Titanium Ingot Manufacturing – Triple VAR Process for High Purity and Uniformity

Titanium Ingot Manufacturing – Triple VAR Process for High Purity and Uniformity

Overview
Titanium ingots, whether commercially pure or alloyed, are produced by melting high-quality titanium sponge. For titanium alloys, additional alloying elements are precisely added. Due to titanium's high reactivity with oxygen, nitrogen, and carbon at elevated temperatures, the melting process is conducted under vacuum or inert atmosphere conditions to avoid contamination.

At Bokang Titanium, we utilize the Triple Consumable Electrode Vacuum Arc Remelting (Triple VAR) method — the most trusted industrial process for ensuring consistent chemistry, dense structure, and ultra-low impurity levels in titanium ingots. The melting takes place in a water-cooled copper crucible, preventing interaction with refractory materials and ensuring a clean melt.

Titanium Ingot Manufacturing Process

First Melt – Electrode Assembly & Initial Arc Melting

The production starts with pressing titanium sponge and clean titanium scrap into compacts, which are then joined into a large electrode via plasma arc welding. This electrode is melted in a vacuum arc remelting (VAR) furnace. As the arc is struck between the electrode and the crucible, the titanium melts gradually and solidifies into the first melt ingot, ensuring minimal contamination and structural cohesion.

Second Melt – Refinement and Homogenization

The first melt ingots are reprocessed as electrodes, then remelted under the same controlled vacuum conditions. This step improves chemical uniformity, removes further inclusions, and enhances metallurgical quality.

Third Melt – Final Purification and Integrity Assurance

To achieve superior internal quality and repeatable consistency, a third vacuum arc remelting is carried out. This final melt significantly reduces trace elements such as Fe, C, H, N, and O, delivering titanium ingots with premium characteristics required for demanding sectors.

Advantages of Triple VAR Titanium Ingots

• Ultra-low impurities and superior homogeneity

• Dense, defect-free structure ideal for high-performance applications

• Customizable alloy compositions based on industry requirements

• Consistent quality control after each melt stage

• Large-size ingots available (up to 10 tons)

Typical Applications

Our titanium ingots are trusted across industries including:

• Medical: Orthopedic implants, surgical instruments, dental devices

• Aerospace: Engine components, fuselage structures, space systems

• Chemical Processing: Reactors, heat exchangers, corrosion-resistant piping

• Power Generation: Components for nuclear and thermal power plants

• Marine & Desalination: Sea water corrosion-resistant equipment

Reliable Titanium Ingots for Global Industries

Bokang Titanium specializes in high-integrity titanium ingot production for global clients. We support customized melting compositions and provide full documentation to meet ASTM, ISO, and AMS standards.

Contact us today for technical consultations or a custom quote.