Model-based melt rate control during vacuum arc remelting of alloy 718

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Vacuum arc remelting (VAR) is used widely throughout the specialty metals industry to produce superalloy and titanium alloy cast ingots. Optimum VAR casting requires that the electrode melting rate be controlled at all times during the process. This is especially difficult when process conditions are such that the temperature distribution in the electrode has not achieved, or has been driven away from, steady state. This condition is encountered during the beginning and closing stages of the VAR process, and also during some process disturbances such as when the melt zone passes through a transverse crack. To address these transient melting situations, a new method of VAR melt rate control has been developed that incorporates an accurate, low-order melting model to continually estimate the temperature distribution in the electrode. This method of model-based control was tested at Carpenter Technology Corporation. In the first test, two 0.43-m-diameter alloy 718 electrodes were melted into 0.51-m-diameter ingots. Aggressive start-up and hot-top procedures were used to test the dynamic capabilities of the control technique. Additionally, a transverse cut was placed in each electrode with an abrasive saw to mimic an electrode crack. Accurate melt rate control was demonstrated throughout each melt. The second test used an electrode size and grade proprietary to the host company. Because it was not stress relieved after the primary casting process, the electrode was known to possess multiple cracks that make accurate melt rate control impossible using standard VAR controller technology. This electrode was also successfully melted with good melt rate control using the model-based controller.