Melting furnace with simultaneously rotatable and movable electrode rod

Abstract

Melting furnace (1), in particular for the production of metal alloys by melting alloying constituents, with a melting crucible (10), a cylindrical electrode rod (40) with a consumable electrode (41) attached thereto and a power supply (50) that is configured to supply the electrode (41) with power via the electrode rod (40), wherein the electrode rod (40) can be rotated about its own axis and moved along its own axis during the melting process.

Claims

1. A melting furnace (1), in particular for producing metal alloys and non-ferrous alloys, comprising: an electrode rod (40) with a consumable electrode (41) attached thereto, the consumable electrode comprising alloying constituents to be remelted; a melting crucible (10); and a power supply (50) that is configured to supply the consumable electrode (41) with power via the electrode rod (40), wherein the electrode rod (40) is rotatable about a longitudinal axis and can be moved along the longitudinal axis during a melting process and wherein a remelted ingot comprising the alloying constituents is formed in the melting crucible during the melting process, and wherein the melting furnace (1) is configured to simultaneously rotate the electrode rod (40) about the longitudinal axis and oscillate the electrode rod (40) along the longitudinal axis during the melting process.

2. The melting furnace (1) according to claim 1, wherein the electrode rod (40) is attached via an electrode receptacle (31) to an electrode carriage (30), and wherein the electrode carriage (30) is held on and movably guided by a furnace column (62).

3. The melting furnace (1) according to claim 2, wherein the electrode carriage (30) is movable by means of a spindle drive (33), wherein the spindle drive (33) is fixed to the electrode carriage (30) and has one or more motor-driven spindle nuts that interact with a spindle (61) that runs substantially parallel to the furnace column (62).

4. The melting furnace (1) according to claim 2, further comprising a motorized rotary drive (32) for rotating the electrode rod (40) about the longitudinal axis, the rotary drive (32) being mounted on the electrode receptacle (31).

5. The melting furnace (1) according to claim 1, wherein the electrode rod (40) is electrically connected to the power supply (50) via a current collector (42), and wherein the current collector (42) has one or more contacting devices (43), which are configured to transfer the current provided by the power supply (50) to the electrode rod (40).

6. The melting furnace (1) according to claim 5, wherein the one or more contacting devices include a receptacle (43a) that is electrically connected to the electrode rod (40) and contains a conductive liquid (43b) in which a current output that is electrically connected to the power supply (50) is immersed; and/or one or more brushes (43d) which are in frictional contact with the electrode rod (40); and/or a shell element (43f) which is in frictional contact with the electrode rod (40).

7. The melting furnace (1) according to claim 5, wherein the conductive liquid (43b) is liquid gallium.

8. The melting furnace (1) according to claim 5, wherein the one or more contacting devices include one or more brushes (43d) which are in frictional contact with the electrode rod (40) and wherein the one or more brushes (43d) are made of a graphite-containing and/or copper-containing material.

9. The melting furnace (1) according to claim 5, wherein the one or more contacting devices include a shell element (43f) which is in frictional contact with the electrode rod (40) and wherein the shell element (43f) is made of a graphite-containing and/or copper-containing material.

10. The melting furnace (1) according to claim 1, further comprising a movable furnace hood (20), which is configured to close the melting crucible (10), wherein the electrode rod (40) and/or the consumable electrode (41) is immersed in the melting crucible (10) through a bushing (21) in the furnace hood (20).

11. The melting furnace (1) according to claim 10, wherein the bushing (21) is vacuum-tight and gas-tight.

12. A melting furnace (1), for producing metal alloys and non-ferrous alloys by melting alloying constituents, comprising: a furnace column (62); a melting crucible (10); a furnace hood (20) which is configured to close the melting crucible (10), the furnace hood (20) being held on movably guided by the furnace column (62); an electrode carriage (30) held on and movably guided by the furnace column (62); an electrode receptacle (31) attached to the electrode carriage (30); an electrode rod (40) with a consumable electrode (41) attached to the electrode receptacle (31); and a power supply (50) that is configured to supply the consumable electrode (41) with power via the electrode rod (40), wherein the electrode rod (40) is rotatable about a longitudinal axis and can be moved along the longitudinal axis during a melting process, and wherein the consumable electrode (41) is immersed in the melting crucible (10) through a bushing (21) in the furnace hood (20), and wherein the furnace hood (20) is attached to the electrode carriage (30) by a hydraulic cylinder (23), the hydraulic cylinder (23) being configured to adjust a relative distance between the furnace hood (20) and the electrode carriage (30).

13. The melting furnace (1) according to claim 12, wherein the melting crucible (10) is attached via a furnace platform (11) to a platform carriage (12), the platform carriage (12) being held on and movably guided by the furnace column (62).

14. The melting furnace (1) according to claim 13, wherein the platform carriage (12) is movable by a platform spindle drive (14), wherein the platform spindle drive (14) is fixed to the platform carriage (12) and has one or more motor-driven spindle nuts that interact with a platform spindle (15) that runs substantially parallel to the furnace column (62).

15. The melting furnace (1) according to claim 13, further comprising at least one weighing cell which is installed on the platform carriage (12).

16. The melting furnace (1) according to claim 12, further comprising one or more weighing cells for weighing a weight of the consumable electrode (41) and/or the melting crucible (10).

17. The melting furnace (1) according to claim 16, wherein at least one of the one or more weighing cells is installed below a base plate of the melting crucible (10).

18. The melting furnace (1) according to claim 16, wherein at least one of the one or more weighing cells is installed on the electrode carriage (30).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows a melting furnace with a melting crucible and a rotatable and movable electrode rod.

(2) FIGS. 2a to 2c show exemplary embodiments of contacting devices for the current-conducting connection of the rotatable and movable electrode rod with a power supply.

(3) FIGS. 3a and 3b show shapes of the electrode tip and the metal sump located below it.

DETAILED DESCRIPTION

(4) In the following, preferred exemplary embodiments are described on the basis of the figures. Thereby, identical, similar or equally effective elements in the figures are marked with identical reference signs, and a repeated description of such elements is sometimes omitted in order to avoid redundancies.

(5) FIG. 1 shows a melting furnace 1, which is used to produce metal alloys by electrically remelting an electrode, possibly under vacuum. For example, the melting furnace 1 is designed as: electroslag remelting unit (ESR) with a stationary and/or sliding melting crucible; pressure electroslag remelting unit (PESR) with a stationary and/or sliding melting crucible; electroslag rapid remelting unit (ESRR) with a stationary and/or sliding melting crucible for the continuous production of electroslag-casted or electroslag remelted billets; vacuum arc remelting furnace (VAR); combination unit consisting of the aforementioned designs, in particular for an ESR unit with a stationary and/or sliding melting crucible along with an electron beam furnace (EB).

(6) The melting furnace 1 has a melting crucible 10, which is preferably lined with cold or refractory materials. The melting crucible 10 is a hollow cylindrical vessel that is closed at the bottom and is designed for melting alloying constituents, additives, etc. The melting furnace 1 also has a furnace hood 20, which is configured to close the melting crucible 10. Preferably, the furnace hood 20 is compatible for different melting crucible dimensions. In addition, the furnace hood 20 preferably has a cooling system, such as a water cooling system.

(7) Above the furnace hood 20, a height-adjustable electrode carriage 30 is provided for holding, pivoting, rotating and moving an electrode rod 40. For this purpose, the electrode carriage 30 has an electrode receptacle 31, which rotatably supports the electrode rod 40. The electrode carriage 30 can also have a rotary drive 32 for rotating or turning the electrode rod 40 about its axis. The rotary drive 32 can, for example, be attached to the electrode receptacle 31 or integrated with it, such that a height adjustment of the electrode carriage 30 together with the electrode rod 40 is ensured, while the electrode rod 40 rotates at the same time.

(8) The electrode rod 40 carries or holds a consumable electrode 41, also known as a “consumable electrode.”

(9) With the furnace hood 20 on, and the electrode carriage 30 and electrode rod 40 in the mounted state, the electrode rod 40 and/or electrode 41 is immersed in the melting crucible 10 through a vacuum-tight and gas-tight bushing 21 in the furnace hood 20. The melting energy inside the melting crucible 10 is generated, for example, by an arc burning between the tip of electrode 41 and the surface of the molten pool S (also designated as a “sump” or “metal sump”). In order to maintain a stable arc, the distance between the electrode tip and the surface of the molten pool S must be kept constant within a defined range.

(10) To apply a melting current to electrode 41, it is connected via power supply lines 51 to a power supply 50, which is preferably a high-current supply. The power supply lines 51 can be implemented by busbars 52 connected to flexible power strips or power cables 53, by flexible power cables 53 alone, or in some other manner, in order to ensure a reliable power supply, despite the adjustability of the electrode carriage 30. The power supply lines 51 are connected to contacting devices 43 of a current collector 42. The current collector 42 is part of the electrode rod 40 or is connected to it, in order to transfer the current provided by the power supply 50 via the contacting devices 43 to the rotatable and movable electrode rod 40. Thereby, the current collector 42 can be structured to be compatible with different formats of the electrode rods 40. The current collector 42 can have bushings to accommodate the power supply lines 51 and/or to protect against damage and dirt. The current collector 42, via which the current is transferred to the electrode rod 40, is preferably water-cooled or air-cooled.

(11) In accordance with the embodiment of FIG. 1, a coupling 44 is provided between the electrode rod 40 and a stub 45, by which a circuit for supplying the electrode 41 and a support of the electrode 41 will be set up, such that an arc can be ignited in the melting crucible 10 between the electrode 41 and the melt, or melt energy can be introduced into the melt, and this can be kept constant over the entire melting time under vacuum, inert gas or atmosphere with the height-adjustable electrode carriage 30.

(12) With units operated under vacuum, such as VAR or EB furnaces, the melting energy is generated by the arc burning between the tip of the electrode 41 and the surface of the molten pool S in the melting crucible 10. In order to maintain a stable arc, the distance between the electrode tip and the surface of the molten pool S must be kept constant. This is done by means of a control not shown, which can be computer-supported and algorithmic, for example. With units operating under inert gas or atmosphere, such as ESR or inert gas ESR units, the melting energy is converted into Joule heat by converting the electrical energy with the resistance of the slag.

(13) For the repositioning, adjustment and oscillation of the electrode rod 30, the furnace 1 has the aforementioned height-adjustable electrode carriage 30 for holding the electrode rod 40. Thereby, the electrode rod 30 can be moved along the axial direction of the electrode rod 40, that is, in the up/down direction in accordance with FIG. 1. The electrode rod 40 is preferably repositioned in an oscillating manner according to the electrode consumption. The oscillation of the electrode 41 keeps the electrode tip in the slag bath constantly within a defined range; in particular, the distance between the electrode tip in the slag bath and the surface of the same is kept constant. The movability is preferably realized by a spindle drive 33, which is part of the electrode carriage 30 or is rigidly connected to it. The spindle drive 33 interacts with a spindle 61 of a frame 60, which carries components of the melting furnace 1, in particular the electrode carriage 30, the furnace hood 20 and the melting crucible 10. For example, the spindle drive 33 can have one or more motor-driven spindle nuts that engage in a thread of spindle 61, in order to adjust the height of the electrode carriage 30 by turning the spindle nuts.

(14) The contacting devices 43 can be structured in different ways and can also consist of different conductive and non-conductive materials, as long as a safe contact with the rotatable electrode rod 40 is ensured. For example, FIG. 2a shows a receptacle 43a in which liquid gallium 43b is introduced. A current output 43c, which is connected to the power supply 50 via the power supply lines 51, is also immersed in the liquid gallium. Other current-conducting liquids can also be used as liquid current transfer medium. FIG. 2b shows an additional example of a current transmission structure using brushes 43d, for example those made of a material containing graphite and/or copper (such as graphite, hard graphite, carbon, carbon fiber, copper, copper alloy, etc.), which, connected to a receptacle 43e, are in frictional contact with the electrode rod 40. FIG. 2c shows an additional structure that uses a shell element 43f instead of the brushes 43d, which is held in a receptacle 43g and is in frictional contact with the electrode rod 40. The shell element 43f can be made in one piece or in several parts; for example, it can be made of a material containing graphite. Furthermore, the shell element 43f can be pressed against the electrode rod 40 by means of elastic elements, such as springs, in order to ensure secure contact.

(15) In addition to being rotatable about its own axis and movable vertically along its own axis (corresponding to the axis of the furnace column 62 described below), the electrode rod 40 can also be mounted so that it can move along or about other axes, in order to improve adjustability and thus stability during melting. Furthermore, the current collector 42 can be configured to be adjustable, in order to fit the electrode rod 40. For this purpose, the current collector 42 can have one or more media connections that are supplied and controlled by corresponding control points.

(16) In order to simplify the power supply via the current collector 42, the interaction between it and the electrode rod 40 can be modularized. For example, the contacting devices 43 can be attached to the current collector 42 by means of fixing devices and can engage in or be accommodated in corresponding fixing receptacles on the electrode rod 40, as shown in the examples of the embodiments in FIGS. 2a to 2c. In this manner, the current collector 42 can be reliably connected to electrode 41 as a consumer. The electrode rod 40 can be divided by the aforementioned coupling 44 (or the electrode 41 can be connected to the electrode rod 40 via the coupling 44), in order to make it easier to change the electrode 41, in particular to replace a used electrode 41 with a new electrode 41. The coupling can be operated hydraulically or pneumatically.

(17) The frame 60 can have a furnace column 62, on which the electrode carriage 30 and/or the furnace hood 20 are guided and held. In addition, additional components, such as the spindle drive 33, can be guided and held on the furnace column 62, in order to achieve a modular structure of the melting furnace 1. Thus, in accordance with the present embodiment, the melting crucible 10 is guided and held by a furnace platform 11 and a platform carriage 12, also on the furnace column 62. While the furnace platform 11 is fixed with a stationary melting crucible unit, in accordance with the embodiment shown in FIG. 1 (sliding melting crucible unit), the melting crucible 10 is height-adjustable in this manner. For this purpose, the furnace platform 11 can be attached to the furnace column 62 in a movable manner via a guide 13 and/or the platform carriage 12. The movability can be realized by a platform spindle drive 14, which interacts with a platform spindle 15. For example, the platform spindle drive 14 can have one or more motor-driven spindle nuts, which engage in a thread of the platform spindle 15, in order to adjust the height of the melting crucible 10 by turning the spindle nuts. Thus, the melting crucible 10 can be lowered and/or raised according to the filling rate of the melting crucible 10 and/or the electrode melting rate. In addition to movability along the axis of the furnace column 62, the melting crucible 10 can also be mounted so that it can be moved along other axes, in order to improve adjustability and thus stability during melting. For example, the adjustment along axes that are perpendicular to the axis of the furnace column 62 can be realized by means that are integrated below the base plate of the melting crucible 10, for example in the furnace platform 11.

(18) The vacuum-tight bushing 21 of the furnace hood 20 ensures the vertical movement of the electrode rod 40 through the center of the furnace hood 20, which, in accordance with the present embodiment, is attached and guided to the furnace column 62 by a hood carriage 22. The height adjustment can also be carried out by means of a spindle drive, or also, as shown in FIG. 1, for example, by means of one or more hydraulic cylinders 23, which are attached on one side to the hood carriage 22 and on the other side to the electrode carriage 40, and are configured to set a relative distance between them.

(19) The rotatable and vertically movable electrode rod 40 makes it possible to change the front surface of the electrode 41 from a conventional V-shape, see FIG. 3a, to a flat U-shape, see FIG. 3b. Thus, the shape of the metal sump S located under electrode 41 is preferably also changed from the V-shape to a flat U-shape.

(20) Preferably, the furnace 1 has one or more weighing cells (16, 17), which are measuring cells for weighing the weight of the electrode 41 and/or the (re)melted ingot or molten pool S in the melting crucible 10. Preferably the weighing cells (16, 17) are installed below the base plate of the melting crucible 10 and/or on the electrode carriage 30 and/or on the platform carriage 12, particularly preferably below the melting crucible 10. In this manner, the measuring accuracy can be improved for a melting furnace 1 with a rotating electrode.

(21) To the extent applicable, all individual features shown in the exemplary embodiments can be combined and/or exchanged without leaving the field of the invention.

LIST OF REFERENCE SIGNS

(22) 1 Melting furnace

(23) 10 Melting crucible

(24) 11 Furnace platform

(25) 12 Platform carriage

(26) 13 Guide

(27) 14 Platform spindle drive

(28) 15 Platform spindle

(29) 16 Weighing cells installed on the platform carriage below a base plate of the melting crucible

(30) 17 Weighing cells installed on the electrode carriage

(31) 20 Furnace hood

(32) 21 Bushing

(33) 22 Hood carriage

(34) 23 Hydraulic cylinder

(35) 30 Electrode carriage

(36) 31 Electrode receptacle

(37) 32 Rotary drive

(38) 33 Spindle drive

(39) 40 Electrode rod

(40) 41 Electrode

(41) 42 Current collector

(42) 43 Contacting device

(43) 43a Receptacle

(44) 43b Liquid gallium

(45) 43c Current output

(46) 43d Brush

(47) 43e Receptacle

(48) 43f Shell element

(49) 43g Receptacle

(50) 44 Coupling

(51) 45 Stub

(52) 50 Power supply

(53) 51 Power

(54) 52 Busbar

(55) 53 Current strip

(56) 60 Frame

(57) 61 Spindle

(58) 62 Furnace column

(59) S Metal sump/molten pool