Ross & Catherall is the world leader in the development and production of continuously cast vacuum superalloys in barstock. This technique allows superalloys, vacuum melted and refined in the traditional manner, to be cast continuously in diameters ranging from 32 to 100 mm (1.25 – 3.94 in.)
The continuous casting process involves the melting of superalloys in a VIM furnace but, instead of being cast vertically, the liquid metal is cast horizontally in a single continuous bar.
During this process the alloy is bottom-poured from the furnace which means that the alloy produced is extremely clean. Further benefits of continuously cast superalloy include improved surface finish which eliminates the need for grinding, an absence of centreline porosity, and reduced waste when cut to weight.
Superalloy barstock made by this process is routinely supplied into the automotive sector for the manufacture of turbocharger wheels and into the medical sector for the manufacture of prosthetic implants.
Additionally, a number of nickel and cobalt alloys used in the aerospace and power generation sectors can be readily produced by this process.
Selected continuously-cast products have been approved by leading aero-engine manufacturers, including Rolls-Royce.