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.
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:
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:
This process is preferred in aerospace and high-pressure technology.
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:
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.
The systems were developed in close cooperation with the renowned manufacturer INTECO. Particularly noteworthy are
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.
Breitenfeld's customers come from highly specialized industries such as
Customers place the highest demands on
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.
Breitenfeld works in full-continuous operation (24/7) in the special steel plant and achieves
Ingot sizes and reworking
An important aspect of sustainability: the material removed during grinding is recycled in the electric arc furnace and fed back into the production cycle.
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.
Each remelted ingot is tested individually. This includes
Quality assurance ensures that every ingot meets the highest requirements.
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.
The investment in the new VAR plant enables
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.
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.