Advanced Copper Solutions for Remelting Technologies

Abstract

The transformation of the steel industry toward more sustainable and efficient production routes requires continuous innovation in remelting technologies such as Vacuum Arc Remelting (VAR) and Electroslag Remelting (ESR). High-performance copper components are essential in this context, as they directly influence process stability, product quality, and resource efficiency. This contribution presents advanced copper solutions for remelting applications, focusing on crucibles, power rams, and alternative melting furnace concepts utilizing slab moulds or short collar moulds. A central aspect is the comparison between forged, one-piece crucibles and longitudinally seam-welded designs. Forged crucibles, manufactured without welding seams, exhibit a homogeneous microstructure and uniform material properties over the entire circumference. This results in significantly increased lifetime, reduced distortion during operation, and enhanced process reliability. In addition, tighter manufacturing tolerances can be achieved, contributing to improved dimensional accuracy and reproducibility. Material innovations further support these advancements. CuCrZr alloys, such as ELBRODUR® G, provide superior mechanical strength and elevated temperature resistance compared to conventional CuDHP copper. Their higher softening and recrystallization temperatures enable stable operation under demanding thermal conditions, reducing wear and extending service intervals. Complementary developments include Cu-HCP power rams with high thermal and electrical conductivity, ensuring efficient energy transfer in VAR and ESR processes. For alternative furnace concepts, advanced slab moulds with reinforced steel frames offer improved structural stability and enhanced re-machining capability compared to tube-type designs. In addition, short collar moulds are analyzed, comparing deep-drilled and slotted configurations in terms of cooling efficiency and operational performance. Overall, these innovations contribute to reduced downtime, optimized resource utilization, and improved energy efficiency, supporting the transition toward more sustainable and competitive steel production.