MELTING PROCESS

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MELTING Process
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Introduction

• The preparation of molten metal for casting is
  referred to simply as melting.
• Casting processes involve the use of molten
  material, usually metal.
• This molten material is then poured into a mould
  cavity that takes the form of the finished part.
  The molten material then cools, with heat
  generally being extracted via the mould, until it
  solidifies into the desired shape.

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Procedures for melting operation
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Melting

• Melting, also called fusion, is a transition
  process that changes metal material status from
  solid to liquid by providing enough heat.
• Melting, or fusion, is a physical process that
  results in the phase transition of a substance
  from a solid to a liquid.
• Chemical changes involve either absorption of
  heat or the release of heat. So melting is an
  endothermic process.

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Coreless induction furnace

• Coreless induction furnaces are widely used in
  steel and alloy production due to
  their flexibility and handling capabilities.
• The magnetic field induces eddy currents,
  circular electric currents, inside the metal, by
  electromagnetic induction.

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Induction furnace

• An induction furnace is an electrical furnace in
  which the heat is applied by induction heating of
  metal. Electric induction furnace is type of
  melting furnace that uses electric current to
  melt the metal.
• Induction furnaces are used in most modern
  foundries as a cleaner method of melting metals.
• The basic Principle induction furnace is a
  induction heating.

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Figure
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Refractories
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Induction furnace units

• Transformer unit
• Crucible unit
• Cooling unit
• Hydraulic unit

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Transformer

• Based on the capacity of the power sharing it can
  be classified into two types
• Mono track
• A two furnace installation will have a single
  power pack and either changeover switch is
  provided.
• Dual tack
• It is a power sharing that is where the one could
  be run at full power and no full power is
  supplied to second furnace but it holds the power
  level and keeps in a certain temperature.

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Stirring

• Once the molten is occurred, the high frequency
  magnetic field is produced.
• So it can also be used to stir the hot metal,
  which is useful in ensuring that alloying
  additions are fully mixed into the melt.
• This process is called electromagnetic stirring.

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Thermocouple

• An electrical device for high-temperature
  laboratory furnaces.
• We are using type R and type S for measuring
  temperature.

Type R Type S
Platinum - 87 Rhodium - 13 Platinum - 90 Rhodium - 10
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Chemistry control

• There are two types of chemical control by
  physical and chemical reaction method.
• In physical method they are classified into two
  types
• Adding
• Dilution
• Adding means by adding the elements.
• Dilution means removing the excess elements in
  the molten metal.
• So, we are making chemistry low as possible.

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Load calculation

• Charge calculation
• (Aim Actual) Furnace capacity/Recovery
• For example
• In WCB the carbon percent is 0.25 but actual
  present is 0.15. So, we need the charge
  calculations.
• C (0.25-0.15)3000/100
• C3kg

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• Thank
• you