Material Selection, Melting & Degassing

Our first goal is to achieve the highest material cleanliness and purity. Our advanced manufacturing process includes single-ladle technology, vacuum degassing and 100% bottom pouring. This technology significantly reduces the impurities and inclusions that lead to roll surface defects like pinholes, cracks and spalls — the direct benefit to our customers is smoother operation of rolls.

Our process begins with stringent requirements for controlled sources of scrap material; a computer-automated blending system (ABS) monitors all scrap and alloy received. Melting is performed in our 130-ton electric arc furnace with a special slag process designed for low phosphorus and sulfur. Tapping, refining and pouring use a multiple-function single ladle, which eliminates any reintroduction of contaminants from changing ladles.

SFS' vacuum degassing is performed in a special tank degasser with argon stirring. Multiple argon-stirring regimes ensure the removal of hydrogen, oxygen and nitrogen — hydrogen levels of ≤ 1 ppm are the norm — and inclusion removal is facilitated by this ladle-metallurgy process. It is the only vacuum-degassing process that can approach the cleanliness produced by Electro-Slag Remelt (ESR).