (metallurgical quality) in the molten state. The stirring frequency ensures that the alloy is completely homogeneous and fresh molten metal is circulated towards the surface of the molten bath to aid in the degassing process.
The Indian company Konsark has developed a new generation of induction melting furnaces that perform ferrous and non-ferrous metal melting processes under vacuum. The company has more than 40 years of experience in the design of induction melting furnaces in vacuum (VIM) and Inducto therm company is a leader in the manufacture of induction melting furnaces and power supply technology.
Due to this new product and the technology and experience of these two large companies, they are cooperating with each other in their specific fields, which results in the introduction of flexible melting systems for melting metals in the air, controlled atmosphere called (VCAP) Vacuum Cap. The VCAP furnace is designed for induction melting and solid charging in the air (or vacuum) atmosphere and in the final stage of vacuum degassing.
In the final stage, the solid metal is poured under air or under a protective atmosphere of neutral gas. The shape of this system is based on the Inductotherm range of induction furnaces with steel bodies, which Consarc has adapted perfectly for operation on molten metal in vacuum.
The furnace body is completely insulated for vacuum operation and is insulated with a cover / flange on top of it. After an air-melting operation (or vacuum / neutral gas if necessary), a water-cooled vacuum cap can be placed on the furnace, which is done by a factory crane or a special forklift with an oscillating (optional) axial arm.
The cap is connected to a multi-stage mechanical vacuum pumping system that can drain the atmosphere above the molten bath.
The induction furnace winding power is supplied through an advanced system of Inductotherm company with power and oscillation commensurate with high melting speed (high efficiency) and optimal agitation (metallurgical quality) in the molten state.
The agitator oscillates so that the alloy is completely homogeneous and the fresh molten metal moves to the surface of the molten bath to accelerate the degassing process.
When the air is evacuated, the degassing process and the intense C-O reaction allow the release of undesirable gases such as hydrogen, nitrogen and oxygen to a much lower than desired level in the air.
At the end of the degassing chain, the vacuum valve can be removed and the protective ring insulated around the flange instead. The furnace is then ready to be emptied into the molds. Evacuation process usually in air (option for protective atmosphere)
Applications and materials
VCAP furnaces can be used for a variety of smelting operations from 80 kg to 20 tonnes (other weights must be requested). Typical applications are as follows:
Low and high carbon steels
Stainless steels
Nickel-plated alloys
Cobalt alloys
Non-ferrous alloys
Metallurgical considerations
Some sample processes that can be performed in the VCAP furnace work area include solid charge melting in air (optional for vacuum melting).
Melting in a controlled atmosphere of solid charge
Homogenization of the alloy and chemical modification
Vacuum degassing (container of hydrogen and nitrogen)
Reduce low vapor pressure of harmful elements such as lead, cadmium, beryllium and zinc
Deoxidation using a combination of vacuum and O-C reaction
Decarbonization – The intense C-O reaction at low pressures allows for excellent decarbonization for extremely high and low carbon surfaces.
De-sulfurization
Purification of argon from metal with porous cap
The most important advantages of VCAP oven are as follows:
In general, significant improvement of mechanical properties such as yield strength – strength with resistance to hammering, fatigue and failure due to availability, properties at high temperatures
– Improvements in technological specifications such as hot efficiency, welding capability and machining capability
Better micro-cleanliness due to strong carbon reducing properties and less residual contents
Extremely reduced dispersion in product properties and characteristics, less waste
Standard units are completed as follows:
Induction furnace and hydraulic system of vacuum body
Water-cooled vacuum valve
Wright ports
Immersed thermocouple
Vacuum pumping system
Water-cooled Mayfold
Control system
Selected accessories can be installed as follows:
Neutral gas purification (argon) porous cap
Automatic vacuum valve replacement
Optical petrometer
Vacuum isolation sampling and soft charging
Platforms
Charging scrap and raw materials
High voltage power supply transformer
SCADA supervision