In arc-melting zirconium metal with a tungsten electrode, tungsten appears in nonuniform anmunts throughout the ingot. To eliminate this, the use of consumable electrodes of zirconium sponge is proposed. All earl)" attempts to use sponge zirconium electrodes were unsuccessful due to instability of the are. This problem was solved by stabilizing the are with a small amount of magnesium metal added to the zirconium sponge used in making up the electrodes. A water-cooled copper sleeve was used as a melting section in the are-melting furnace. Melting was done under an inert atmosphere of argon or helium. Metallographic and radiographic studies show the finished ingots to be sound.
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