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Krane, Matthew; Kharicha, Abdellay; and Ward, Mark (Ed.)Magnetic measurements coupled with traditional VAR process measurements have enabled the characterization of the spatial distribution of electrical current through the furnace; a process variable that today’s VAR furnaces do not measure. This work presents data acquired by VARmetric, a high density magnetic sensor array, on an industrial VAR furnace processing Fe and Ni- based alloys. VARmetric is used to identify events which would go undetected through traditional process signal analysis, and importantly, can be used to distinguish between distinct arc modes, e.g. diffuse arcs, constricted arcs, and glows. This information facilitates a new method to assess the quality of an ingot in terms of the probability of segregation defects along the ingot axis.more » « less
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King, Paul E.; Cibula, Matthew; Motley, Joshua (, The minerals metals materials series)Peng, Zhiwei; Hwang, Jiann-Yang; Downey, Jerome P.; Gregurek, Dean; Zhao, Baojin; Yucel, Onuralp; Keskinkilic, Ender; Jiang, Tao; Mahmoud, Morsi Mohamed (Ed.)Ampere Scientific has previously developed and provided industrial validation of the VARmetricTM measurement system to measure the location of electric arcs during vacuum arc remelting (VAR) of high temperature specialty alloys. With the advent of VARmetricTM, it is nowpossible to continuously monitor and control arc distributions in order to tailor the heat flux that drives solidification during the VAR process. Laboratory experiments have applied transverse magnetic fields to generate specified Lorentz forces as a control mechanism across the arc gap in order to drive arc locations to predetermined distributions. This type of control makes it possible to react to undesirable arc conditions during VAR operations or to provide a continuous control to specify a thermal profile for heat input to the melt pool necessary for ensuring defect-free ingots.more » « less
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