Vacuum Induction Melting  Strip Casting (VIM-SC) furnaces from Consarc play a key role in the domestic production of rare earth permanent magnets, delivering clean, consistent flake with precise alloy control under vacuum conditions. Most recently commissioned at Vulcan Elements’ new facility in Durham, North Carolina, this advanced furnace system is part of a collaborative effort to strengthen the U.S. rare earth supply chain.

The Strip Casting process begins with the creation of a precise alloy of neodymium (Nd), iron (Fe), boron (B), and often other elements such as dysprosium (Dy) or Terbium (Tb) for enhanced thermal stability. Due to the reactive nature of certain rare-earth elements at high temperatures, these materials are melted together in an induction furnace under vacuum or controlled atmosphere. To create the necessary fine-grained microstructure for magnetic qualities, the molten alloy must undergo a rapid solidification process. As molten alloy is poured onto a rotating, water-cooled copper quench wheel, it solidifies into thin flakes or strips as it contacts the cold surface. A water-cooled material collection system breaks up and cools the solidified metal further, maintaining a fine-grained, uniform microstructure which is necessary for high-performance magnetic material.

Features:

• Variable-speed water-cooled copper quench wheel
• Strip breakup system for improved material cooling
• Water-cooled collection hopper
• Variable position tundish
• Inductotherm® induction melting coils specifically designed for vacuum operation
• Inductotherm® VIP Power Supplies
• Temperature measurement – dip thermocouple, optical pyrometer
• Robust process controls including melting and pouring profiles
• PC-based SCADA
• Multiple options available for material charging, alloy additions, and melt sampling
• Video monitoring and recording

Applications:

• Strip casting of rare-earth magnets
• High-purity alloy casting for defense and energy applications
• Controlled vacuum melting and solidification of specialty metals