At Special Melted Products, everything starts with melting. It’s the very first and one of the most critical stages in our manufacturing process – where precision, expertise, and innovation come together to create the high-integrity alloys that our customers rely on across aerospace, oil & gas, nuclear and defence sectors.
Melting isn’t just about turning metal into liquid; it’s about control, integrity, and consistency. At SMP, our state-of-the-art meting facilities ensure that every heat meets the highest standards of quality and performance. This is where the journey begins – transforming carefully selected raw materials into premium quality alloys that form the foundation of everything we produce.
Primary Melting: Precision from the Start
Our melting operations begin with primary melting carried out in two world-class vacuum furnaces:
- Vacuum Induction Melting (VIM):10-ton capacity
- Vacuum Induction Degassing and Pouring (VIDP): 6-ton capacity
These furnaces allow us to melt under vacuum conditions, providing exceptional control over temperature, chemistry, and cleanliness, The vacuum environment prevents contamination from atmospheric gases such as oxygen and nitrogen, ensuring the production of exceptionally clean steels.
Secondary Remelting: Refining for Perfection
Once the primary melt is complete, the electrode undergoes secondary Remelting to further remove impurities and enhance chemical homogeneity. SMP operates a range of advanced remelting facilities, including:
- Vacuum Arc Remelting (VAR): 2 x 10-ton and 3 x 20-ton furnaces
- Electroslag Remelting (ESR): 1 x 10-ton and 1 x 20-ton furnaces
Each process serves a distinct purpose:
- VAR removes dissolved gases by melting under high vacuum and enhances chemical homogeneity and structural integrity through directional solidification.
- ESR melts the electrode using a molten metal-oxide flux. Inclusions are removed by chemical reaction as metal droplets travel through the molten flux.
- Some alloys used in safety critical applications require the use of VIM, ESR and VAR to combine the benefits of each process.
These advanced remelting techniques ensure our alloys achieve the exceptional levels of purity and performance that SMP is known for worldwide.
People and Precision Working Together
Behind every successful melt is a highly skilled team of metallurgists, furnace operators, and engineers. Their expertise, attention to detail, and commitment to safety are what makes SMP’s melting operations world-class.
Working with molten metal at temperatures exceeding 1600◦C requires not only advanced technology but also precision, teamwork, and a deep understanding of the process. From charging the furnace to pouring and analysis, every step is carefully executed to maintain consistency and ensure product excellence.
Setting the Standard for Quality
At SMP, melting is more than just the first stage of production – it’s where quality is built from the very beginning. Through continual investment in our equipment, processes, and people, we ensure that each melt delivers steel with the integrity and reliability our customer’s trust.
Melting is where every products journey begins – and at SMP, it’s where we set the standard for everything that follows.
