Truck Castings

9 MT 8000 kW Steel Shell Furnaces

Automotive Castings
20 MT 15,000 kW Steel Shell Furnaces

Heating & Heat Treating

Finished Goods

Induction Heater

65 MT Channel Holding Furnace

Meltminder Charge Material Batch Make-up

Noise-Limiting Charge Conveyors

Meltminder Computer Control

Camshaft Heat Treatment

Crankshaft Heat Treatment

Water System Valves

10 MT 9000 kW Multi-Trak Furnaces

Pipe Connectors
9 MT 7000 kW Steel Shell Furnaces

Pipe Caster
150 MT Channel Holding Furnace

Triple-Output Induction Power Unit

Automatic Pouring for Gray & Ductile Iron

Charge Loading System

Automatic Pouring for Gray & Ductile Iron

Mini-Heel Holding Furnace

Automated Pressure Pour

Thin-Walled Castings
1 MT 750 kW Dura-Line Furnaces

Prototype & Lab Castings

2 kg 35 kW Mini-Melt Hand Tilt Furnaces

Tool Castings
4 MT Steel Shell Furnaces

Dura-Line Furnace

Dual-Output Induction Power Supply

Small Dura-Line Furnace

35kW Induction Power Supply

Small Steel Shell Furnace

Automatic Pouring For Continuously Moving Lines

Casting for Transportation & Heavy Machinery

Drying & Charging Melting Alloying Pouring

A 20 MT 16.5 MW heavy steel shell induction furnace supplies iron for the worlds leading agricultural equipment manufacturer. Inductotherm, with more than 15,000 installations worldwide, is the leading manufacturer of induction melting systems. Its high power density, heavy steel shell coreless furnaces and efficient VIP power supplies are leading a productivity revolution in high-production foundries. Together with Inductotherm automation technologies for material charge drying/preheating, furnace charging, alloy batch preparation, computer control, fume collection and lining removal, these systems are

An inductively heated pressure vessel holds gray or ductile iron for a precise Visipour stopper-rod automatic pouring system. increasing casting production while reducing energy and labor costs. On the mold line, Inductotherms high-speed automated pouring systems include both unheated tundish units and inductively heated pressure pour furnaces for gray and ductile iron. These designs feature adaptive and precise stopper-rod pouring mechanisms for lines pouring in excess of 400 molds per hour.

Foundries serving the automotive/trucking, construction/agricultural equipment, rail and marine industries are typically high production facilities. For both high production and high quality, these foundries rely on Inductotherm melt shop and automatic pouring systems. Clean and efficient, high power density induction systems are replacing not only older induction furnaces, but also cupola and arc furnaces.

Dryers and preheaters enhance charging safety and may reduce energy costs.

This automated charging system uses conveyors with noise reduction technology.

An automated hopper system uses computer control to assemble ferro-alloy adds.

Melting Power & Control Furnace Options

Casting for Transportation & Heavy Machinery

A dual-output induction power supply allocates power between these two furnaces for a continuous supply of metal. Inductotherm dual-output and multiple-output induction power supplies enable foundries to optimize the flexibility and efficiency of their melting operations by increasing power supply utilization approaching 100 percent. These systems also help foundries use power more efficiently for melting and holding without increasing electric utility demand charges. Inductotherm Meltminder computer systems allow

A back-slagging feature makes slag removal more effective in large furnaces, while a fume collection cover reduces emissions. furnace operators to manage melting operations more precisely and safely while automating the collection of key performance data. Heavy steel shell furnaces, including wide-bodied designs, minimize coil deformation; Inductoflex coil insulation minimizes the chance of coil arcing. Hydraulic furnace lining removal systems make lining replacement faster and cleaner.

Advanced technologies for the efficient operation of large systems for melting and holding gray, ductile and malleable iron are helping high-production foundries compete globally. Inductotherm induction melting systems from 2500 kW to 16,500 kW applying up to 1000 kW per ton of furnace capacity, have been installed in more than 1000 high production foundries

Meltminder computer systems offer the furnace operator a familiar Windows OS interface.
Windows is a registered trademark of Microsoft Corporation.

Wide-bodied furnaces allow foundries to use larger, lower-priced scrap.

Inductoflex II coil insulation helps reduce coil arcing caused by metallic debris or splash.

worldwide.

Casting for Infrastructure

Drying & Charging Melting & Holding Fume Collection Remote Slagging

This integral fume collection furnace cover helps a municipal casting foundry comply with MACT emission standards. Inductotherm customers melt substantial quantities of metal to produce gray and ductile iron pipes, pipe fittings and connectors, municipal castings, electrical boxes and other infrastructure castings. Inductotherm scrap drying and automated charging systems enhance safety and keep pace with melting operations. High-capacity heavy steel shell coreless melting furnaces, Mini-Heel coreless holding furnaces and channel holding furnaces

A major supplier of petro-chemical industry castings pours ductile base iron into a treatment ladle. assure a steady supply of on-specification molten iron. Integral fume collection covers help with local air pollution compliance. Back-slagging features or automated clamshell collectors provide fast and effective slag removal. Inductotherm melt shop and automatic pouring systems, like infrastructure castings themselves, are built for rugged durability, practical maintenance and long service life.

Inductotherm Group customers make the iron castings that support the worlds infrastructure. Iron pipes bring water and carry away waste. Iron fittings, valves and pumps form the backbone of the petro-chemical industry. Municipal castings protect and provide access to the infrastructure beneath towns and cities. Electric power infrastructure equipment uses a wide variety of iron components.

A remotely controlled grappler is used to load scrap into charge weigh hoppers.

The magnet operator also runs the scrap dryer at this electric component foundry.

Hydraulically operated slag collectors are effective for large furnaces.

Metal Holding Automatic Pouring

Casting Production for Infrastructure

A tundish automatic pouring system with Visipour control technology pours high-quality pipe connector castings. Inductotherm automatic pouring systems include both heated pressure and tundish units that can be optimized for ductile iron. High quality is essential in casting malleable and ductile iron pipe fittings, valves and pump components. Visipour stopperrod based, vision controlled automatic pouring systems provide precisely controlled pours for the highest casting quality. Inductotherm pressure pour automatic pouring furnaces are used to dispense

This 150 MT channel furnace provides a major pipe foundry with on-spec iron at the precise temperature needed. iron for transfer to centrifugal pipe casters. For metal holding, Inductotherm Mini-Heel coreless induction furnaces are able to maintain efficient power usage with as little as a 10% heel. Channel furnaces provide needed holding capacity when low power usage for around-the-clock operation is the top priority. They also provide the metal volume needed to allow the desired metal chemistry and temperature to be maintained over time. Cast iron pipe installed in London before the Battle of Waterloo in 1815 remains in service today. All foundries producing infrastructure castings, ranging from the most complex valve to the most basic manhole cover, recognize that their castings must have the durability needed to ensure long service life. Thats why most depend on melt shop and pouring systems from Inductotherm.

Visipour automatic systems control pour after pour without operator intervention.

Mini-Heel coreless holding furnaces offer volume and alloy flexibility.

Pressure pour automatic pouring systems supply metal to centrifugal pipe casters. 7

Casting for General Manufacturing

Melting & Holding Melt Shop Automation Automatic Pouring

A scrap metal supplier uses a small Dura-Line furnace with a fume collection ring to sample metal batches. Inductotherm offers a broad range of furnace sizes and types, as well as a full range of energy efficient induction power supplies. Whether a foundry needs a small hand-tilted furnace for 2 kg castings or a 20 ton furnace ready to pour every half-hour, Inductotherm offers the appropriately sized induction equipment with a guaranteed melt rate and a foundry-proven design.

The ARMS system can slag a furnace while the operator is located in a safe control room off the melt deck. Recognizing that working on a melt deck is hard and sometimes dangerous, Inductotherm developed equipment that is designed to keep people away from molten metal. The ARMS (Automated Robotic Melt Shop) system is designed to perform all the dangerous melt deck operations such as slagging, temperature taking, metal sampling, making alloy additions, and verifying proper grounding.

Most foundries are not massive facilities dedicated to a single industry. Rather, they range from small, individually owned shops serving a specific locale or market niche, to larger facilities doing jobbing work that serve general manufacturing and produce a wide variety of castings. While their furnaces may not be massive, their need for efficiencies is no less demanding. 8

Mini-Melt furnaces are ideal where smaller amounts of molten metal are needed.

Three Dura-Line furnaces are mounted on a turntable serving this counter-gravity caster.

This 1 MT small steel shell furnace is equipped with a fume collection ring.

Induction Melt Shop Automation Automatic Pouring

Casting for General Manufacturing

A Dual-Trak unit allocates power between two furnaces, ideal for batch melting operations. Inductotherm power units are the worlds most reliable and efficient. Dual-Trak dual-output induction power units, starting at just 125 kW, offer even small foundries the operational efficiencies available to high production melt shops. Designed to maximize the productivity of two-furnace batch melting operations, a Dual-Trak power unit allows power to be allocated between the melting and pouring furnaces simultaneously.

This automatic pouring system uses a moving shuttle reservoir to track and fill molds on a continuously moving line. Inductotherm computer controls include the MeltManager Plus system. This system is built into the power supply or remote panel and helps the operator run crucial melting and holding operations. Most often found on high-speed flaskless mold lines, Inductotherm automatic pouring systems are also ideal for both indexing and continuously moving flask lines.

Even the smallest foundries are turning to automation to increase production, enhance safety, improve quality and reduce costs. Like the systems designed for the largest facilities, melting and holding systems for smaller facilities also can be equipped with charge drying and automated material charging systems, dual-output power supplies, integral fume collection covers, computerized controls and automatic pouring.

This Dual-Trak power unit uses built-in Melt-Manager Plus computer controls.

Melt-Manager Plus features a full-color touch screen interface for ease of control and data entry.

This Visipour stopper-rod system pours precise castings for a stove manufacturer.

Thermal Processing for Iron

DRI Production Heating Heat Treating

This rotary hearth furnace produces Direct Reduced Iron (DRI) to replace or supplement scrap charge materials. Bricmont designs and builds rotary hearth furnaces for the production of Direct Reduced Iron (DRI). In a DRI system, iron ore pellets are heated with coal or gas to produce metallic iron briquettes used to replace or supplement scrap charge materials. Inductoheat builds a complete line of heating and heat treating systems designed to enhance

In engine manufacturing, camshafts, crankshafts and other castings require induction heating to achieve long service life. the physical properties of iron castings. One of the most common applications of induction heat treatment is hardening iron parts such as camshafts, crankshafts, liners, gears, and rollers. For example, Inductoheat vertical scanners are used to inductively heat and harden cast gray iron cylinder liners and camshafts and to harden and temper cast ductile iron crankshafts.

From massive rotary hearth furnaces used in the production of Direct Reduced Iron (DRI) to induction heating and heat treating systems for gray iron, nodular cast iron and ductile iron, Inductotherm Group companies manufacture equipment for a wide range of specialized thermal processes.

Unlike most scrap, DRI briquettes offer consistent metallurgical properties. 10

InductoScan IFP (Independent Frequency and Power) modular systems offer maximum flexibility for heat treating.

Crank and camshafts are both inductively heated and quenched using patented SHarP-C technology.