Methods for producing even wall down-hole power sections
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[0034] A simplified schematic of a vacuum arc remelting (VAR) process 200 is shown in FIG. 2A. A cylindrically shaped, alloy electrode 201 is loaded into a liquid-cooled, copper crucible or mold 202 of a VAR furnace, the furnace is evacuated, and a direct current (dc) electrical arc is struck between the electrode (cathode) and some start material (e.g., metal chips) at the bottom of the crucible (anode) 202. Alternatively, the electrode 201 may be continuously fed into the mold 202 and the mold may be made from graphite or another conductive material. Preferably, the electrode 201 is made from a metal, such as steel. The arc heats both the start material and the electrode tip, eventually melting both. As the electrode tip is melted away, molten metal drips off, forming a part 203 beneath while the electrode 201 is consumed. Because the crucible diameter is larger than the electrode diameter, the electrode must be translated downwards toward the anode pool to keep the mean distance ...
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