Villares Metals' production of special steel begins with the melting process (scrap and alloys), followed by liquid steel treatment, which is then solidified in predefined formats. At this stage, the process follows these steps:

• Electric Arc Furnace

Responsible for heating and thus melting the metal load, followed by liquid metal treatment and removal of undesirable elements, such as phosphorus.

• Ladle Furnace

Place where it is possible to control the temperature of the liquid metal and, through inert gas injection, to thermally homogenize the metal and all iron alloys added to formulate the desired steel. At the same time, the secondary refining takes place, meanwhile, deoxidization and desulfurization occur.

• Vacuum treatments

Used to modify the thermodynamic conditions and to ensure the control of chemical reactions, thus avoiding oxidation of some elements, for instance, and increasing process performance. This step ensures the liquid metal will have excellent thermal and chemical homogeneity, making it ready for casting, that is, poured into molds and solidified.

• Conventional casting

This process uses cast iron ingot molds, which serve as molds for liquid steel solidification. When the material is removed, ingots are hot forged or rolled.

• Continuous casting

Alternative process that goes through a distributor (Tundish), followed by a water-cooled mold (fitted with a roller system) and a billet cutting and adjustment system. Finally, the material is cut in predetermined sizes and then hot rolled.