Vacuum Induction Melting and Casting Systems

Thanks to their modular structures and tried-and-tested system design, VSG induction-heated vacuum induction melting and casting systems can be used anywhere and will prove very reliable, and are ideally suited to melting and casting metals, alloys, and special materials, as well as production.

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VSG induction-heated vacuum melting and casting systems from PVA are cold-wall furnaces made of corrosion-resistant stainless steel with water-cooled double jackets. The melting and casting equipment comprises the tiltable induction coil with a coaxial power and coolant supply and the die holder. The crucible material used is adapted to suit the molten material. If the molten material is allowed to come into contact with material that contains carbon, the crucible can be made of graphite or graphite clay; otherwise, crucibles made of oxide ceramics are used. If necessary, crucibles made of metals with high melting points can also be used, provided that the molten material will not react with them. In these cases, the crucible acts as a secondary winding. Power is supplied via static medium-frequency converters in transistor technology.

Depending on customer requirements, either high-vacuum or fine-vacuum pumps are used; in their default configuration, these consist of a combination of a rotary vane pump and a Roots pump. Oil diffusion pumps are provided for high-vacuum applications. These present less potential for problems than other HV pumps in terms of metal vapor and dust. Vacuum melting and casting systems are available with single or multiple chambers and comprise the following basic modules: system vessel, vacuum pump, power supply and controller, melting and casting equipment, and an airlock mechanism with tools for handling the melt. These modules can be combined in various configurations as required, and an extensive selection of accessories can be added to them.

Our Vacuum Induction melting and Casting Systems

Standard VSG Systems
Special VSG System Designs

Vacuum Induction Melting and Casting - Standard Systems (VSG)

PVA’s VSG vacuum melting and casting systems are available in various sizes for charge weights of up to 500 kg. Based on a standard series including the VSG 002, VSG 010, VSG 030, VSG 100, and VSG 300, the systems are available as fine-vacuum or high-vacuum versions fitted with various configurations of accessories and tailored to specific customer requirements. In addition to the molten material and the maximum melt volume, the necessary installation space for dies or molds is a factor in determining the dimensions of the system.

One particular optional accessory that customers often choose is an airlock mechanism above the melting coil that can be used to place various tools into the vacuum chamber in succession without disturbing the vacuum in the furnace chamber, such as an immersion thermocouple to measure melt temperature, a sampling spear or material addition equipment.

VSG 002

Vacuum melting and casting system for melt volumes of up to 0.35 dm³ used in material development and teaching.

VSG 010

Vacuum melting and casting system for melt volumes of up to 2.5 dm³ used especially for material development or precious metal machining.

VSG 030

Vacuum melting and casting system for melt volumes of up to 5.5 dm³ used primarily for precious metals, shape-memory alloys and material development.

VSG 100

Vacuum melting and casting system for melt volumes of up to 14 dm³ for ingot or mold casting with high-alloy steels, coating materials (sputtering targets), or material development.

VSG 300

Vacuum melting and casting system for melt volumes of up to 40 dm³ with critical applications relating to the processing of high-alloy metals and pilot systems for steel mills.

VSG - P

Multi-chamber plants are essentially consisting of a melting chamber and a lock chamber, which are connected by a lock valve and a transport system. The separation of the vacuum chambers allows an increase of productivity by shortening the cycle time. At the same time as the melting process in the permanently evacuated melting chamber is carried out, the cooling and ventilation of the previous casting takes place in the lock chamber, followed by the evacuation of the fresh forms or molds. With the transport system, the interim feeding and discharging of forms / molds is carried out. In general, multi-chamber systems can be offered in horizontal or vertical design. The horizontal design allows a lower overall height and less height levels for the operation of the system, vertical systems are particularly suitable for applications with directional solidification on a smaller footprint but noticeably greater height.
Vacuum Induction Melting and Casting - Special System Designs (VSG)

In the event of special applications, VSG systems are adapted to the specific requirements on the basis of the standard series, featuring the VSG 002, VSG 010, VSG 030, VSG 100, and VSG 300. Examples include:

VSG - S

This is intended for special designs with side doors through which the molds/dies can be loaded or removed if top-loading is not suitable.

VSG - D

Suitable for positive pressures of up to 10 bar so that the pressure of the gas atmosphere above the molten bath can be varied as appropriate for certain special alloys. This system version has already been used several times in size VSG 002 D.

VSG - DS

For applications with directional solidification.

VSG - B

This is intended for the bottom tapping casting process, whereby the melt drains away downward through a hole in the base of the crucible.