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Recycling machined superalloy scrap, such as turnings and borings, is a highly desirable goal, yet it presents significant challenges for conventional remelting techniques. The scrap’s high volume-to-weight ratio complicates handling and melting, particularly within vacuum melting processes. Furthermore, remelting in electric arc or induction furnaces can result in substantial burnout or oxidation losses, potentially accounting for up to 20% of the valuable alloying elements. The fine nature of the scrap, often combined with surface oxidation, results in low density and poor electrical conductivity, thereby reducing the efficiency of induction melting. Additionally, the conventional method of consumable-electrode ESR is often impractical because of the difficulty of compacting loose scrap into an electrode of satisfactory quality.
To overcome these limitations, a feasibility study was undertaken employing Electro Slag Remelting (ESR) technology but utilizing a specially designed non-consumable, water-cooled electrode instead of the traditional consumable type.
The success of this approach hinges on the electrode design, which underwent significant development and optimization. The basic structure comprised two concentric mild-steel pipes, with the lower tip section of the outer pipe fabricated from copper, specifically machined from a solid rod to eliminate welds in the high-temperature zone. Water cooling, which was necessary to keep the electrode from melting, came in through the inner pipe and went out through the space between the pipes. This cooling system was designed for operation at 5000A and 200 kW, with a water flow rate of 12 m³/h, calculated to minimize temperature rise and prevent vapor formation by achieving a target velocity of 3 m/s.
Several operational challenges necessitated specific design solutions. Conventional ‘solid start’ procedures, which involved an arc to melt the initial slag, were found to cause electrode erosion and melt contamination. The adopted solution was to use a ‘liquid start’ technique, in which pre-melted slag was poured into the mould. However, during this liquid start, the cold electrode surface formed an insulating slag shell immediately, hindering process initiation. To counteract this issue, three Molybdenum (Mo) tips were attached to the electrode bottom; their refractory nature and lower thermal conductivity facilitated penetration of the initial chill layer and sustained current flow, although the tips themselves experienced some erosion during operation. Another issue was the erosion of the electrode’s exposed copper surface, resulting in melt contamination. This was resolved by reducing the copper wall thickness from an initial 30mm to 20mm. This reduction improved cooling efficiency, allowing a stable, protective slag skin (less than 2mm thick) to form on the copper surface during operation, thereby preventing further erosion and reducing copper pick-up in the melt to below 0.05 wt%.
A systematic experimental procedure was implemented to test the process. Machined scrap, compositionally similar to Nimonic 80A, was cleaned, magnetically separated, and preheated at 300°C for 4 hours to remove contaminants and improve its flow characteristics. The slag used consisted of 70% CaF₂ and 30% Al₂O₃, with an addition of 6-8% TiO₂; it was preheated to 850°C for 2 hours before approximately 6 kg was melted for the liquid start. The ESR operation was conducted in a 350 kVA AC ESR furnace equipped with a 150-mm diameter water-cooled mould. The 90 mm outer diameter non-consumable electrode was positioned, the molten slag was poured, and then the prepared scrap was fed into the mould through the annular gap between the electrode and the mould wall.
Based on process stability and the resulting ingot surface finish, the process parameters were set at about 44V, 3.5kA, 150-160kW, and a scrap feed rate of about 1.0 kg/min (see Table 1 in the source text). It was noted that keeping a small amount of unmelted scrap above the slag bath resulted in the best, smoothest feeding. A hot topping procedure, involving gradual power reduction, was applied at the end of the melt. Subsequent post-ESR analysis included assessing ingot soundness via radiography and examining the macrostructure after etching. Chemical analysis was performed on both the starting scrap (using AAS/ICP) and the final ingot (using XRF/LECO). The ingots were then subjected to thermomechanical processing, including soaking at 1150°C for 1 hour, forging to a 3:1 reduction ratio, and a standard heat treatment cycle (solution treatment at 1080°C for 3 hours with water quenching, then aging at 700°C for 4 hours with air cooling). Microstructure was examined using optical microscopy and EPMA on both as-cast and forged/heat-treated samples. Finally, mechanical properties were evaluated by tensile testing of the forged and heat-treated material using an MTS machine, with subsequent fractography performed by SEM.
The study of Satyaprasad et al. (1996) yielded predominantly positive results. Under optimized conditions, sound ingots with excellent surface finish were consistently produced, whereas non-optimal parameters led to surface defects and slag entrapment. The ingots exhibited a columnar macrostructure free from major casting defects. Chemically, a slight loss of aluminum and a corresponding pick-up of titanium were observed, attributed to slag-metal reactions influenced by the slag’s TiO₂ content; however, the final compositions remained within the alloy’s specifications. Importantly, impurity levels of sulfur and phosphorus were found to be very low in the remelted ingot.
Microstructurally, the as-cast ingots displayed a dendritic structure, which transformed into a recrystallized grain structure after forging and heat treatment. The presence of TiC and TiN precipitates, typical of this class of superalloys, was confirmed under both conditions. Mechanically, the tensile properties of the forged and heat-treated ESR material proved comparable to the minimum specifications established for the conventional wrought alloy. Examination of the tensile fracture surfaces revealed extensive dimpling, characteristic of a ductile fracture mode.
Recycling superalloy scrap using ESR with a non-consumable water-cooled electrode is technically feasible and can be successfully implemented. Success depends on careful electrode design, which includes effective water cooling, molybdenum tips to start the process, and an optimized copper wall thickness to encourage the formation of a protective slag skin. It also depends on careful process control, which includes using a liquid start and optimizing operating parameters.
The process demonstrated its ability to yield a final product whose chemical composition and mechanical properties are comparable to those of conventionally produced material. Consequently, this method has the potential to be highly cost-effective by upgrading low-value scrap into a high-value product. Furthermore, the process shows promise for scaling up to produce larger diameter ingots and for application to a diverse range of superalloy scrap types.