ElectroSlag Remelting (ESR) Furnaces

Electroslag Remelting furnaces from Consarc unlock unparalleled purity and microstructure in critical metals for aerospace, power generation, medical, and oil & gas industries. Our revolutionary ESR design, paired with modern automation, ensures superior efficiency and consistent ingot quality.

Product Details

Overview

Electroslag Remelting (ESR) is a secondary refining process used for purifying and enhancing metal ingot microstructures. A molten slag bath is heated by electric current, through which the electrode, made in the primary melt Electric Arc Furnace (EAF) plus Argon Oxygen Decarburization (AOD) or Vacuum Induction Melt (VIM), material gradually melts and refines. This unique approach delivers unparalleled benefits for critical applications in:

Aerospace: Turbine blades, landing gear, bearings
Power generation: Gas turbine components, nuclear reactor parts
Medical: Prosthetic implants, surgical tools
Defense: High-strength armor, weapons systems
Oil and Gas: Equipment exposed to harsh environments

In the 1960s, Consarc revolutionized electroslag remelting with a groundbreaking design: high fill ratio electrodes paired with coaxial power conductors. This innovative approach not only boosted efficiency and ingot quality, but also minimized power consumption and stray heating. Today, this core principle remains the cornerstone of every Consarc ESR furnace, now paired with modern fully automated, computer-controlled systems that ensure precise, repeatable performance.

Features

Consarc ESRs feature current furnace designs to reduce magnetic stirring within the solidifying ingot, and X-Y electrode positioning to center the electrode and improve ingot quality.

Inert Gas Melting System (IGMs)
Canterlever design ESR furnace enabling minimized footprint providing additional space for maintenance or additional furnaces in a given furnace hall
Highly robust power supply custom designed and built by Consarc specifically for the arduous VAR process with closed loop deionized cooling system
Fully coaxial
Precision electrode drive
Fully automated melt control
X-Y electrode centering
Precise load cells
Capable of producing round, round-cornered square, or slab ingots

Purpose-Designed AC Power Supplies

Consarc is the only ESR furnace supplier that designs and builds our own power supplies. These units are specifically designed to meet the demanding requirements of the ESR melting application. This provides Consarc ESR customers with a single source responsibility for the complete ESR and power transmission system. Consarc have developed low frequency cycloconverter and 3-phase low frequency inverter power supply options for larger ESR applications.

Tech Specs

Description	20” (500 mm)	26” (650 mm)	30” (760 mm)	36” (900 mm)	40” (1000 mm)	44” (1100 mm)	48” (1200 mm)
Maximum Ingot Weight	9,000 lbs (4,000 kg)	13,000 lbs (6,000 kg)	22,000 lbs (10,000 kg)	33,000 lbs (15,000 kg)	44,000 lbs (20,000 kg)	66,000 lbs (30,000 kg)	77,000 lbs (35,000 kg)
Maximum Crucible Diameter	20” (508 mm)	26” (650 mm)	30” (760 mm)	36” (914 mm)	40” (1016 mm)	44” (1117 mm)	48” (1219 mm)
Baseplate Dimension	32.5” (825 mm)	40” (1016 mm)	40” (1016 mm)	48” (1219 mm)	54” (1372 mm)	54” (1372 mm)	58” (1473 mm)
Power Supply Rating	15,000 amps	20,000 amps	25,000 amps	30,000 amps	35,000 amps	40,000 amps	40,000 amps

Accessories

Dry or Liquid Slag Start Capable

Most ESR furnaces today are started “cold” with dry pre-fused slag. Consarc can also provide a slag melting furnace with the ESR system that gives “hot” (liquid) slag start capability. This is most useful in situations where humidity and moisture are concerns, as well as in locations where sourcing of pre-fused slag is problematic.

Inert Gas Melting System

Today many Oxygen and Nitrogen sensitive alloys are melted under an inert gas atmosphere. The major benefits of the Inert Gas Melting System are:

Improved control of Oxygen and Nitrogen levels in the final ingot compared to melting in air or dry air
Fully-enclosed system preventing the possibility of contamination from the melt shop during melting
Different slags can be used because the oxidation of the slag is no longer a concern
Minimal to no deoxidant is required – deoxidant can be a principal source of inclusions in ESR ingots
Alloys requiring higher nitrogen levels can be remelted in an inert gas atmosphere that includes a higher percentage of nitrogen, reducing the outgassing of that element from the alloy
Capable of operating in 100% argon or argon-nitrogen mixed atmosphere
Vacuum pre-evacuation prior to melting can be optioned to reduce inert gas consumption

Product Images

Interested in this product? Connect with an Inductotherm Group company in your region to learn more.

Consarc Corp.

100 Indel Avenue P.O. Box 156
Rancocas, NJ 08073-0156 USA

609-267-8000 | sales@consarc.com

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Inductotherm Group Brasil

R. Herminio de Mello, 526, Indaiatuba/SP
CEP 13347-330

+55-19-3885-6800 | contato@inductothermgroup.com.br

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Inductotherm Group Australia

62 Bardia Avenue, Seaford. Victoria 3198
Australia

+61-3-9786-6000 | furnaces@inductotherm.com.au

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Inductotherm Group China

Inductotherm Industries (Shanghai) Ltd.
50 Guoshoujing Road, Zhangjiang High-tech Park, Pudong, Shanghai
+86-021-3895-3220 I sales@inductotherm.com.cn

Inductotherm Group China Ltd.
92 Ximei Road, Xinwu District, Wuxi, Jiangsu

+86-510-8523-1010 | sales@inductotherm.com.cn

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Inductotherm Group Japan

1-3-10 Mibemibefu,
Nishi-Ku, Kobe 651-2116 Japan

+81-78-974-2552 | info@inductothermgroup.jp

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Consarc Engineering

9 Woodside, Eurocentral, Holytown
North Lanarkshire, ML1 4XL Scotland UK

+44-1698-730430 | sales@consarceng.com

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Inductotherm Group France

LE SARIA. 14 Avenue de SARIA, 77700 Serris, France

+33-1-6417-9919 | sav@inductothermie.fr

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Inductotherm Group India

INDUCTOTHERM (INDIA) PVT. LTD.
Plot No. SM-6&7, Road No.11 Sanand-II, Industrial Estate, BOL Village, Sanand Ahmedabad- 382170
Toll free: 1 800 419 2900
Sales: +9193745 78586
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