Method and casting device for producing casting products

Abstract

The invention relates to a method for casting in a furnace (22a; 22b; 22b) using an electrode (5) in a casting device (100). The invention relates to a method for producing a cast part (1) from titanium-containing scrap metal (2) in a furnace (22a; 22b), in which method an electrode (5) and the scrap metal (2) are melted in a furnace (22a; 22a; 22b) is melted in a vacuum atmosphere in a melting chamber (20), the scrap metal (2) being fed from at least one storage container (18) into the melting furnace (22a; 22b), in which a furnace (22a; 22b) having a cooled inner wall (55) is used; 22a, 22b) at which components of the molten metal are partially solidified, and wherein the liquefied metal is melted from the furnace (22a; 22b) into at least one casting mould (26) in order to produce a cast part (1).

Description

Technical Field

[0001] The present invention relates to a method for producing castings using consumable electrodes and titanium-containing scrap metal in a casting apparatus, and a casting apparatus designed to implement the method according to the invention.

[0002] Existing technology The production of castings from titanium-containing scrap metal and consumable electrodes in casting plants places special demands on process control. Specifically, it is desired or intended that inclusions of low or similar density (such as titanium nitride) contained in the electrodes and titanium scrap, as well as foreign particles of relatively high density, be completely dissolved in the melt in an inert furnace during the melting of the scrap metal, or be bound in the inert furnace by gravity segregation, thus preventing them from entering the castings or allowing only minimal entry. One possible method is to melt the scrap metal in a furnace with cooled inner walls. This process, carried out under vacuum, causes the aforementioned components in the molten metal (which are undesirable in castings) to either evaporate and dissolve, or, in cases where their density is higher than the other components, to sink in the molten pool and adhere to the shell formed by the solidified melt in the area of ​​the furnace's inner wall. These solidified components are then bound in a liquid / doughy state within the transition zone of the furnace, thus preventing them from entering the casting mold or the casting itself during the pouring of the remaining molten metal. This solidified metal shell on the furnace's inner wall is referred to in this technical field as a "skull."

[0003] This method is known in US 6,006,821 A. This known method has the features of the preamble of claim 1, further characterized in that the scrap metal is supplied or provided from the storage container in a single operation before the start of the production cycle. In other words, only a single storage container is provided in the storage space, which extracts scrap during the processing cycle. Furthermore, it should be mentioned that the casting apparatus known in US 6,006,821 A1 uses only a furnace and therefore only a storage container with a maximum allowable pouring volume of approximately 50 kg. Therefore, the apparatus and methods known in the aforementioned documents are not designed to achieve larger pouring volumes or castings during the production process. Furthermore, it should be mentioned that with increasing volume, the handling of the storage container for storing scrap metal places increasingly higher mechanical demands on the machinery due to the increased structural dimensions and mass of the storage container (including the greater mass of the scrap metal). Therefore, in other casting apparatuses used for processing scrap metal, the amount of scrap stored in the storage container is limited, typically to a few tons, for example, a maximum of 6 tons. Therefore, if larger castings are to be produced, they can only be produced gradually or through multiple continuous production processes, accompanied by intermittent new evacuation processes within the casting equipment. This is not only time-consuming, costly, and energy-intensive, but also problematic in terms of quality. Summary of the Invention

[0004] The method for producing castings from titanium-containing scrap metal and consumable electrodes according to claim 1 has the advantages of enabling particularly high productivity in the mass production of castings in a casting apparatus and enabling large quantities of titanium-containing scrap metal to be processed into one or more castings.

[0005] This invention is based on the concept of achieving high-quality castings by storing a relatively large quantity of scrap metal for melting in multiple storage containers within a vacuum atmosphere required for processing. This allows scrap metal from the storage containers to be processed or added in portions to the furnace while the molten scrap metal is being poured out, until all the provided scrap metal is used up. Combined with correspondingly large-volume or high-mass electrodes, this enables the batch processing of large quantities of scrap metal into castings. In particular, the use of multiple storage containers for scrap metal allows for a relatively simple, cost-effective, and low-quality design of the installation technology (starter and storage container installation) while still enabling the processing of large quantities of scrap metal, even into high-quality castings, during the production cycle. Furthermore, scrap metal with varying titanium ratios can be stored in the storage containers, making it very easy to produce castings with different compositions by selectively choosing or using storage containers for individual castings, which are then produced in different casting molds.

[0006] In practice, this means that, using appropriate casting equipment, castings with a total weight of up to 18 tons can be produced in a single production cycle using multiple castings, whereas methods known in the prior art typically only allow for the production of a single large casting with a significantly lower weight, at a maximum of 6 tons. Due to the multiple storage containers used for scrap metal, the amount that can be extracted from the furnace is typically between approximately 500 kg and 2500 kg, but in any case less than 5000 kg, to facilitate easy or low-quality handling of the storage containers and the furnace. The weight of the produced casting consists of the weight of the electrodes and the weight of the scrap metal, minus the mass of the cold shell remaining in the furnace. This cold shell can be machined into electrodes or used as electrodes for subsequent melting processes.

[0007] In view of the above description, the method according to the invention for producing castings in a casting apparatus from titanium-containing scrap metal and consumable electrodes has the features of claim 1, thus providing the electrodes used, the scrap metal being stored in multiple storage containers in the storage space of the casting apparatus, the scrap metal being introduced from the storage containers into the furnace in partial or fractional amounts, and the amount extracted from the furnace being greater than 500 kg, preferably between 500 kg and 2500 kg.

[0008] "Partial" refers to the sequential and complete emptying of each storage container at once, and / or the continuous extraction of a portion of the scrap metal from a storage container.

[0009] Advantageous embodiments of the method according to the invention for producing castings from titanium-containing scrap metal are specified in the dependent claims.

[0010] As described above, it is particularly advantageous that the liquefied metal from the furnace is poured into at least one casting mold, at least between some filling processes of scrap metal from the storage container. This allows the use of furnaces with relatively small mass or relatively small volume, which reduces its handling in the melting chamber, and in particular reduces the requirements placed on necessary actuators, such as those for tilting to discharge the liquefied metal into the casting mold.

[0011] Furthermore, particularly preferably, during the melting process, scrap metal or any additives used to correct the composition of the metal are discharged into at least one trough-shaped furnace having an elongated elliptical shape, laterally close to an electrode that protrudes into the cross-section of the furnace. This has the advantage that the electrode does not need to be lifted or removed from the furnace to refill it with scrap metal, which simplifies the process and makes refilling with scrap metal or additives particularly easy. In particular, this means that the melting process in the furnace does not need to be interrupted during refilling with scrap metal, which is advantageous in terms of the desired melting process and the removal of unwanted components from the scrap metal, and thus can improve the quality of the casting. Furthermore, the elongated elliptical shape of the furnace has the advantage that a uniform temperature input occurs in the metal even with horizontal relative movement between the electrode and the furnace, because the electrode can also move at a constant distance from the furnace wall in each lateral (corner) region of the furnace.

[0012] Further or additional measures to improve quality involve using an electromagnetic stirrer to agitate the molten metal in the furnace. This particularly promotes the homogenization of the molten metal and improves the dissolution of low-density titanium nitride in the melt, which is not desirable on its own.

[0013] The melting process can also be improved or optimized by moving the furnace horizontally below the consumable electrodes during the melting process in order to homogenize the energy input via the electrodes. In particular, this is achieved by using a furnace with a long, elliptical cross-section, which has the effect that the electrodes gradually cover the entire cross-section of the furnace, thereby covering the scrap metal and molten metal contained therein, resulting in a uniform temperature input within the metal.

[0014] Another particularly preferred embodiment of the method provides the generation of a vacuum atmosphere in at least two sections separated from each other by a vacuum lock or similar mechanism, the first section for receiving a storage container in a storage space and forming a melting chamber, and the second section for receiving at least one casting mold in a pouring chamber. This allows castings produced in the pouring chamber to be removed from the pouring chamber and new casting molds to be introduced into the pouring chamber by connecting the pouring chamber to an external atmosphere, without removing the vacuum atmosphere from the melting chamber.

[0015] Another aspect of the invention relates to a requirement, particularly in the aerospace industry, where castings produced from molten scrap metal can be obtained from repeatedly melted metal in order to reduce unwanted components. To this end, the invention provides the production of castings using two electrodes, namely a first electrode and a second electrode, wherein the first electrode melts a first portion of the scrap metal at the start of the process, and the second electrode is formed from the casting produced using the first electrode and the scrap metal molten in a furnace designed for this purpose, meaning that the material of the first electrode and the scrap metal is subsequently completely melted again by the second electrode.

[0016] Furthermore, the present invention also includes a casting apparatus specifically configured to perform the method according to the invention as described above. The casting apparatus according to the invention includes a furnace having a cooled inner wall made of an inert material and for receiving scrap metal in a melting chamber. The inner wall includes a bottom region and side wall regions of the furnace. Further, mechanisms are provided for positioning consumable electrodes for melting the scrap metal, and storage space is provided for storing a plurality of storage containers for the scrap metal. A casting chamber is used to house at least one casting mold for receiving liquefied metal from the furnace. Further, a vacuum system is configured to evacuate the storage space, melting chamber, and casting chamber, and a feeding device is configured to transfer scrap metal from one of the plurality of storage containers to the furnace. Furthermore, the furnace has dimensions or volume that extracts more than 500 kg per extraction, preferably between 500 kg and 2500 kg.

[0017] To improve the handling of the casting mold in the casting chamber, at least the melting chamber and the casting chamber should be separated from each other or can be separated by a vacuum lock or similar mechanism to generate separate vacuum atmospheres.

[0018] If the furnace interacts with an electromagnetically operated stirrer used to melt the metal, then molten metal is obtained, and thus the castings also achieve a particularly uniform quality.

[0019] The scrap metal stored in multiple storage containers is preferably provided for discharge into the furnace by means of a mechanism on which the storage containers are configured to rotate about an axis on a shared pitch circle diameter. By rotating the mechanism about the axis, the storage containers to be emptied can be moved, for example, to be aligned with or near the furnace, or to be operatively connected to a conveying device, which may be formed by a downpipe, chute, etc. However, rotary roller conveyors or vibrating conveyors may also be used alternatively.

[0020] To enable the production of multiple or different castings from scrap metal, it is further preferred to arrange multiple casting molds in a single pouring chamber, with the platform configured to position the casting molds within the melting chamber. This allows molten metal to be discharged into the casting molds in question by simply pivoting or tilting the furnace around an inclined axis.

[0021] As explained at the beginning, the cooled inner wall of the furnace is designed to ensure that the relatively high-density components of the titanium-containing scrap metal and the electrodes (which, if possible, should not be present in the casting) accumulate or adhere there on the inner wall. To prevent the deposition or solidification of other liquefied metals used in the casting on the cooled inner wall, it is necessary to pour the liquefied metal from the furnace into the casting mold as quickly as possible to transfer as much liquefied metal from the furnace to the casting mold. For this purpose, the electrodes need to be lifted out of the furnace area before tilting or pivoting the furnace. To achieve this as quickly as possible, a preferred embodiment of the casting apparatus provides two separate actuators configured to move the electrodes to lift and / or immerse them in the furnace. The actuators include an electrically operated first actuator and a hydraulically operated second actuator. The first actuator is used for precise positioning of the electrodes in the furnace area for melting the scrap metal, and the second actuator has a significantly greater lifting speed than the first actuator.

[0022] Finally, the preferred configuration of the casting apparatus is characterized in that the melting chamber comprises a shell having an upper shell portion and a lower shell portion, which, when connected to each other, form diagonally separating planes. The upper shell portion is configured to move, together with a mechanism for positioning consumable electrodes, to a lateral position relative to the lower shell portion, and in this lateral position, to access the furnace disposed within the lower shell portion. In this lateral position, the furnace within the lower shell portion can be easily accessed.

[0023] Other advantages, features, and details of the invention will become apparent from the following description and drawings of preferred embodiments of the invention. Attached Figure Description

[0024] Figure 1A lateral longitudinal section view of a casting apparatus is shown, which is used to produce castings from titanium-containing scrap metal using consumable electrodes.

[0025] Figures 2 to 6 It shows the use of Figure 1 A schematic diagram showing the different time sequence steps in the production of castings using a casting apparatus. Detailed Implementation

[0026] In the figures, the same elements or elements with the same function are represented by the same reference numerals.

[0027] Figure 1 The casting apparatus 100 shown is used to produce castings 1, such as ingots, from titanium-containing scrap metal 2 using a consumable metal electrode 5, which also contains titanium. The scrap metal 2 is preferably prepared by crushing or grinding it into fragments, etc., so as to leave as little space as possible between the various parts of the scrap metal 2. The consumable electrode 5 contains titanium in a specific proportion to the remaining metal and can have a mass, for example, up to 8 tons. However, other masses or dimensions of the electrode 5 are conceivable depending on the application.

[0028] The casting apparatus 100 essentially has four functional zones 10-13. The first functional zone 10 forms a storage space 16 for accommodating multiple (e.g., ten) storage containers 18 for scrap metal 2. A second functional zone 11, laterally disposed adjacent to the first functional zone 10, includes columnar mechanisms 19 for accommodating, clamping, and positioning consumable electrodes 5. A third functional zone 12, disposed below the second functional zone 11 and laterally below the first functional zone 10, forms a melting chamber 20, in which at least one furnace 22a, 22b is disposed laterally. The at least one furnace 22a, 22b is composed of an inert material, particularly copper. A fourth functional zone 13 forms a pouring chamber 24, disposed below the third functional zone 12. At least one pouring mold 26, preferably multiple pouring molds 26, is disposed in the pouring chamber 24, particularly in the form of ingot molds, for forming castings 1 from scrap metal 2 and consumable electrodes 5. The volume or size of furnaces 22a and 22b allows them to produce casting or extraction volumes greater than 500 kg, preferably between 500 kg and 2500 kg, but in any case less than 5000 kg.

[0029] A vacuum atmosphere can be generated within the storage space 16, as well as within the melting chamber 20 and the casting chamber 24. For this purpose, these areas can be connected to a vacuum system 28, which... Figure 1The components are represented only by symbols and include necessary elements such as control valves and pipes. Furthermore, a horizontally adjustable vacuum-sealed door 30 is provided between the melting chamber 20 and the pouring chamber 24; when open, the vacuum-sealed door 30 forms a channel opening between the melting chamber 20 and the pouring chamber 24 for discharging molten metal from the furnaces 22a and 22b into the pouring mold 26. When the vacuum-sealed door 30 is closed, the pouring chamber 24 can be opened via a laterally movable clamping member 31 for the pouring mold 26 for removing the casting 1 or the pouring mold 26 or inserting a new pouring mold 26, during which time the external atmosphere then dominates in the pouring chamber 24. However, simultaneously, a vacuum atmosphere can continue to dominate in the melting chamber 20 and the storage space 16.

[0030] The clamping member 31, together with the side wall 32, forms part of the housing 34 of the casting chamber 24, and can be as follows: Figure 1 The pouring chamber 24 is opened by moving laterally in the direction of arrow 35. Inside the pouring chamber 24, a vertical platform 38 is provided, which is rotatable about a vertical axis 36. The pouring mold 26 can be placed on or removed from the vertical platform 38 by the lifting actuator of the clamping member 31. The vertical platform 38 is used to align the pouring mold 26, which can be filled with molten metal, with the vacuum-sealed door 30 and the furnaces 22a, 22b.

[0031] In addition, the vertical platform 38 can also be optionally used to mount additional components for the casting mold 26, such as rotators, electromagnetic stirrers, etc., known in the prior art.

[0032] The melting chamber 20 has a diagonally separated box-shaped housing 40, which is composed of two housing portions 41 and 42. When connected to each other, the two housing portions 41 and 42 form a diagonally separating plane 44. The lower housing portion 41 is fixed in place together with the housing 34 of the casting chamber 24. Conversely, the upper housing portion 42, together with the storage space 16 attached to the upper housing portion 42 and the mechanism 19 for the electrode 5, can be moved laterally according to arrow 46 to access the interior 45 of the housing 40.

[0033] Inside the shell 40, 45, furnaces 22a and 22b are mounted on a platform 50, which can be moved along... Figure 1 The platform 50 can move horizontally in the direction of the double arrow 48. Furthermore, the platform 50 can rotate around a direction perpendicular to the direction of the rotation arrow 52. Figure 1The axis of the drawing plane is tilted to allow for the pouring of molten metal from furnaces 22a and 22b. The metal is discharged via a funnel 53 aligned with the vacuum seal door 30 (when the vacuum seal door 30 is open) into a casting mold 26 aligned with the funnel 53. The horizontal mobility of the platform 50 is specifically used to align furnaces 22a and 22b with the electrode 5, and also to optimize the melting process.

[0034] exist Figure 1 In the illustrated embodiment, the furnace 22a has a circular cross-section, the inner diameter of which is typically only slightly larger than the outer diameter of the electrode 5 that can be immersed in the furnace 22a. Conversely, Figures 2 to 6 The furnace 22b has a groove-shaped cross-section with an elliptical, elongated, or rectangular cross-section, and its maximum internal length can, for example, correspond to twice its internal width. The internal width of the furnace 22b corresponds to the inner diameter of the furnace 22a. The elongated elliptical cross-section of the furnace 22b has two parallel sidewalls with semi-circular edge regions.

[0035] When processing titanium-containing scrap metal 5, furnaces 22a and 22b are specifically equipped with cooling devices (not shown) in the form of water-based cooling mechanisms, which cool the inner walls 55, particularly the bottom and inner walls 55, or the side walls of furnaces 22a and 22b to a temperature below the melting point of scrap metal 5. Such cooling devices on furnaces 22a and 22b are known in the prior art (US6,006,821). This causes components of scrap metal 2 and electrode 5 with a higher density than the rest of scrap metal 2 (which are undesirable in the casting 1 to be formed) to sink to the inner walls 55 or bottom during the melting process, or to accumulate on the side walls and solidify there, forming a shell-shaped metal layer 7 (called a cold shell), so that the material of the metal layer 7 is not poured into the casting mold 26 or does not enter the casting mold 26.

[0036] Furthermore, furnaces 22a and 22b can be configured to be operationally connected to an electromagnetic stirrer 56, which is also located on platform 50, in order to specifically improve the quality or uniformity of the molten metal.

[0037] The storage container 18 for scrap metal 2, located in storage space 16, is preferably mounted on a turntable-shaped mechanism 58 (only on...). Figures 2 to 6 As can be seen in the image, mechanism 58 can rotate about a vertical axis of rotation 59. This allows the storage container 18 to be emptied to be aligned with the conveying mechanism 60. Figure 1 The conveying mechanism 60 shown in a simplified form can be designed as an inclined drop tube or chute, which discharges the scrap metal 2 into the furnaces 22a and 22b in the direction of arrow 62 by gravity.

[0038] The mechanism 19 for receiving, clamping, and positioning the consumable electrode 5 has an electrode space 64 for receiving the electrode 5; the electrode space 63 is connected to the melting chamber 20, so that the vacuum system 28 can also establish or generate a vacuum atmosphere in the electrode space 64. The cylindrical electrode 5 is connected to the lifting mechanism 70 via a support rod 66, which passes through the electrode space 64 in a sealed manner in the area of ​​the upper wall 67. The lifting mechanism 70 has two independently controllable actuators 72, 74, both of which can vertically move the support rod 66, and thus vertically move the electrode 5. The first actuator 72 is designed as an electric actuator and is used for fine adjustment or positioning of the electrode 5 relative to the scrap metal 2 during the melting process, and in particular for generating and maintaining an electric arc for melting the scrap metal 2 when different voltage potentials are applied to the electrode 5 and the scrap metal 2, as is known in the prior art and therefore will not be further explained. The second actuator 74 is designed as a hydraulic actuator, enabling the electrode 5 to have a significantly greater lifting speed than the first actuator 72, for example, at least ten times the lifting speed of the first actuator 72. The second actuator 74 is used to lift the electrode 5 from the inclined region of the furnaces 22a and 22b as quickly as possible before the liquefied metal is poured out of the furnaces 22a and 22b, so as to prevent or minimize the solidification of the liquefied metal on the inner wall 55.

[0039] The following reference Figures 2 to 6 The operating mode of the casting apparatus 100 described above is explained using the trough-shaped cooling furnace 22b in the following order: In order to... Figure 2 In preparation for the production process, the storage containers 18 in storage space 16 are filled with scrap metal 2, for example, by filling each of the ten storage containers 18 with 500 kg of scrap metal. The furnace 22b is also filled with an initial amount of scrap metal 2, for example, 1200 kg. An electrode 5 is positioned via mechanism 19. It has a mass, for example, of approximately 8000 kg. The mass of the electrode 5 is matched to the mass of the scrap metal 2 in the storage containers 18 and the furnace 22b in such a way that the electrode 5 can completely process or melt all the scrap metal 2 during the production process. Furthermore, three casting molds 26 are provided in the casting chamber 24; for example, two casting molds 26 are used to produce castings 1 or ingots each weighing 2500 kg, and one casting mold 26 is used to produce castings 1 or ingots weighing 8000 kg.

[0040] The subsequent casting mold 26 used to produce casting 1 weighing 8000 kg can also be specifically used to produce another electrode 5. This means that the material of the electrode 5 is remelted in subsequent production processes, which improves the quality or material composition of casting 1, especially considering the requirements of the aerospace industry.

[0041] Once the above preparations are completed, the vacuum system 28 generates a vacuum atmosphere in the storage space 16, the melting chamber 20, and the casting chamber 24.

[0042] Then, as Figure 3 As shown, electrode 5 is lowered into furnace 22b to generate an electric arc, and scrap metal 2 is melted using electrode 5. Electrode 5 is partially consumed and its mass is reduced by, for example, 1800 kg during the process. To optimize the melting process, electrode 5 is moved by first actuator 72 during the melting of scrap metal 2, and furnace 22b is moved horizontally by platform 50 to achieve optimal coverage between electrode 5 and scrap metal 2. Electromagnetic stirrer 56 (if present) can also be activated. During the melting process, the relatively high-density component of titanium, which is undesirable in casting 1, sinks into furnace 22b or solidifies on the cooled inner wall 55 of furnace 22b, while the relatively light, undesirable titanium component dissolves in the molten metal through the optimized melting process.

[0043] Once the initial amount of scrap metal 2 has been completely melted, electrode 5 is rapidly lifted out of furnace 22b by the second actuator 74, as follows: Figure 4 As shown, liquefied metal is poured into a casting mold 26 through a tilting furnace 22b. Figure 4 The solidified metal layer 7 (cold shell), which has been produced by the cooled inner wall 55 and mainly contains the undesirable component of titanium, remains in the furnace 22b.

[0044] Then, as Figure 5 As shown, for example, when electrode 5 is lifted, scrap metal 2 is discharged from a storage container 18 into furnace 22b. This process is then repeated. Figures 3 to 5 The steps shown continue until all storage containers 18 have been emptied, i.e., casting 1 has been produced.

[0045] Figure 6 The image shows the final liquefied scrap metal 2 being poured into the final casting mold 26. Furthermore, it can be seen that electrode 5 has been consumed, except for the unusable final short stub.

[0046] It should also be mentioned that the figures depict and illustrate filling the furnace 22b from the storage container 18 after the liquefied scrap metal 2 has been poured out. However, within the scope of the invention and even proven advantageous, it is preferable to add the scrap metal 2 from the storage container 18 at least partially during the melting process of the scrap metal 2 itself. For this purpose, particularly when using the furnace 22b, the electrode 5 can be moved via the platform 50 to a region of the side wall of the furnace 22b, thereby creating sufficient space or clearance on that side for discharging the scrap metal 2 from the storage container 18 into the furnace 22b. This means that the melting process does not need to be interrupted; rather, refilling can be carried out during the melting process itself.

[0047] Without departing from the spirit of the invention, the casting apparatus 100 and the method for producing casting 1 from titanium-containing scrap metal 2 and titanium-containing electrodes 5 can be modified or altered in various ways. Therefore, the use of the casting apparatus 100 is not limited to processing titanium-containing scrap metal 2 and electrodes 5. In fact, it can also process other metals or different types of scrap metal 2.

[0048] Figure Labels 1 casting 2 scrap metal 5 electrodes 7 metal layers Functional areas 10-13 16 storage spaces 18 storage containers 19 institutions 20 melting chambers Furnaces 22a and 22b 24 casting chamber 26 casting mold 28 Vacuum System 30 Vacuum-sealed door 31 clamping parts 32 sidewalls 34 housing 35 arrow 36 axis 38 vertical platform 40 housing 41, 42 Shell parts 44 Separation plane 45 Internal 46 arrows 48 double arrows 50 platform 52 Rotating Arrows 53 funnel 55 Inner Wall 56 Mixer 58 organizations 59 Rotation axis 60 transmission mechanism 62 arrows 64 electrode space 66 support rod 67 walls 70 Lifting Organization 72, 74 drives 100 casting equipment.

Claims

1. A method for producing a casting (1) from titanium-containing scrap metal (2) and consumable electrodes (5) in a furnace (22a; 22b) made of an inert material within a casting apparatus (100), the casting apparatus (100) comprising a pouring chamber (24) for placing at least one pouring mold (26) therein for receiving liquefied metal from the furnace (22a; 22b), a vacuum system (28) configured to evacuate a storage space (16), a melting chamber (20), and the pouring chamber (24) for producing the casting (1). The electrode (5) and the scrap metal (2) are melted in the furnace (22a; 22b) under a vacuum atmosphere in the melting chamber (20). The scrap metal (2) is introduced into the furnace (22a; 22b) from at least one storage container (18). Using the furnace (22a; 22b) with a cooled inner wall (55), the components of the molten metal partially solidify on the inner wall (55) and form a metal layer (7) thereon. The liquefied metal is poured from the furnace (22a; 22b) into at least one casting mold (26) for the production of the casting (1). Its features are, Using consumable electrodes (5) made of titanium, the scrap metal (2) is stored in multiple storage containers (18) in the storage space (16) of the casting apparatus (100), the scrap metal (2) is introduced into the furnace (22a; 22b) in portions from the storage containers (18), and the amount extracted from the furnace (22a; 22b) is greater than 500 kg, preferably between 500 kg and 2500 kg.

2. The method according to claim 1, Its features are, Between at least some filling processes of the scrap metal (2) from the storage container (18), liquefied metal is poured from the furnace (22a; 22b) into the at least one casting mold (26).

3. The method according to claim 1 or 2, Its features are, During the melting process or between pouring into the at least one casting mold (26), the scrap metal (2) is introduced into at least one trough-shaped furnace (22b), the furnace (22b) having an elongated elliptical shape and being laterally close to the electrode (5), the electrode (5) protruding into the cross-section of the furnace (22b).

4. The method according to any one of claims 1 to 3, Its features are, An electromagnetic stirrer (56) agitates the molten metal located in the furnace (22a; 22b).

5. The method according to any one of claims 1 to 4, Its features are, During the melting process, the furnace (22a; 22b) moves horizontally below the consumable electrode (5).

6. The method according to any one of claims 1 to 5, Its features are, The vacuum atmosphere is generated in at least two sections separated from each other by a vacuum lock (30) or similar mechanism. The first section is used to receive the storage container (18) in the storage space (16) and form the melting chamber (20). The second section is used to receive the at least one casting mold (26) in the casting chamber (24).

7. The method according to any one of claims 1 to 6, Its features are, The casting (1) is produced using two electrodes (5), wherein the first electrode (5) melts a first portion of the scrap metal (2) at the start of the process, and the second electrode (5) is formed from the casting (1), which is produced by the first electrode (5) and the scrap metal (2) melted in a furnace designed for this purpose, meaning that the material of the first electrode (5) and the scrap metal (2) is subsequently completely melted again by the second electrode (5).

8. A casting apparatus (100), preferably configured to perform the method according to any one of claims 1 to 7, the casting apparatus (100) comprising: A furnace (22a; 22b) having a cooled inner wall (55) made of an inert material and for receiving scrap metal (2) in a melting chamber (20); a mechanism (19) for positioning an electrode (5) for melting the scrap metal (2); a storage space (16) for storing a plurality of storage containers (18) for the scrap metal (2); and a casting chamber (24) for placing at least one casting mold (26) therein for receiving scrap metal (2). The furnace (22a; 22b) contains liquefied metal; a vacuum system (28) configured to evacuate the storage space (16), the melting chamber (20), and the casting chamber (24); and a feeding device (58, 60) configured to transfer the scrap metal (2) from one of the plurality of storage containers (18) into the furnace (22a; 22b), and the furnace (22a; 22b) has dimensions or volume for a discharge volume greater than 500 kg, preferably between 500 kg and 2500 kg.

9. The casting apparatus according to claim 8, Its features are, At least the melting chamber (20) and the casting chamber (24) are separated from each other or can be separated by a vacuum lock (30) or similar mechanism to generate separate vacuum atmospheres.

10. The casting apparatus according to claim 8 or 9, Its features are, The furnace (22b) is configured to be horizontally displaced within the melting chamber (20).

11. The casting apparatus according to any one of claims 8 to 10, Its features are, The furnace (22a; 22b) interacts with the electromagnetic stirrer (56).

12. The casting apparatus according to any one of claims 8 to 11, Its features are, The storage container (18) is disposed on the mechanism (58) and is configured to rotate about an axis (59) on a shared pitch circle diameter.

13. The casting apparatus according to any one of claims 8 to 12, Its features are, Multiple casting molds (26) are arranged in a casting chamber (24), and a platform (38) is configured to position the casting molds (26) relative to the melting chamber (20).

14. The casting apparatus according to any one of claims 8 to 13, Its features are, Two separate actuators (72, 74) are configured to move the electrode (5) in or from the furnace (22a; 22b), the actuators (72, 74) comprising an electric first actuator (72) and a hydraulic second actuator (74), the first actuator (72) being used for fine positioning of the electrode (5) in the region of the furnace (22a; 22b) during the melting process, and the second actuator (74) having a greater lifting speed than the first actuator (72).

15. The casting apparatus according to any one of claims 8 to 14, Its features are, The melting chamber (20) includes a shell (40) having an upper shell portion (41) and a lower shell portion (42) that form a diagonal separation plane (44) when connected to each other, and the upper shell portion (42) is configured to move together with the mechanism (19) for positioning the electrode (5) to a lateral position fixed in place of the lower shell portion (41), and to be able to enter the furnace (22a; 22b) disposed in the lower shell portion in the lateral position.

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