The MRI of Remelting Furnace Systems
Driven by Arc Position Sensing Technology
We invented the patented award-winning Arc Position Sensing (APS) technology at the US Department of Energy’s National Energy Technology Laboratory with the goal to improve vacuum arc remelting (VAR) and electro-slag remelting (ESR) processes.
Until now, there has been no way to “see” the electric arcs during melting or quantify the relationship between arc location and defects. APS solves this problem by tracking the positions of arcs in real time during the melting process, providing two distinct advantages over previous technology:
- Advanced furnace process: APS provides the feedback necessary to improve process control leading to defect reduction, increased yield, lower costs, and greater reliability.
- Improved safety: APS automatically identifies undesirable operating conditions such as side-arcing, or can issue a warning and take measures automatically to avoid these deleterious conditions.
VARmetric – Arc Position Sensing Applied
APS serves as the driver of our VARmetric measurement suite. APS gives VARmetric the capability to locate electric arcs beneath the electrode in a VAR furnace. VARmetric systems are customized to each furnace to provide the information you need to improve safety and quality, and reduce costs.
VARmetric couples APS with standard process signals to evaluate process dynamics and correlate this data with product quality measures. It allows you to monitor arc location during melting in real time, and identify deleterious operating conditions quickly to avoid known conditions that could lead to defect formation.
ObserVAR and AnalyVAR
ObserVAR and AnalyVAR software tools are integral parts of the VARmetric system. Together, they visualize and interpret results. ObserVAR provides real-time information and event detection during melts. AnalyVAR processes the data, generates reports on arc distributions during melts, and indicates the quality of the melt.
ObserVAR features real-time APS and ingot height calculation, anomalous event detection, side-arc detection, improved safety features, vertical and overhead arc distributions, and the option to integrate automatic feedback into your furnace.
AnalyVAR features variable APS melt scans displaying the vertical and overhead arc distributions, ingot height calculation, automatic report generation, and defect probability calculations through advanced solidification modeling.