Combining our skilled workforce with the world’s most advanced equipment gives you an exceptionally reliable product, backed by the best warranty in the business.
Our products are used in applications that demand the most stringent requirements for cleanliness, strength, fatigue and impact toughness. We manufacture our steel using a state-of-the-art 50-ton electric arc furnace (EAF), ladle refining, and vacuum degassing equipment. The EAF is dedicated to fast melting, and the ASEA-SKF split secondary steelmaking unit is used only for refining. Advanced ladle metallurgy techniques produce ultra-clean steels with minimal chemistry variation in all grades.
This tight control in the melt shop means we can produce custom-designed chemistries for special applications. The very low sulfur and oxide content allows for excellent machining and polishing characteristics. Supplemental VAR and ESR re-melting are also available for applications demanding an even higher level of quality.
First, scrap is loaded into clam-shell buckets and charged into an ultra-high powered (UHP) eccentric bottom-tapping (EBT) electric arc furnace. After the scrap is melted, carbon and phosphorus are removed under an oxidizing slag. Steel is then tapped slag-free into a preheated ladle. During tapping, deoxidation and alloy additions are charged, followed by a reducing top slag.
The ladle is transferred to one of two refining stations for alloy adjustment and refining. Arc heating and induction stirring at this step ensure homogenous mixing and interaction of steel and slag.
The ladle is then transferred to a vacuum degassing station whereby hydrogen can be removed to a level of less than 1ppm. Combined induction and argon gas bubbling are used during vacuum treatment.
Heats are sent to teem at a consistent pre-designated temperature. All ingots are bottom-poured at a controlled rate of rise. A teeming car is used to enable faster turnaround. Argon shrouding is employed to minimize reoxidation and pick-up of nitrogen and hydrogen.
Our forging facilities comprise four hydraulic presses, automated forge heating furnaces, manipulators, and auxiliary equipment. Knowledgeable, dedicated employees oversee every aspect of the manufacturing process to give you predictable, precise products manufactured in a fraction of the time normally required.
Heat Treating and Machining
Under the watchful eyes of skilled operators working to meet your exacting specifications, thermal treatments maximize the properties of forged steel. Employing a sophisticated workflow model, steel is cycled through the thermal treatment process required to meet the metallurgical demands of your final application. This can include quenching in agitated water or polymer baths, tempering, annealing, normalizing, and stress relieving. We maintain one of the industry’s most extensive selections of machining equipment and systems to ensure that you get the degree of finishing you require.
With our rigorous testing and attention to detail, the quality you demand is built right in. Our specialty steels undergo testing throughout all stages of manufacture, often beyond your requirements. We perform:
- Chemical analysis
- Mechanical testing
- Nondestructive testing, including Level III ultrasonic
- Liquid penetrant and magnetic particle testing
- Dimensional inspection.
Rest assured, at Ellwood Specialty Steel we’re totally committed to quality. With manufacturing facilities certified to ISO 9002, our products adhere to standards of a world-recognized quality management system.