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Super Alloys

Superalloys, High Performance Alloys

India is fast developing economy with population over 120 million with vast border. To meet the growing demand of our population and protect our border, growth of technology is inevitable. The growth of technology is relevant to sectors like Biomedical, Aerospace, Petrochemical, Thermal and Nuclear Plants, Defense, Arnament, Transport etc. To attain high level of perfection in this sectors depends, on availability of stringent quality of rawmaterial. As on date most of raw material is imported.

Government of India has embarked upon ambitious program of self reliance through make in India program. Sunflag widely accepted as marque company in supplying high quality material to automobile and general Engg industries wish to enter this high tech area. The fast developing electrical vehicle technology may also require these advanced high tech material in high volume.

These hi tech material are used in making Aircraft Parts, Bio Medical Implants, Industrial and Vehicle Gas Turbines, Super Critical Power Plants Parts, Space Vehicles and Rocket Engines, Submarine Parts, Nuclear Reactor, Missiles and Arnaments etc.

The high performance high tech alloys required by these industries are required to be operated at a load and temperature above 500 degree centigrade with resistance to oxidation and environmental attack, that are usually prevalent at this temp. Hence the raw material used for this high sectors requires low level of impurities and meeting with stringent spec.

In nature, we rarely come across very pure material and it contains metallic impurities like lead, bismuth, etc, non metallic impurities like sulphur. phosphorous etc, residual gases like oxygen. hydrogen and nitrogen and nonmetallic impurities like oxides, nitrides. Sulphide etc.

The above impurities considerably reduced in conventional technology of arc furnace, AOD, LRF and VOD and the low level of impurities required by these hi-tech industries can be achieved only by melting at Vacuum Induction Melting [VIM], Electro Slag Refining [ESR] and Vaccum Arc Re-melting furnace [VAR] etc apart from other specialised melting.

Sunflag has put up VIM, ESR, VAR facility at Bhandara Plant near Nagpur. These equipment have latest technology and supplied by the World Leaders in this field, Sunflag also have tie up with DAIDO Japan, who are well known have equity participation with Sunflag. DAIDO also provide inputs for improvement in the technology.

Sunflag other facilities include Concast, Blooming Mill, specialised Rolling Mill, Heat Treatment facilities and Bright Bar and Centerless Grinding Facility.

To test these high tech material, most modern lab equiped with good analytical instruments, metallographic equipments, mechanical testing equipment for testing RT, LT and HT specimens. Online Phase Arrey Machines for testing UT, eddy current, MPl and FPT tests also available to test the product to various national and international standards

Sunflag has trained manpower who have specialised skill to operate these most modern equipments & control.

SUNFLAG HI TECH GRADES

SUNFLAG HI TECH GRADES

TYPICAL PROPERTIES OF SOME GRADES

SUPER ALLOYS DIVISION

Infrastructure for Manufacture of Super Alloys

EQUIPMENTMakeCapacity (M T)
Vaccum Induction Melting (VIM) CONSARC (USA)6.5 MT
Vaccum Arc Re-Melting (VAR)CONSARC (USA) & ALD (GERMANY)2.2 MT & 16 MT
Electro Slag Re-melting (ESR)CONSARC (USA) & ALD (GERMANY)1.8 MT & 22 MT

ELECTRO SLAG REMELTING (ESR)

ProductRange:1.8MT to 22MT

Salient Features :

  • Automatic Electrode Feed Control System.
  • Real Time Automatic melt Control System through pre defined recipe.
  • Full automatic operation
  • Automatic start phase of the furnace by a defined power/time profile
  • Realtime Melting rate control through maintaining melting rate or melting power profile with
    respect to the consumed weight of electrode
  • Automatic hot topping as per recipe defined power/time profile
  • Pre—defined profiles for various stages of processing e.g. slag resistance
    set point profile or swing set point profiles.
  • Digital Operator Interface and data acquisition system
  • Furnace head provided with x—y angular corrections of electrode and
    total sealed system for argon shielded melting
  • Fume exhaust and environment protection hood
  • Fully coaxial high current feedings system

Vacuum Arc Remelting (VAR)

Product Range:2 MT to 16 MT

Salient Features :

  • Fully computerized automatic melt control system based or dynamic electrode feed control system with arc voltage
    control/drip short pulse rate control
  • Real Time Automatic melt Control System through pre-defined recipe
  • Full automatic operation
  • Automatic start phase of the furnace by a defined power/time profile
  • Realtime Melting rate control through maintaining melting rate or

    melting power profile with respect to the consumed weight of electrode

  • Automatic hot topping as per recipe defined power/time profile
  • Recipe defined profiles for electrode control feed systems for star‘t-melt—hot topping phase.
  • Digital Operator Interface and data acquisition system
  • Furnace head provided with X—y angular corrections of electrode and total sealed system
  • Fume exhaust and environment protection hood
  • Fully coaxial high current feedings system
  • Ultimate vacuum level of 1x10–3 mbar

Vacuum Induction Melting (VIM)

Product Range: 1 MT to 6 MT

Salient Features:

  1. Furnace equipped with mould height 4000 MM
  2. Facility for Rapid exchange of crucible
  3. Multiple mould pouring
  4. Facility for bulk and additional charging of mix under vacuum
  5. Sampling and temperature measurements under vacuum.
  6. Fully Rollaway head for facilitating cleaning of melt chamber.
  7. Ultimate vacuum level of 1x10–4 mbar .

Vacuum Induction Melting Furnace

6.5 Ton x 4000 mm (Tall Vacuum Induction Melting & Casting Furnace for lngot elctrode Production) Vacuum Induction Melting (VIM) is the melting of metal via electromagnetic induction under vacuum. An induction furnace containing a refractory lined crucible surrounded by an induction coil is located inside a vacuum chamber. The induction furnace is connected to an AC Power source a frequency precisely correlating to the furnace size and material being melted.

 

VIM is a process used to make super alloys, stainless steels, magnetic alloys, electronic alloys, and other demanding high value alloys.

Super Alloys

Superalloys, High Performance Alloys
India is fast developing economy with population over 120 million with vast border. To meet the growing demand of our population and protect our border, growth of technology is inevitable. The growth of technology is relevant to sectors like Biomedical, Aerospace, Petrochemical, Thermal and Nuclear Plants, Defense, Armament, Transport etc. To attain high level of perfection in this sectors depends on availability of stringent quality of raw material. As on date most of raw material is imported.

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