BÖHLER Production Technologies

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BÖHLER remelting technologies

Superior grade special steel demand is increasing rapidly from the automotive, aircraft, offshore energy and medical industries, in fact from all of those industries where better isotropic values of hardness, cleanliness and corrosion resistance etc. are required.  The “Melt” is the secret to achieve these enhanced properties.  Our investments in state-of-the-art technology such as Pressure Electro Slag Remelting (PESR), Vacuum Induction Melting (VIM) and Vacuum Arc Remelting (VAR) are the result of research showing a real need for these new generation steels.  We are literally filling vacuums to meet customer needs.

Steel and alloys with special technological properties are put to use in particularly demanding settings. These applications frequently require the highest degree of micro-purity and structural homogeneity from high-performance materials; factors that can only be guaranteed by selected special melting processes.

At the Böhler Edelstahl plant in Kapfenberg the following melting and casting facilities are available for the manufacture and production of such materials:





BÖHLER is the only company in the world to have installed all melting and remelting processes in one plant.

Legend

EAF   :Electro Arc Furnace

VIM   :Vacuum Induction Melting Furnace

VAR   :Vacuum Arc Furnace

ESR   :Electroslag Remelting

PESR:Pressure/Protective-Gas Electroslag Remelting



Vacuum Arc Furnace Remelting (VAR)

Features
• Remelting of consumable electrodes under vacuum, operating pressure 10-3 mbar (from 1st melting)
• Two melting stations offset by 90°
• Microprocessor-controlled melting rate
Advantages
• Minimum gas contents
• Reduction of trace elements such as Pb, Bi, Te
• Absence of ingot segregations
• Minimum microsegregations in the ingot centre
• Low susceptibility to the formation of freckles (segregations)
• Minimum levels of nonmetallic inclusions
• Optimum polishability
• Excellent material properties (virtually isotropic properties, especially with regards to toughness)
• Highly precise chemical analysis ty
Examples of steel grades
• Hot work tool steels e.g. W400 VMR®, W403 VMR®
• Plastic mould steels e.g. M268 VMR®, M330 VMR®
• Stainless CrNi and Cr steels
• Nonferrous metal alloys
Examples of application
• Die casting dies under severe cyclical thermal stresses
• Plastics moulds requiring very high polishing finish
• Severely stressed components for the aviation and aerospace industries, die casting tools ...
• Medical engineering, vehicle construction ...
• Mirror finished strips for the production of technical foils

Böhler Edelstahl plant in Kapfenberg has 6 VAR plants, capacity approx. 10,000 t/year.



Pressure/Protective-Gas Electroslag Remelting (PESR)

Features
• Remelting of consumable electrodes under protective gas (Ar, N2) or pressure up to 16 bar (from 1st melting)
• Two melting stations offset by 90°
• Microprocessor-controlled melting rate
Advantages
• No hydrogen pick up
• Nitrogen alloying up to approx. 0.8%
• Absence of ingot segregations
• Only minor crystal segregations
• Minimum sulphur contents
• Minimum levels of nonmetallic inclusions
• Optimum polishability
• Excellent material properties (virtually isotropic properties, especially with regards to toughness)
• Lowmelting loss of elements with high oxygen affinity
Examples of steel grades
• Plastic mould steels e.g. M303 ISOPLAST®, M333 ISOPLAST®, M340 ISOPLAST®
• Stainless Cr steels e.g. N360 ISOEXTRA®
Examples of application
• Plastics moulds requiring very high polishing finish and wear resistance

Böhler Edelstahl plant in Kapfenberg has 4 PESR plants, capacity approx. 9,000 t/year.



Electroslag Remelting (ESR)

Features
• Remelting of consumable electrodes (from 1st melting)
• Microprocessor-controlled melting rate
• Flexible ingot weights
Advantages
• Absence of ingot segregations
• Only minor crystal segregations
• Minimum sulphur contents
• Minimum levels of nonmetallic inclusions
• Optimum polishability
• Excellent material properties (virtually isotropic properties, especially with regards to toughness)
Examples of steel grades
• Creep resistant steels
• Hot work tool steels e.g. W302 ISOBLOC®, W303 ISOBLOC®, W360 ISOBLOC®
• Plastic mould steels e.g. M303 ISOPLAST®, M310 ISOPLAST®
• Cold work tool steels e.g. K340 ISODUR®, K360 ISODUR®
• High speed steels e.g. S600 ISORAPID®
• Stainless CrNi and Cr steels e.g. N690 ISOEXTRA®, N700 ISOEXTRA®
• Constructional steels
• Nonferrous metal alloys
Examples of application
• Die-casting dies for Al alloys, Cu alloys etc.
• Plastics moulds requiring very high polishing finish
• Cold forming and punching tools requiring very good toughness and wear resistance
• Turbines, thermal engines ...
• Processing of heavy metal alloys
• Surgical instruments ...
• Components for operating temperature from –75° C up to +500° C
• Cutting tools, compact stamping tools
• Screw taps, reamers ...
• Compressors, valves, turbine discs ...

Böhler Edelstahl plant in Kapfenberg has 4 ESR plants, capacity approx. 12,000 t/year.



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