How does consumable-electrode arc melting produce a titanium ingot?

Consumable-electrode arc melting is the primary method used to convert purified titanium sponge into structural ingots. The process is conducted within a vacuum or argon environment to prevent contamination.1

The production steps are as follows:

• Electrode Preparation: Titanium sponge, alloying elements, and sometimes recycled scrap are mechanically compacted and welded together to form a long, cylindrical electrode.1
• Melting: The electrode is positioned vertically above a water-cooled copper crucible. An electric current is passed through the electrode, creating an arc that melts the material into the crucible.1
• Remelting: To ensure the alloying elements are distributed uniformly throughout the metal, the resulting primary ingot is remelted at least once using the same process.1

This method produces large ingots that can weigh between 4 and 10 tons and reach diameters of up to 1,050 millimetres. Once consolidated, these ingots are processed into various mill products, such as plate, sheet, wire, and tubing, using traditional steel facilities.1