Karl Schwenk

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Electromagnetic Caster Stirrer designs

Electromagnetic caster stirrer designs vary depending on use

Electromagnetic stirrers for steel applications produce very low frequency, high amplitude magnetic fields to agitate steel when molten. Steel applications include ladle stirring and stirring in continuous cast steel for alloy integrity. Always under water during operation, cooling water wicks the heat away from these induction coil sets. Depending on how the stirrer is used…

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Promote better induction power cable coolant flow by building in a Constant Flow Ring (CFR) into your swivel nut terminal design

Induction power cable terminal design options

Metal casting power needs are as varied as each induction melt system and application. The good news is you've got power cable design options! The industry standard is a conventional crimped, swivel nut design. At I2r POWER we recommend promoting better coolant flow by building into this design a Constant Flow Ring (CFR). A CFR…

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I2r Rack of products

Keep Your EAF/LMF Power Cable Spares Ready for a Really Bad Day

The unthinkable has just happened. You got the word that a power cable needs to be replaced, and NOW! So…where are the spares? Are they in the storeroom? Behind the furnace? Outside in the yard? Here's what I'm hoping you'll find: Spare cables are laying flat in stackable trays or suspended vertically to maintain wire…

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Terminal flare end of induction power cable

How to measure your power cable length

There's more than one way the industry measures induction power cables, unfortunately creating confusion. Some measure the hose length. We prefer to go with the overall length, and by that we mean we measure from copper terminal flare to the terminal flare edge on the other side of the cable. This flare-to-flare method is an…

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Tightening or loosening fittings on an induction power cable is a job for two wrenches

How much torque to apply when installing induction cables?

How much torque to apply when installing induction cables Often we’re asked for recommendations when tightening or loosening fittings on an induction power cable. First, this is a job for two wrenches! And, depending on your connection, be sure to avoid tightening or loosening soldered pipe threads. Here is the procedure for applying torque to…

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I2r POWER engineers designed a 14,000MCM EAF rotating terminal assembly for what might be the largest EAF power cable in North America

Notable Project: Enormous CMC Steel-Sayreville EAF power cable

CMC Steel – Sayreville, NJ Massive Rotating Terminal Design Problem: The customer needed to enhance the longevity of their EAF power cable and mitigate hose binding during operation. Solution: In what might be the largest EAF rotating terminal assembly built in North America, our engineers custom designed a 14,000 MCM terminal assembly measuring 27.25” with…

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A new weldment of high-grade corrosion-resistant stainless alloy was designed and built to stop corrosion on this electromagnetic caster stirrer

Notable Project: TimkenSteel – Harrison Mill Final Stirrer

TimkenSteel - Harrison Mill Final Stirrer Problem: Caustic flux powder used in the continuous casting process was violently attacking the carbon steel weldment of TimkenSteel's electromagnetic final stirrer. Solution: A new weldment of high-grade corrosion-resistant stainless alloy was designed, built and fabricated to stop corrosion. It's not out the door yet, because we're storing it…

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In the workshop

Notable Project: CarTech’s Dual Station ESR Furnace bus tubes

Carpenter Technologies - Latrobe, PA Problem: The retrofit and rebuild of Carpenter Technologies’ dual station ESR furnace bus tubes took some finesse. The ESR is an older furnace built circa 1960, and consequently sourcing spare components and the craftsmanship to perform the work is difficult. Solution: The replacement bus tube components arrived at the customer’s…

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DC Reactor Coils

Notable Project: Gerdau Long Steel – St. Paul DC reactor coils

Gerdau Long Steel - St. Paul, MN Problem:  Our customer’s existing DC reactor coils were beginning to leak coolant, and the OEM, General Electric, no longer supported the equipment. Gerdau Long Steel could not continue to operate their DC electric arc furnace with their existing coils, and were having difficulty solving their problem. Solution: The…

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