What does ESR mean in UNCLASSIFIED

Process

The ESR process begins by melting the metal or alloy in a crucible. A consumable electrode is then immersed into the molten pool, and a direct current (DC) is passed through the system. The electrical resistance between the electrode and the molten slag generates heat, which causes the electrode to melt. As the electrode melts, the molten metal drips through the molten slag and solidifies below it, forming an ingot.

Advantages

ESR offers several advantages over conventional melting techniques:

• Improved purity: The molten slag acts as a filter, removing impurities from the metal or alloy. This results in a refined product with reduced levels of inclusions, gases, and other contaminants.
• Enhanced mechanical properties: The slow solidification rate in the ESR process promotes the formation of a fine-grained, homogeneous microstructure. This contributes to improved mechanical properties, such as strength, toughness, and fatigue resistance.
• Reduced segregation: ESR minimizes the segregation of alloying elements, ensuring a more uniform distribution throughout the ingot.
• Macrostructure control: The process allows for precise control over the solidification process, enabling the production of ingots with specific macrostructures, such as columnar or equiaxed grains.

Applications

ESR is primarily used in the production of high-performance metals and alloys, such as:

• Superalloys
• Tool steels
• Stainless steels
• Titanium alloys

These materials are widely employed in demanding applications, including:

• Aerospace components (e.g., turbine blades)
• Medical implants
• High-strength tools
• Nuclear energy components