The process - Plasma Metall

A one step thing

The special procedure
of Plasma Metal

A closer look: The steps of our process explained.

What exactly makes our process so unique? We would like to explain this in more detail at this point. In the Plasma Metall process, we rely on the SinglePAM melting process. The innovation in this process is that the chemical quality of a triple-melted ingot can be ensured in just one melting operation, which makes the manufacturing process significantly accelerated. In addition, this process allows the first-time use of recycled material in primary melting. This leads to a cost reduction compared to established processes. Possible materials range from titanium aluminides to alloys based on Molybdenum, Nobium, Nickel, Iron or Cobalt. You can learn more details about each step of the process by clicking through our process below.

Experienced.

With Plasma Metall you gain a reliable and experienced partner for your projects in the field of high temperature alloys.

Individual.

Our process not only allows you a high degree of individuality in the material requirements, but also offers a highly innovative approach.

Personal.

When supporting our customers and partners, we rely on individual agreements and personal contact persons.

Step 1: The material selection & dosage

For exact raw material dosing, we work with an EDP-supported weighing and mixing station. The raw materials consist of a basic element, such as titanium sponge, and elementary metals and/or master alloys for refractory metals. This process step forms the elementary basis for the final alloy, as it is where the essential chemical composition of the end product is set.

Precise dosing by means of an EDP-supported weighing and mixing station
Basis for the chemical composition of the final product

Step 2: Compression

In the process step of compressing - also called briquetting - the melting electrodes are prepared. For this purpose, the base element of the alloy together with the other alloying constituents of the material selection are cold isostatically compressed into briquettes (compacts) in a press.

Preparation of the melting electrodes
Compression of the starting material into briquettes/compacts

Step 3: The preparation of the melting process

The SinglePAM melting process is the innovative heart of our process. The melting process of Plasma Metall has a single-stage structure, unlike other processes in Europe. For the first time, our plant technology allows direct melting of the raw materials with simultaneous casting of the primary ingot. But let's start from the beginning: The melting process - which takes place completely under an inert gas atmosphere - begins with the transport of the pressed briquettes into the water-cooled cold wall crucible for melting. In this crucible, the briquettes are completely melted by the plasma torch, which is supplied with an energy of 350-600 kWh.

Innovative single-stage melting process (SinglePAM melting process)
Melting capacity of up to 600 kWh

Step 4: The melting

The ignited plasma flame is guided over the entire surface of the melt pool according to predefined movement patterns until the briquettes are completely melted. While the melt pool is forming, additional briquettes are added with the ingot conveyor to completely fill the melting crucible. After complete melting of the briquettes, the homogenization phase follows. The innovative arrangement of an induction coil underneath the crucible enables the molten bath to be stirred without contact. After a certain dwell time, continuous casting takes place by tipping the melt into a water-cooled copper mold. The development of the continuous casting mold is a completely new approach to ingot casting. The mold is an extended continuous casting mold with an additional induction coil. This innovative design gives our process the possibility of directly controlling the solidification process in the head area of the ingot by means of the induced energy and minimizing possible casting solidification defects.

Homogenization of the liquid melt to reduce segregation
New type of bar casting to minimize casting solidification defects

Step 5: The analysis

Following the melting process, an analysis of the melted material is carried out. To ensure quality, the chemical analysis is carried out by means of a spark OES process. This method also offers significant cost potentials for the analysis compared to conventional methods (ICP-OES, XRF).

Analysis by spark OES method
Significant cost potentials compared to conventional processes

Expert insight

Closing the material loop.

"Thanks to the single-stage melting process, we enable direct remelting of raw materials into semi-finished products in the Plasma Metall process. Maximum homogenization and optimization of the semi-finished products is achieved by the parallel use of two different melting technologies (PAM, KIT). Thus, only a small proportion of the raw material is lost in the process and the waste material can be reused after further processing."

Phillip Albers – Sales