High-performance materials are indispensable for numerous key industries, as they guarantee high resilience, exceptional purity and maximum safety. Their production requires specialized processes, state-of-the-art equipment and maximum precision.
At Breitenfeld Edelstahl AG in St. Barbara, innovative remelting processes such as the electroslag remelting process (ESR) and the vacuum arc furnace (VAR) are used to produce steel ingots of the highest purity and quality.
"These processes ensure purity and optimize the mechanical properties of the products."
Andreas Graf, CTO and head of the special steel plant, explains the special features of these processes and their importance for demanding industries such as aerospace, high-pressure technology and electronics.
Why high-performance materials are crucial
High-performance materials are used wherever extreme loads, maximum precision and exceptional purity are required. In sectors such as aerospace, the semiconductor industry and high-pressure technology, they are the basis for safety, efficiency and progress.Applications of the remelting processes
Electro-slag remelting process (ESR)
Originally developed to reduce sulphur content in steels, the ESR process has become an indispensable process for applications requiring high purity, reproducibility and traceability. Typical applications include:
- High pressure engineering: for components exposed to extreme pressure conditions.
- Aerospace: Materials that must meet exceptional strength and safety requirements.
Vacuum arc furnace (VAR)
The VAR complements the ESR process with its ability to effectively remove unwanted dissolved gases such as hydrogen, nitrogen and trace elements under extreme low vacuum conditions (up to 10-³ millibars). The advantages include:
- Micro-pure structure: Perfect for high-precision components.
- Optimized block structure: Ideal for mechanically resilient materials.
This process is preferred in aerospace and high-pressure technology.
Triple-Melt: The combination of ESU and VAR
The triple-melt process combines the strengths of both remelting processes by ensuring maximum purity, better block structures and thus optimized material properties. This results in exceptional resilience and improved resistance to corrosion and mechanical stresses. It is primarily used where maximum safety is required, for example in:
- Turbines for aviation
- Heavy-duty components in the electronics and chemical industries
Special features of the systems
Breitenfeld's remelting systems
Breitenfeld operates five remelting systems, including three ESR furnaces and two VLBO furnaces. Compared to many of its competitors, who often only process their remelted products internally, Breitenfeld sets itself apart by selling remelted ingots directly to forges and rolling mills.
This unique market position offers customers particular flexibility and customized solutions.
Cooperation with INTECO
The systems were developed in close cooperation with the renowned manufacturer INTECO. Particularly noteworthy are
- ESU plants: Combination of sliding crucible and standing crucible technology, which enables flexible block weights and individual requirements.
- VLBO plants: refining in a deep vacuum (up to 10^-3 millibar), which separates unwanted gases such as hydrogen and nitrogen as well as trace elements.
The new VAR plant, an investment of 7.5 million euros, was commissioned in 2024. This additional plant enables the annual processing of up to 15,000 tons of remelted material per year in Breitenfeld.
Customers and their requirements
Typical customers
Breitenfeld's customers come from highly specialized industries such as
- Aerospace
- Electronics and semiconductor industry
- High pressure technology
- Chemical industry
Process requirements
Customers place the highest demands on
- Reproducibility and narrowest analysis limits
- Best block structures
- Absolute purity and traceability
Special projects
An outstanding example is the production of ultra-fine wires with diameters of less than 20 micrometers (the thickness of a hair is 70µm by comparison).
These wires are used in semiconductor technology, where they are used for the production of high-precision electrical connections in microchips. This precision requires the highest material purity without inclusions and segregations.
Production and capacities
Breitenfeld works in full-continuous operation (24/7) in the special steel plant and achieves
- Annual capacity: 15,000 tons of remelted material
- VAR: 3,500 to 4,000 tons
- ESU: residual capacity
Ingot sizes and reworking
- Maximum ESU ingot weight: 30 tons
- Diameter: Up to 1,200 mm
- Post-processing: Sawing, grinding, removal of surface impurities
An important aspect of sustainability: the material removed during grinding is recycled in the electric arc furnace and fed back into the production cycle.
Quality assurance and certifications
Certifications
The most important certification is EN 9100, which is a prerequisite for delivery to the aerospace industry. It forms the basis for many other applications.
Test procedure
Each remelted ingot is tested individually. This includes
- Chemical analyses directly on the ingot or non-destructive testing methods such as ultrasound
- Mechanical tests such as tensile tests and notched bar impact tests on the forged bar steel
Quality assurance ensures that every ingot meets the highest requirements.
Differentiation and market position
Unique market position
Breitenfeld sets itself apart by producing remelted ingots that are supplied directly to customers such as forges and rolling mills. Many competitors only process such products internally.
Advantages for customers
The investment in the new VAR plant enables
- Production of heavier ingots
- Greater flexibility for individual customer requirements
- Optimum price-performance ratios thanks to efficient production processes
Securing the future
Breitenfeld's success is based on the decision to consistently invest in remelting technologies since 2003. This focus enables the company to meet increasing demands in forging and bar steel production.
Conclusion
With state-of-the-art technology, sustainable processes and a clear focus on quality, Breitenfeld Edelstahl is a leader in the production of high-performance materials.
With innovative remelting processes such as ESR and VAR as well as the combination in the triple-melt process, Breitenfeld is setting new standards in the production of high-performance materials.
Investments in state-of-the-art equipment and a focus on top quality secure the company's market position and offer customers tailor-made solutions.
Breitenfeld remains a reliable partner for demanding industries where purity, precision and sustainability are top priorities.
Would you like to find out more about our innovative processes or discuss a customized solution for your project?
Feel free to contact us - our team of experts is always at your disposal.
