ALD Vacuum Technologies GmbH

ALD Vacuum Technologies GmbH
Otto-von-Guericke-Platz 1 • 63457 Hanau • Germany
Tel:
Fax:
+49 . 6181 . 307 - 0
+49 . 6181 . 307 - 3290
Invitation to ALD’s 7th VIM/ESR/VAR-Workshop, September 21st – 24th 2016
ALD Vacuum Technologies GmbH cordially invites you to our 7th VIM/ESR/VAR Workshop and
Conference September 21-24, 2016.
We are very pleased to host our workshop this time at the new ALD Vacuum Technologies GmbH
headquarter, with technology centre and production site, including a VIP tour of the Isabellenhuette
Heusler, an ALD VIDP-customer at Dillenburg combined with a visit of Dillenburg’s historical site.
Our conference will focus on the practical operational aspects most interesting to ALD’s customers and
suppliers of VIM, ESR and VAR furnaces and supporting technologies. The agenda is for one full day of
interesting papers followed by a tour of the Isabellenhuette Heusler in Dillenburg on the second day. We
encourage our attendees to share their experiences and hold intensive conversations in a pleasant and
convenient setting.
ALD continues our tradition of hosting our conference for our worldwide customers in distinctive locations.
We are proud to have the opportunity to open our new headquarter, technology centre and production site to
our customers.
Our workshop this year will feature the historic castle hill of Dillenburg, its Casemates, the Wilhelmstower
and Villa Gruen, dated back to the year 1130.
Please note: There will be no charge for the workshop and conference.
If you would like to participate in the workshop, please reply at your earliest convenience by filling in
and returning back the registration form and ALD will make your hotel arrangements.
With best regards,
Ulrich Biebricher
Vice President Melting and Remelting Systems
ALD Vacuum Technologies GmbH
Andreas Eich
Product Manager Melting Systems
ALD Vacuum Technologies GmbH
ALD Vacuum Technologies GmbH, Otto-von-Guericke-Platz 1, 63457 Hanau, Germany | Phone: +49.6181.307-0 | Facs: +49.6181.307-3290
Member of the AMG Advanced Metallurgical Group N.V., Amsterdam, The Netherlands
Board of Directors: Dr. Markus Holz (Chairman), Michael Protzmann
Company Register HRB-Nr. 92377; VAT: DE258853629
Bank Accounts: UniCredit Bank AG (BLZ 795 200 70), Konto 366 829 849, IBAN DE56 7952 0070 0366 8298 49, Swift HYVE DE MM 407
HSBC Trinkaus & Burkhardt AG (BLZ 300 308 80), Konto 060 0224 018, IBAN DE10 3003 0880 0600 2240 18, Swift TUBD DE DD
ALD Vacuum Technologies GmbH
Otto-von-Guericke-Platz 1 • 63457 Hanau • Germany
Tel:
Fax:
+49 . 6181 . 307 - 0
+49 . 6181 . 307 - 3290
ALD Vacuum Technologies GmbH, Hanau
7th VIM/ESR/VAR Workshop, September 21st – 24th 2016
Travel Information, ALD Contact Persons and Registration Form
If you have questions, please do not hesitate to contact:
Ms. Karola Scheuer
Mr. Ulrich Biebricher
Mr. Andreas Eich
Phone: +49 (0) 6181 / 307-3110
Phone: +49 (0) 6181 / 307-3297
Phone: +49 (0) 6181 / 307-3078
e-mail: [email protected]
e-mail: [email protected]
e-mail: [email protected]
Nearby airport: Frankfurt am Main – approx. 45 minute drive (40 km)
For your convenience you can call taxi Gültekin. They offer special rates for
ALD-airport pick up.
Taxi Gültekin: +49 1716908958
A rental car is not necessary since all transfers during the workshop will be provided by ALD
Vacuum Technologies GmbH.
ALD, Ms. Karola Scheuer can assist you with these arrangements.
ALD Vacuum Technologies GmbH, Otto-von-Guericke-Platz 1, 63457 Hanau, Germany | Phone: +49.6181.307-0 | Facs: +49.6181.307-3290
Member of the AMG Advanced Metallurgical Group N.V., Amsterdam, The Netherlands
Board of Directors: Dr. Markus Holz (Chairman), Michael Protzmann
Company Register HRB-Nr. 92377; VAT: DE258853629
Bank Accounts: UniCredit Bank AG (BLZ 795 200 70), Konto 366 829 849, IBAN DE56 7952 0070 0366 8298 49, Swift HYVE DE MM 407
HSBC Trinkaus & Burkhardt AG (BLZ 300 308 80), Konto 060 0224 018, IBAN DE10 3003 0880 0600 2240 18, Swift TUBD DE DD
ALD Vacuum Technologies GmbH
Otto-von-Guericke-Platz 1 • 63457 Hanau • Germany
Tel:
Fax:
+49 . 6181 . 307 - 0
+49 . 6181 . 307 - 3290
BEST WESTERN PREMIER
Hotel Villa Stokkum
Steinheimer Vorstadt 70
63456 Hanau-Steinheim
http://www.villastokkum.de/
ALD Vacuum Technologies GmbH has reserved a
contingent of rooms for conference attendees at a
preferred rate through
118.00 $ incl. breakfast buffet/night
With your binding registration you will be signed in for
one of these rooms.
Extended stays – before and after the workshop,
September 19 - 21 and 24 – 25 will be charged by Best
Western at the preferred rate above.
Cancellation policy:
84 – 42 days before arrival: 30 % of total amount
41 – 28 days before arrival: 60 % of total amount
27 – 00 days before arrival: 90 % of total amount
Isabellenhütte Heusler GmbH & Co. KG
Eibacher Weg 3-5
35683 Dillenburg
http://www.isabellenhuette.de
Dillenburger Museumsverein e.V.
Schlossberg 3
35683 Dillenburg
www.dillenburger-museumsverein.de
REGISTRATION DEADLINE: AUGUST 31, 2016
Return completed form to:
Ms. Karola Scheuer
Phone: +49 6181 3073110
Fax:
+49 6181 307383110
E-Mail: [email protected]
ALD Vacuum Technologies GmbH, Otto-von-Guericke-Platz 1, 63457 Hanau, Germany | Phone: +49.6181.307-0 | Facs: +49.6181.307-3290
Member of the AMG Advanced Metallurgical Group N.V., Amsterdam, The Netherlands
Board of Directors: Dr. Markus Holz (Chairman), Michael Protzmann
Company Register HRB-Nr. 92377; VAT: DE258853629
Bank Accounts: UniCredit Bank AG (BLZ 795 200 70), Konto 366 829 849, IBAN DE56 7952 0070 0366 8298 49, Swift HYVE DE MM 407
HSBC Trinkaus & Burkhardt AG (BLZ 300 308 80), Konto 060 0224 018, IBAN DE10 3003 0880 0600 2240 18, Swift TUBD DE DD
ALD Vacuum Technologies GmbH
Otto-von-Guericke-Platz 1 • 63457 Hanau • Germany
Tel:
Fax:
+49 . 6181 . 307 - 0
+49 . 6181 . 307 - 3290
ALD Vacuum Technologies GmbH, Hanau
7th VIM/ESR/VAR Workshop, September 21st – 24th 2016
Programme
Wednesday, September 21st, 2016
06:00 – 09:00 pm
Arrival at Best Western Hotel, Villa
Stokkum, Hanau
Registration and Welcome Reception
on Patio
Thursday, September 22nd, 2016
07:30 – 08:30 am
08:30 am
09:00 – 09:25 am
09:25 – 9:50 am
09:50 – 10:15 am
10:15 – 10:40 am
10:40 – 11:05 am
11:05 – 11:30 am
11:30 – 11:55 am
11:55 – 01:00 pm
01:00 – 02:30 pm
02:30 – 02:50 pm
Best Western Villa Stokkum
Transfer to ALD Vacuum
Technologies, Hanau
Markus Holz, CEO
ALD Vacuum Technologies GmbH
Alexander Buckow,
Expert Group Manager Materials
Technology
Fraunhofer Institute for Silicate
Research ISC, Hanau
Benedikt Blitz,
Managing Director
SMR Premium, Duesseldorf
Martin Schwenk
Scientific Engineer
IME/RWTH Aachen University
Coffee Break
Juergen Jakumeit
Priv. Lecturer
Access. e.V., Aachen
Egbert Baake
Institute of Electrotechnology
Leibnitz University Hannover
Lunch Break
ALD Factory Tour
Christoph Genter Managing Director
AMCG Unternehmensberatung
GmbH, München
02:50 – 03:10pm
Frederik Knauf,
Sales Open-die Forging Presses
SMS Group GmbH,
Moenchengladbach
03:10 – 03:20 pm
Uwe Zöllig, Head of Global Market,
Oerlikon Leybold Vacuum GmbH,
Cologne
Breakfast Buffet
By coach
Welcome/Opening Remarks
Keynote:
Permanent Magnets –
Key for Future Energy Technologies
Update on Remelted Special Steels
and Powder Metallurgical Steels
Role and Effects of Slag Components
in ESR Processes
Simulation of Metal Processing
Facilities
Analysis and Design of Induction
Liquid Metal Processes using
advanced Computer Simulation
Market for Titanium and Ti-alloys
Cooperation between Melt and
Forging Shop – One possible Outlook
Cost-Efficient and Low-Maintenance
Dry Vacuum Pump Systems for
VIM/ESR/VAR
ALD Vacuum Technologies GmbH, Otto-von-Guericke-Platz 1, 63457 Hanau, Germany | Phone: +49.6181.307-0 | Facs: +49.6181.307-3290
Member of the AMG Advanced Metallurgical Group N.V., Amsterdam, The Netherlands
Board of Directors: Dr. Markus Holz (Chairman), Michael Protzmann
Company Register HRB-Nr. 92377; VAT: DE258853629
Bank Accounts: UniCredit Bank AG (BLZ 795 200 70), Konto 366 829 849, IBAN DE56 7952 0070 0366 8298 49, Swift HYVE DE MM 407
HSBC Trinkaus & Burkhardt AG (BLZ 300 308 80), Konto 060 0224 018, IBAN DE10 3003 0880 0600 2240 18, Swift TUBD DE DD
ALD Vacuum Technologies GmbH
Otto-von-Guericke-Platz 1 • 63457 Hanau • Germany
Tel:
Fax:
+49 . 6181 . 307 - 0
+49 . 6181 . 307 - 3290
03:20 - 03:50 pm
03:50 – 04:10 pm
04:10 – 04:30 pm
04:30 – 04:50 pm
04:50 – 05:10 pm
05:10 – 06.15 pm
06:15 – 10:30 pm
10:30 pm
Coffee break
Yilmaz Yildir,
Head of Sales After Market
ABP Induction Systems GmbH,
Dortmund
Franz Hofmann
Technical Service Manager
Metallurgy
Wacker Chemie, Munich
Gerhard Richter, Vice President –
Steel Cutting & Grinding Machines
Division
Voecklabruck, Austria
Michael Hohmann,
Senior Vice President Metallurgy
ALD Vacuum Technologies GmbH
Time to exchange
Transfer by coach to Blankenbach
Transfer by coach back to hotel
Experiences and Developments of
high current Converters for Vacuum
Induction Furnaces
Densities of Premelted ESR-Slags
Innovative Solutions Abrasive Cutting
and Grinding of Large-Scale Ingots
and Forgings
Closing Remarks
ALD Vacuum Technologies GmbH
Brennhaus Behl, 63825 Blankenbach
Best Western Villa Stokkum, Hanau
Friday, September 23rd, 2016
06:30 – 08:45 am
09:00 am –
02:30 pm
Best Western Villa Stokkum,
Hanau
Pick up by coach at Hotel for
transfer to Isabellenhuette
Heusler, Dillenburg
02:30 – 06:00 pm
Pick up by coach for sightseeing
06:00 – 09:00 pm
09:00 – 10:30 pm
Pick up by coach for dinner
Transfer back to Hanau
Breakfast buffet
VIP Factory Tour
Tour of Dillenburg’s Casemates,
Wilhelmstower and Villa Gruen
Please bring jacket!
Golfrestaurant Dillenburg
Best Western Villa Stokkum
Saturday, September 24th, 2016
08:00 – 09:00 am
09:00 – 11:00 am
Best Western Villa Stokkum,
Hanau
Best Western Villa Stokkum,
Hanau
Breakfast buffet.
Meeting adjourns.
Check-out and departure.
Morning moderation: Ulrich Biebricher, Vice President Melting and Remelting
Afternoon moderation: Andreas Eich, Product Manager Melting Products.
ALD Vacuum Technologies GmbH, Otto-von-Guericke-Platz 1, 63457 Hanau, Germany | Phone: +49.6181.307-0 | Facs: +49.6181.307-3290
Member of the AMG Advanced Metallurgical Group N.V., Amsterdam, The Netherlands
Board of Directors: Dr. Markus Holz (Chairman), Michael Protzmann
Company Register HRB-Nr. 92377; VAT: DE258853629
Bank Accounts: UniCredit Bank AG (BLZ 795 200 70), Konto 366 829 849, IBAN DE56 7952 0070 0366 8298 49, Swift HYVE DE MM 407
HSBC Trinkaus & Burkhardt AG (BLZ 300 308 80), Konto 060 0224 018, IBAN DE10 3003 0880 0600 2240 18, Swift TUBD DE DD
ALD Vacuum Technologies GmbH
Otto-von-Guericke-Platz 1 • 63457 Hanau • Germany
Tel:
Fax:
+49 . 6181 . 307 - 0
+49 . 6181 . 307 - 3290
ALD Vacuum Technologies GmbH, Hanau
7th VIM/ESR/VAR Workshop, September 21st – 24th 2016
Registration Form
_______________________________________________________________________________________________
Surname, Given name
_____________________________________________________________________________________
Title/occupation in company
_____________________________________________________________________________________
Company and country
_____________________________________________________________________________________
Cellular-/mobile-phone no.
_____________________________________________________________________________________
E-Mail
_____________________________________________________________________________________
Arrival date
Flight-no.
Arrival Time
Departure date
Flight-no.
Pick-up time
Please circle, where appropriate:
Airport transfer – Arrival - required
yes
no
Airport transfer – Departure - required
yes
no
Accommodation required - check-in date _________ check-out date __________
yes
no
Reception and Dinner at Villa Stokkum, Hanau-Steinheim, www.villastokkum.de
September 21th, 2016
yes
no
Workshop day, at ALD Vacuum Technologies, Hanau, www.ald-vt.com
nd
September 22 2016
yes
no
yes
no
Tour at Isabellenhuette Heusler, Dillenburg, www.Isabellenhuette.de, September 23 , 2016
yes
no
Tour at Dillenburg’s historical site – the Casemates, Wilhelmstower and Villa Gruen,
rd
September, 23 , 2016, www.dillenburger-museumsverein.de
yes
no
yes
no
nd
Dinner at Hotel Brennhaus Behl, Blankenbach, www.behl.de September 22 , 2016
rd
rd
Dinner at Golfrestaurant Dillenburg, September 23 , 2016
ALD Vacuum Technologies GmbH, Otto-von-Guericke-Platz 1, 63457 Hanau, Germany | Phone: +49.6181.307-0 | Facs: +49.6181.307-3290
Member of the AMG Advanced Metallurgical Group N.V., Amsterdam, The Netherlands
Board of Directors: Dr. Markus Holz (Chairman), Michael Protzmann
Company Register HRB-Nr. 92377; VAT: DE258853629
Bank Accounts: UniCredit Bank AG (BLZ 795 200 70), Konto 366 829 849, IBAN DE56 7952 0070 0366 8298 49, Swift HYVE DE MM 407
HSBC Trinkaus & Burkhardt AG (BLZ 300 308 80), Konto 060 0224 018, IBAN DE10 3003 0880 0600 2240 18, Swift TUBD DE DD
ALD Vacuum Technologies GmbH
Otto-von-Guericke-Platz 1 • 63457 Hanau • Germany
Tel:
Fax:
+49 . 6181 . 307 - 0
+49 . 6181 . 307 - 3290
ALD Vacuum Technologies GmbH, Otto-von-Guericke-Platz 1, 63457 Hanau, Germany | Phone: +49.6181.307-0 | Facs: +49.6181.307-3290
Member of the AMG Advanced Metallurgical Group N.V., Amsterdam, The Netherlands
Board of Directors: Dr. Markus Holz (Chairman), Michael Protzmann
Company Register HRB-Nr. 92377; VAT: DE258853629
Bank Accounts: UniCredit Bank AG (BLZ 795 200 70), Konto 366 829 849, IBAN DE56 7952 0070 0366 8298 49, Swift HYVE DE MM 407
HSBC Trinkaus & Burkhardt AG (BLZ 300 308 80), Konto 060 0224 018, IBAN DE10 3003 0880 0600 2240 18, Swift TUBD DE DD
ALD Vacuum Technologies GmbH
Otto-von-Guericke-Platz 1 • 63457 Hanau • Germany
Tel:
Fax:
+49 . 6181 . 307 - 0
+49 . 6181 . 307 - 3290
Abstracts for 7th VIM/ESR/VAR-Workshop at
ALD Vacuum Technologies GmbH, Hanau
Fraunhofer-Institut für Silicatforschung ISC
Dr.-Ing. Alexander Buckow
Expert Group Manager Materials Technology
Permanent Magnets – Key for future energy technologies
Rare earth permanent magnets play a key role in many different kinds of mass market
technologies and they are a core functional material in the mobility and energy supply
sector, in particular magnets for e-mobility and wind-power. After 30 years of research, the
excellent magnetic properties of Nd-Fe-B still stand out. The fact that its main constituents
(iron and the abundant rare earth metal neodymium) were cheap and widely available was
just as important for the acceptance of the alloy by industry worldwide. Today, rare earths
are still abundant. However, rare earth primary production as well as the production of the
rare earth permanent magnets are strongly concentrated in one country, which has led to
an unfavourable monopole situation in the production of a strategic material.
The Fraunhofer Project Group Materials Recycling and Resource Strategies works on
technologies to reduce the rare earth content in permanent magnets on one side and to
establish recycling routes and processes to enable an alternative raw material source for
the production of new magnets on the other side. The presentation shows different
approaches for material development and recycling routes to face the challenges in
materials supply for the energy revolution and suggest some answers regarding ecological
aspects in green energy.
ALD Vacuum Technologies GmbH, Otto-von-Guericke-Platz 1, 63457 Hanau, Germany | Phone: +49.6181.307-0 | Facs: +49.6181.307-3290
Member of the AMG Advanced Metallurgical Group N.V., Amsterdam, The Netherlands
Board of Directors: Dr. Markus Holz (Chairman), Michael Protzmann
Company Register HRB-Nr. 92377; VAT: DE258853629
Bank Accounts: UniCredit Bank AG (BLZ 795 200 70), Konto 366 829 849, IBAN DE56 7952 0070 0366 8298 49, Swift HYVE DE MM 407
HSBC Trinkaus & Burkhardt AG (BLZ 300 308 80), Konto 060 0224 018, IBAN DE10 3003 0880 0600 2240 18, Swift TUBD DE DD
ALD Vacuum Technologies GmbH
Otto-von-Guericke-Platz 1 • 63457 Hanau • Germany
Tel:
Fax:
+49 . 6181 . 307 - 0
+49 . 6181 . 307 - 3290
SMR Premium GmbH
Benedikt BLITZ, Managing Director
Update on Remelted Special Steels and Powder Metallurgical Steels'
The presentation will highlight the recent developments in the world of remelted special
steels (titanium, nickel alloys, stainless steel, alloy tool steel and alloy steel) as well as will
give an overview about end-user demand and structures of these special steels as well as
summarize the actual status of installations (VIM, VAR and ESR) on a global scale. Also
the presentation will focus on the production of Metal Powders and Powder Metallurgical
Steels and especially its associated production technologies like HIP, MIM and AM. As
they are and will become key future core technologies for a number of demanding
products and thus for the usage in different associated industries. The presentation will
highlight the actual supply and demand
situation of metal powders and the manufactured metal powder steels, will introduce
leading manufacturers of both powders and steels, and summarizes installed capacity and
new capacity that are on the way.
ALD Vacuum Technologies GmbH, Otto-von-Guericke-Platz 1, 63457 Hanau, Germany | Phone: +49.6181.307-0 | Facs: +49.6181.307-3290
Member of the AMG Advanced Metallurgical Group N.V., Amsterdam, The Netherlands
Board of Directors: Dr. Markus Holz (Chairman), Michael Protzmann
Company Register HRB-Nr. 92377; VAT: DE258853629
Bank Accounts: UniCredit Bank AG (BLZ 795 200 70), Konto 366 829 849, IBAN DE56 7952 0070 0366 8298 49, Swift HYVE DE MM 407
HSBC Trinkaus & Burkhardt AG (BLZ 300 308 80), Konto 060 0224 018, IBAN DE10 3003 0880 0600 2240 18, Swift TUBD DE DD
ALD Vacuum Technologies GmbH
Otto-von-Guericke-Platz 1 • 63457 Hanau • Germany
Tel:
Fax:
+49 . 6181 . 307 - 0
+49 . 6181 . 307 - 3290
IME Metallurgische Prozesstechnik und Metallrecycling Institut und Lehrstuhl der
RWTH Aachen
Martin Schwenk: Scientific Engineer
Role and effects of slag components in ESR processes
The electroslag remelting process (ESR) is a well-known refining process suitable for the
production of high quality metals with advanced properties. Typical applications are the
field of the aviation- or energy-sector for example. For many years the ESR process is
under investigation at the IME, RWTH Aachen University. After a short review of the ESR
process fundamentals, this paper gives an overview on various components used in slag
systems, their necessity for and their effects on the process itself.
One of the most commonly used slag system consists of varying amounts of the
components CaF2, Al2O3 and CaO. It is well known that this system is suitable for a wide
range of steel and nickel alloys. Additionally there are some other additives like MgO, SiO2
or TiO2 whose influence on refining capabilities and chemical or thermochemical behavior
are stated out.
Otherwise, while focusing on the before mentioned slag system, the remelting of titanium
and its alloys need different slag systems usually containing CaF2 and varying amounts of
NaF or MgF2 for example. The properties and influence of these components are also
reviewed in this paper.
Lastly, some characteristics of the laboratory scale ESR furnace and some examples
about recent research activities at the IME are presented.
Access e.V., Intzestr. 5, 52072 Aachen
Dr. Jürgen Jakumeit, Private Lecturer
Simulation of metal processing facilities
Simulation is a well-established tool to optimize not only the design of technical equipment
but also the manufacturing process. The later can give detailed information on flow and
temperature field, effect of radiation and other aspects, by solving the underlying physics
in a strongly coupled manner. Advanced simulation approaches like the Lagrange particle
and Discrete Element model can add information on particle movement and deposit. The
effect of process parameter like casting temperature, flow rate and tundish movement can
be investigated and adjusted to optimize the process. Since many years Access in
collaboration with CD-adapco, is involved in the development of the commercial simulation
code STAR-Cast to address this topic. In this talk the simulation of metal production
facilities using STAR-Cast will be demonstrated using the VIDP-process as example.
ALD Vacuum Technologies GmbH, Otto-von-Guericke-Platz 1, 63457 Hanau, Germany | Phone: +49.6181.307-0 | Facs: +49.6181.307-3290
Member of the AMG Advanced Metallurgical Group N.V., Amsterdam, The Netherlands
Board of Directors: Dr. Markus Holz (Chairman), Michael Protzmann
Company Register HRB-Nr. 92377; VAT: DE258853629
Bank Accounts: UniCredit Bank AG (BLZ 795 200 70), Konto 366 829 849, IBAN DE56 7952 0070 0366 8298 49, Swift HYVE DE MM 407
HSBC Trinkaus & Burkhardt AG (BLZ 300 308 80), Konto 060 0224 018, IBAN DE10 3003 0880 0600 2240 18, Swift TUBD DE DD
ALD Vacuum Technologies GmbH
Otto-von-Guericke-Platz 1 • 63457 Hanau • Germany
Tel:
Fax:
+49 . 6181 . 307 - 0
+49 . 6181 . 307 - 3290
Leibnitz University Hannover
Prof. Dr.-Ing. E. Baake, Institute for Electrotechnology
Analysis and design of induction liquid metal processes using advanced computer
simulation
Melting and casting processes are an important part of many industrial processes in
particular in the production and further treatment of products in metallurgical applications.
But due to the increasing complexity of the applications and the strong requirements
regarding the reduction of time and costs for the development of new processes and
technologies, the computer simulation becomes more and more important for the analysis
and design of industrial liquid metal processes.
Along selected examples different approaches for three-dimensional (3D) simulation of the
multi-physical processes in liquid metal applications will be presented. The 3D numerical
models for the calculation of the in-stationary turbulent melt flow, temperature distribution
and heat and mass exchange in the melt is realized by using different turbulence models
including an advanced Large Eddy Simulation (LES) turbulence description.
The computer simulation methods have been applied for laboratory and industrial scale
applications, like induction crucible and channel furnaces, semi-levitation and full levitation
melting processes in induction furnace with cold crucible, electromagnetic levitation
melting in conventional cylinder symmetric arrangement and a new drip- and leakage-free
levitation melting set-up using horizontal single- and two-frequency electromagnetic fields.
The simulation results obtained are verified with experimental results.
ALD Vacuum Technologies GmbH, Otto-von-Guericke-Platz 1, 63457 Hanau, Germany | Phone: +49.6181.307-0 | Facs: +49.6181.307-3290
Member of the AMG Advanced Metallurgical Group N.V., Amsterdam, The Netherlands
Board of Directors: Dr. Markus Holz (Chairman), Michael Protzmann
Company Register HRB-Nr. 92377; VAT: DE258853629
Bank Accounts: UniCredit Bank AG (BLZ 795 200 70), Konto 366 829 849, IBAN DE56 7952 0070 0366 8298 49, Swift HYVE DE MM 407
HSBC Trinkaus & Burkhardt AG (BLZ 300 308 80), Konto 060 0224 018, IBAN DE10 3003 0880 0600 2240 18, Swift TUBD DE DD
ALD Vacuum Technologies GmbH
Otto-von-Guericke-Platz 1 • 63457 Hanau • Germany
Tel:
Fax:
+49 . 6181 . 307 - 0
+49 . 6181 . 307 - 3290
AMCG Unternehmensberatung GmbH, Munich
Mr. Christoph Genter, Managing Director
Market for titanium and titanium alloys
The goal of the presentation is to give an overview about the global business with titanium
metals.
The results of a survey about the market by countries and applications will be shown as
well as the future outlook and the opportunities and threats in the markets.
The emerging business with titanium powder products in the aerospace industry as well as
the processing technologies (additive manufacturing, metal injection molding etc.) will be
part of the presentation.
Furthermore, the battlefield will be covered, the suppliers, their market shares and the
driving forces in this industry.
Finally, trends in the customer and user industries for titanium metals are evaluated and
their consequences and strategic impact for the future business of titanium metal
companies.
SMS group GmbH, Moenchengladbach
Dr. Frederik Knauf, Sales Open-die Forging Presses
Cooperation between melt and forging shop – one possible outlook
In the past, inquiries mainly focused on large machines. Customers often inquire machines
more powerful and larger than previous machines or competitor solutions. This situation
changed in recent years.
Recently customers’ inquiries often require highly flexible and effective solutions out of one
hand. Especially emerging markets, like Southeast Asia for example, requires high flexible
production routes for less tonnage from source to final product. This is often driven by the
aim of getting independent from foreign manufacturers.
This “new” situation results in projects, which require new planning methods – higher
complexity supplied by one main project partner, team working with all involved partners.
The projects are often characterised by a complete solution covering melting and forming.
To fulfil customers’ requirements deep cooperation between melting and forming – often
between different suppliers is required.
This publication will give a possible outlook for future production shops by the example of
melting and forging deeply co-working for achieving best solution for the customer. The
possible outlook will concentrate on examples of manufacturing of products in less
numbers of pieces and varying alloys.
ALD Vacuum Technologies GmbH, Otto-von-Guericke-Platz 1, 63457 Hanau, Germany | Phone: +49.6181.307-0 | Facs: +49.6181.307-3290
Member of the AMG Advanced Metallurgical Group N.V., Amsterdam, The Netherlands
Board of Directors: Dr. Markus Holz (Chairman), Michael Protzmann
Company Register HRB-Nr. 92377; VAT: DE258853629
Bank Accounts: UniCredit Bank AG (BLZ 795 200 70), Konto 366 829 849, IBAN DE56 7952 0070 0366 8298 49, Swift HYVE DE MM 407
HSBC Trinkaus & Burkhardt AG (BLZ 300 308 80), Konto 060 0224 018, IBAN DE10 3003 0880 0600 2240 18, Swift TUBD DE DD
ALD Vacuum Technologies GmbH
Otto-von-Guericke-Platz 1 • 63457 Hanau • Germany
Tel:
Fax:
+49 . 6181 . 307 - 0
+49 . 6181 . 307 - 3290
Oerlikon Leybold Vacuum GmbH, Cologne
Mr. Uwe Zoelling, Head of Global Market
Cost-efficient and low-maintenance dry vacuum pump systems for VIM / VAR / ESR
The presenter wants to highlight the developments in the field of vacuum pump technology
utilized for secondary metallurgy vacuum degassing technologies. Established dry vacuum
solutions and their unique features for these applications will be presented. Next to this we
will highlight cost saving opportunities of dry pumps compared with conventional oil-sealed
vacuum pumps and possibilities for preventive service concepts.
Dry compressing screw-type vacuum pumps have demonstrated to be a very practicable,
reliable and powerful vacuum supply for vacuum metallurgy. While the investment for dry
compressing vacuum system compared with conventional oil-sealed pumps is still slightly
higher, at demanding application end users will realize clear cost of ownership savings
over the complete system lifetime. A sample case calculation will visualize the saving
potential.
In modern production facilities up-time of equipment is extremely valuable as users must
deliver just-in-time. To avoid unplanned standstill of the equipment, users must follow a
suitable maintenance strategy.
The Time-oriented maintenance strategy proactively initiates maintenance work on fixed
time interval. This reduces risk on unscheduled failures but service is often done even
before the equipment reaches its operation limits.
As alternative a condition-oriented maintenance strategy could be followed where
maintenance is only done when really required.
To find the right timing for exchange of wear parts indicators of increasing wear must be
monitored continuously. Trend indicators will be analyzed and potential maintenance will
be triggered only if conditions predict an increased risk for unscheduled downtime.
Users should evaluate all options the recent developments offer them. Modern pump
technology is robust, reliable and environmental friendly – apart from bringing down
operational costs. Modern remote monitoring systems enable the user to ensure lowest
equipment down-time combined with cost-optimized maintenance efforts.
ALD Vacuum Technologies GmbH, Otto-von-Guericke-Platz 1, 63457 Hanau, Germany | Phone: +49.6181.307-0 | Facs: +49.6181.307-3290
Member of the AMG Advanced Metallurgical Group N.V., Amsterdam, The Netherlands
Board of Directors: Dr. Markus Holz (Chairman), Michael Protzmann
Company Register HRB-Nr. 92377; VAT: DE258853629
Bank Accounts: UniCredit Bank AG (BLZ 795 200 70), Konto 366 829 849, IBAN DE56 7952 0070 0366 8298 49, Swift HYVE DE MM 407
HSBC Trinkaus & Burkhardt AG (BLZ 300 308 80), Konto 060 0224 018, IBAN DE10 3003 0880 0600 2240 18, Swift TUBD DE DD
ALD Vacuum Technologies GmbH
Otto-von-Guericke-Platz 1 • 63457 Hanau • Germany
Tel:
Fax:
+49 . 6181 . 307 - 0
+49 . 6181 . 307 - 3290
ABP Induction Systems GmbH, Dortmund, Germany
Yilmaz Yildir– Head of After Sales Market
Hatim Britechi–Sales Manager Steel Melting
ABP Converter Technology
The basic function of the converter system is to convert line frequency, three phase power
from the utility network to a variable, load governed frequency that is appropriate for a
particular induction melting or heating load.
In today’s foundries and steel plants induction melting furnaces are powered basically by
two types of converter systems
· Parallel converter systems (current fed inverter)
· Series converter systems (voltage fed inverter
a) Parallel resonant circuit
The ABP power supply design is based on the current source, parallel compensated
operating principle. The heavy duty smoothing reactor, filters the AC ripple from the
rectifier output and provides constant current to the inverter (current source). This reliable
heavy duty component is the only device needed for filtering the rectifier output current.
The reactor’s inductance also provides added system safety by limiting the rate of rise or
fall of current in the event of a breakdown in the
inverter, capacitor bank, or furnace coil.
The capacitors carry the non-productive reactive current and the inverter thyristors carry
only the productive compensated current. Therefore the current flows through the
converter components is as lower as 8 to 10 times compared to the serial inverter for
ferrous applications.
Compared with competitive systems, the ABP parallel inverter uses as few as 1/3 of the
number of components. This facilitates maintenance and troubleshooting while reducing
the overall number of required spare parts.
b) Series resonant circuit
ALD Vacuum Technologies GmbH, Otto-von-Guericke-Platz 1, 63457 Hanau, Germany | Phone: +49.6181.307-0 | Facs: +49.6181.307-3290
Member of the AMG Advanced Metallurgical Group N.V., Amsterdam, The Netherlands
Board of Directors: Dr. Markus Holz (Chairman), Michael Protzmann
Company Register HRB-Nr. 92377; VAT: DE258853629
Bank Accounts: UniCredit Bank AG (BLZ 795 200 70), Konto 366 829 849, IBAN DE56 7952 0070 0366 8298 49, Swift HYVE DE MM 407
HSBC Trinkaus & Burkhardt AG (BLZ 300 308 80), Konto 060 0224 018, IBAN DE10 3003 0880 0600 2240 18, Swift TUBD DE DD
ALD Vacuum Technologies GmbH
Otto-von-Guericke-Platz 1 • 63457 Hanau • Germany
Tel:
Fax:
+49 . 6181 . 307 - 0
+49 . 6181 . 307 - 3290
In a series converter system the rectifier is uncontrolled; the intermediate circuit consists of
a smoothing choke (smaller compared to parallel converter system) and a large smoothing
capacitor.
In the series inverter design, the power factor compensating capacitors are connected in
series with the furnace coil. Therefore the full furnace current must flow through the
inverter thyristors and the smoothing capacitor is independent from the inverter status
completely loaded. This means that if a malfunction in the furnace or inverter a high
current impulse can be released, which potentially causes damages to the converter’s
components.
The inverter needs additional diodes to reduce the effects of short circuits on the inverter
thyristors and they are needed for the loaded smoothing capacitor, when the inverter is
shut-off. In the load circuit the capacitor is connected in series to the furnace coil. A
starting device is not necessary.
1) The ABP IGBT Converter as a Hybrid Solution
ABP can now look back on more than 15 years of experience in IGBT (Insulated Gate
Bipolar Transistor) technology for inductive melting plants. The ABP IGBT converter
combines the advantages of both technologies. The ABP IGBT Converter system has the
highest possible efficiency of any induction furnace converter. Through the ABP modular
design by separated IGBT module units an easy mount and dismount of the components
is guaranteed, in order to increase the system availability by reducing the maintenance
time in case of failure. Furthermore the ABP IGBT converter has no requirements on the
quality of the cooling water (No de-ionized water necessary).
2) Outlooks
In Vacuum induction furnaces besides melting is stirring the most important process
applied for treatment in the liquid state and adjustment of chemical composition. It is
necessary to use a stirring transformer for the adjustment of alloy composition. (E.g. for
degassing).
ABP is working together with ALD on a new development to fulfil this demand of stirring by
the new converter power supply. This enables to reduce the amount of components, which
has an impact on investment, operation and maintenance costs.
ALD Vacuum Technologies GmbH, Otto-von-Guericke-Platz 1, 63457 Hanau, Germany | Phone: +49.6181.307-0 | Facs: +49.6181.307-3290
Member of the AMG Advanced Metallurgical Group N.V., Amsterdam, The Netherlands
Board of Directors: Dr. Markus Holz (Chairman), Michael Protzmann
Company Register HRB-Nr. 92377; VAT: DE258853629
Bank Accounts: UniCredit Bank AG (BLZ 795 200 70), Konto 366 829 849, IBAN DE56 7952 0070 0366 8298 49, Swift HYVE DE MM 407
HSBC Trinkaus & Burkhardt AG (BLZ 300 308 80), Konto 060 0224 018, IBAN DE10 3003 0880 0600 2240 18, Swift TUBD DE DD
ALD Vacuum Technologies GmbH
Otto-von-Guericke-Platz 1 • 63457 Hanau • Germany
Tel:
Fax:
+49 . 6181 . 307 - 0
+49 . 6181 . 307 - 3290
Wacker Chemie, Munich
Mr. Franz Hofmann, Technical Service Manager Metallurgy
Densities of Premelted ESR-Slags
For the Electro-Slag-Remeling process (ESR) CaF2 based Electro Remelting Slags are
used almost exclusively. The main composition of these slags is based on the components
of CaF2-CaO-Al2O3. They fulfill a number of tasks in the ESR process, such as the
transmission of the current, enabling a quiet start-up phase, the complete dissolution of all
the slag components and forming of a homogeneous melt, the reaction with undesirable
elements and their removal, the absorption of existing inclusions and non-metallic
particles, prevention of surface defects, etc. For the selection of a suitable slag product, in
addition to its particular composition, liquidus temperature and electrical conductivity, the
knowledge of its density is helpful. Molten heavy metals and steels have a sufficient
density difference to molten slag, so that no problems come up in this regard during ESR
process. When re-melting light metals, knowledge of the density of available products may
also be relevant to the choice of the right slag product.
The following is a summary of the determined densities of pre-melted slags, which are
accepted and used mainly in the market, worldwide. These high-quality products are
manufactured in Germany and marketed under the name Wacker® Electroflux.
Braun Maschinenfabrik GmbH, Voecklabrueck, Austria
Mr. Gerhard Richter, Vice President - Steel Cutting & Grinding Machines Division
Innovative Solutions Abrasive Cutting and Grinding of Large-Scale Ingots and
Forgings
Prior to further processing of semi-finished steel and special alloy products, it must be
ensured that the surface of the workpieces is free from scale and flaws. In addition to that,
these products also need to be cut and the cut surface needs to be free from heavy burr
and surface hardening. For both applications, even for increasingly large product
dimensions and regardless if the product to be ground or cut is cold or hot, BRAUN
provide customized, state-of-the-art solutions: a multi-functional HP (high-pressure/highperformance) grinding machine for bright-grinding of the product surface, a highperformance abrasive cut-off machine for cutting the product precisely and efficiently, as
well as a highly flexible deburring grinding machine for a reliable removal of possible burr
from the corners and edges of the product.
ALD Vacuum Technologies GmbH, Otto-von-Guericke-Platz 1, 63457 Hanau, Germany | Phone: +49.6181.307-0 | Facs: +49.6181.307-3290
Member of the AMG Advanced Metallurgical Group N.V., Amsterdam, The Netherlands
Board of Directors: Dr. Markus Holz (Chairman), Michael Protzmann
Company Register HRB-Nr. 92377; VAT: DE258853629
Bank Accounts: UniCredit Bank AG (BLZ 795 200 70), Konto 366 829 849, IBAN DE56 7952 0070 0366 8298 49, Swift HYVE DE MM 407
HSBC Trinkaus & Burkhardt AG (BLZ 300 308 80), Konto 060 0224 018, IBAN DE10 3003 0880 0600 2240 18, Swift TUBD DE DD

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