Alloy Ingots manufacturing by VIM

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Vaccum Induction Mellting and Casting Furnace

Equipment: Vacuum Induction melting (VIM)

Make: Consarc- Inductotherm
Capacity: 50 Kg

Vacuum Induction melting (VIM) uses the principle of electromagnetic induction under vacuum for melting of metals.

Scope:

  • Manufacturers of super alloys, precious metals, special alloys for the electronics and Aerospace industry
  • Precision casting with controlled melting and state of art refining process.
Melting services Melting services 2
PML Alloys Matrix

Process

  • Before starting the melting process, a VIM furnace is charged with precharged raw material either in the normal atmosphere or under vacuum.
  • The charged material is then melted under vacuum.
  • Charging of trace elements for alloy adjustment is also possible without breaking the vacuum.
  • Online temperature measurement, Spectro and oxygen meter allows controlled melting and refining process till the desired composition specs of ingots are met.
  • The melt is poured in predesigned metallic mould with sophisticated automatic tilting mechanism under vacuum only.

Alloywise chemical composition and mechanical properties

Chemical composition (Typical) for Nickel & Cobalt base alloys in %
Alloy Ni Fe C S Mn Si Cu Cr Co Mo Al Ti Nb Others
Nickel 200 99.5 0.2 0.08 0.005 0.018 0.18 0.13 - - - - - - -
Nickel 201 99.5 0.2 0.01 0.005 0.018 0.18 0.13 - - - - - - -
Nickel 205 99.5 0.01 0.08 0.004 0.018 0.08 0.08 - - - - 0.03 - 0.05
Monel 400 64 2.5 max 0.02 max 0.02 max 1 0.05 max 32 - - - - - - -
Monel 500 63 2 max 0.02 max 0.01 max 1.5 max 0.5 30 - - - 2.9 0.6 - -
Inconel 600 72 8 0.15 max - 1 max - - 15.5 - - - - 3.7 -
Inconel 625 60.3 5 - - - - - 22 - 9 - - 3.7 -
Inconel 713 71.3 2.5 max - - 0.25 max 0.2 - 13 - 4.5 5.5 0.5 2.5 -
Inconel 718 52.5 19 - - - - - 19 - 3.1 0.5 0.9 5.1 -
18Ni300 18.5 66.7 - - - - - - 9 5 0.1 0.7 - -
Nimonic 80A 75.9 - - - - - - 19.5 1 - 1.4 2.3 - -
Hastelloy 276 58.5 6 0.01 - 1 0.08 - 15 - 16 - - - -
NIFE50 47.5 52.5 - - - 0.1 max - - - - - - - -
Ni80Fe20 79.5 16 - - 0.2 max 0.2 max - - - 4.5 - - - -
Fe49Co49V2 - 49 - - - - - - 49 - - - - V2
Mechanical properties for Nickel & Cobalt base alloys
Nickel alloy UTS 21 Deg cen(MPa) UTS 540 Deg cen(MPa) UTS 760 Deg cen(MPa) UTS 21 Deg cen(MPa) UTS 540 Deg cen(MPa) UTS 760 Deg cen(MPa) Tensile elongation at 21 Deg Cen% Tensile elongation at 540 Deg Cen% Tensile elongation at 760 Deg Cen% Remarks
Nickel 200 462 - - 148 - - 47 - - Chemical & Electronic industry
Nickel 201 403 - - 103 - - 50 - - Chemical & Electronic industry
Nickel 205 345 - - 90 - - 45 - - Chemical & Electronic industry
Monel 400 545 - - 207 - - 48 - - Corrosion resistant alloy
Monel 500 669 - - 338 - - 44 - - Corrosion resistant alloy
Inconel 600 660 560 260 285 220 180 45 41 70 Super alloys
Inconel 625 965 910 550 490 415 415 50 50 45 Super alloys
Inconel 713 758 - - 689 - - 3 - - Super alloys
Inconel 718 1435 1275 950 1185 1065 740 21 18 25 Super alloys
18Ni300 1034 - - 758 - - 18 - - Maraging steel
Nimonic 80A 1000 875 600 620 530 505 39 37 17 Super alloys
Hastelloy 276 750 - - 310 - - 30 - - Super alloys
NI50FE50 500 - - 250 - - 40 - - Soft magnetic alloy
Ni80Fe20 650 - - 280 - - 35 - - Soft Magnetic alloy
Fe49Co49V2 600 - - 400 - - 5.5 - 49 Soft Magnetic alloy

Process capability

Input : Batch size Output Alloying Elements Chemistry tolerance Impurities Max
30 kgs to 50 Kgs Ingot of required size and shape. Fe, Ni, Co, Cr, Mn, Cu , Al, Mo, Nb, Ti, V, Si +/- 0.5 % for Higher level % (Above 2 digit) and +/- 0.3 % for lower level % (Single digit) Oxygen < 30 ppm, Hydrogen < 10 ppm,
Nitrogen < 30ppm,
All other impurities < 30 ppm 
including carbon

Benefits

  • It is possible to melt and cast ingots / bars of required size and composition.
  • Ensures highest quality on a reproducible basis.
  • Possible to restrict gas impurities to the lowest negligible levels. Non ferrous impurities (Sn, Zn, Pb, Sb) evaporates completely in vacuum at high temperatures.
  • State of art process reduces non metallic oxide inclusions in the final alloy.
  • Ready to use ingots for further processing like powder manufacturing for MIM, Strip manufacturing by hot and cold rolling, forging etc.
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