SRIF has conducted profound research in the principal theories and application of ESRC technology. Enormous work has been done on temperature distribution simulation and perfection of advanced casting process for shaped castings for power stations. We have successfully produced shaped castings of variable camber with ESRC technology developed by SRIF, and won the second prize of National Scientific and Technological Progress Award in 2007.
Our ESRC production base, covering 3200m2, is equipped with four ESRC furnaces with the capacity of 700KVA, 2000 KVA, 3000 KVA, and 8000 KVA respectively, by which individual castings of 0.1-80t can be produced and an annual production capacity of 4000 tons can be reached. Over the years, we have supplied over 10,000 tons of premium ESRC castings to dozens of large and medium hydraulic power stations at home and abroad, including Three Gorges. Our products are exported to USA, Japan, France, Canada, Brazil, Russia, Austria, Vietnam, Turkey, etc.
Advantages of ESRC
1.Progressive solidification and self padding: the density of final products is much higher than that of sand mold castings.
2.Slag refining: the sulfur content and other impurities are reduced and the toughness, fatigue resistance and welding ability is higher than those of sand mold castings.
3.The result of ultrasonic tests proves to meet the requirement of CCH70-3 and the highest level of ASTM A609, 1-2 levels higher than the result of sand mold castings.
4.Cavitation resistance is increased by 30% compared with sand mold castings.
5.Metal mold casting process creates less environmental pollution.
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| ESRC workshop 8000KVA ESRC furnace | |
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ESRC process | control room for ESRC furnace |
Working principle of ESRC
The ESRC process completes electro-slag remelting, refining and casting at the same time, so the castings produced by ESRC boast not only good inner quality, but also good material properties.
At the beginning of the ESRC process, a pool of molten slag with the depth of 100-200mm is formed at the bottom of a crucible. When the consumable electrode connected to a power source is submerged into the molten slag, strong electric current passes through the slag pool, producing heat to increase the temperature of slag. When the temperature of slag exceeds the melting point of the consumable electrode, the electrode melts to form steel droplets on the surface which then fall through the slag pool due to gravity. In this process, the harmful elements and the impurities in the consumable electrode are lowered. The molten steel forms a metal pool under the slag pool. Cooled by circulating water, the molten steel gradually solidifies and eventually forms a casting. In the ESRC process, the melting of the consumable electrode, the refining of molten steel, the filling of the crucible and the solidification continuously proceed in turn until the crucible is fully filled and a casting thus made from bottom to top.
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