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August 2025
In preparation
Janik Brenk
Investigation of an alternative pyrometallurgical process for the production of copper-chromium alloys
In this work, an alternative process route for the production of copper-chromium alloys is developed. This involves copper-chromium alloys, which have a chromium content of around 15 - 25 wt.-% and are used as contact materials in medium-voltage switches. The production of copper-chromium alloys using a common pyrometallurgical process is not feasible because of the large miscibility gap in the phase field of copper and chromium. Usually established process routes are using hot isostatic pressing and/or vacuum arc remelting. The alternative route used in this work consist of two process steps: Alloying using aluminothermic reduction (ATR) followed by a refining step in a vacuum arc remelting (VAR) furnace.
The first part of this work deals with ATR and the challenges of creating an alloy without too many non-metallic inclusions, too much aluminium or too strong macro segregations. To avoid a consolidating melt phase that would lead to further segregations, inline casting is used to directly obtain electrodes remelt-able in a VAR out of the ATR process in a second part of this work. The third part of this work deals with the remelting of these electrodes in a VAR. The refining step of VAR is needed to remove aluminium and non-metallic inclusions which consist of slag particles from ATR as well as to homogenise the resulting ingot.
The first part of this work deals with ATR and the challenges of creating an alloy without too many non-metallic inclusions, too much aluminium or too strong macro segregations. To avoid a consolidating melt phase that would lead to further segregations, inline casting is used to directly obtain electrodes remelt-able in a VAR out of the ATR process in a second part of this work. The third part of this work deals with the remelting of these electrodes in a VAR. The refining step of VAR is needed to remove aluminium and non-metallic inclusions which consist of slag particles from ATR as well as to homogenise the resulting ingot.
Keywords: Copper Chromium; Aluminothermic Reduction; Vacuum Arc Remelting
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