Chapter 4

DESIGN AND FABRICATION OF FURNACE

4.1 POWER REQUIREMENT:

Taking size of chamber as reference the heating coil is designed as shown as below

 Dimension off the chamber : 12” * 10 ” * 10”

 Max weight of the charge : 5kg
 Mazimum molten metal temperature = 800 oC

The quantity of heat (Q) that will be transferred to stock can be calculated with this equation:

Q = m×C p ( T 2−T 1 )

Where , Q = quantity of heat of stock in kCal

m = weight of stock in kg

Cp = mean specific heat of stock in kCal/kgoC

T 2= final temperature of stock in oC

T 1= initial temperature of the stock before it enters the furnace in oC

Let the stock be the aluminium,

Heat added = mass × specific heat × (T final−T initial) + (mass × Lh)

= 5 * 913*(1073-303) + 5*38*105

= 54.15050 * 105 joules

(1Watt = 1 joule/sec)

= 54.15050 * 105/60*60*1000

= 1.5KW

 65% efficiency power required = 1.504/0.65 = 2.31KWHR

 40 min to melt power required = 2.314*60/40 = 3.471KW
  The power required is 3.54KW

4.2 HEATING ELEMENT DESIGN FOR CRUCIBLE FURNACE :

 Size of chamber = 300mm * 250mm * 250mm
 Total power rating = 3.5KW
 Electric supply = 240V, 1PW, 50Hz AC
 Current = Power /voltage = 3500/240 = 14.58A
 Resistance of element/ phrase = voltage/ current = 240/14.58 = 16.46 Ω
 Resistance of element at ambient temp. = Rh/temp factor = 16.46/1.04
=15.82Ω

For better service life the surface load shall be in the range of 2 to 2.5W/sq.cm

From the reference table it can be noted that

(I2Ct)/surface load = sq inch / Ω (Ct = temperature factor)

The surface load of 1 Wsq.inch = 6.45W/sq.cm

I = 14.58A, Ct= temp. factor = 1.04 for 1000℃ (from Kanthal A1 handbook)

Assume surface load about 2.2W/sq.cm (14.213W/sq.inch)

sq inch / Ω = 14.582 * 1.04/14.213 = 15.54sq.inch/Ω

compare this values against different gauges and select the nearest which is found as 16.1 and
the guage of wire is 15SWG (1.83mm)

recalculate the surface load again using the formula

(I2Ct)/ surface load = sq inch/Ω

i.e., (14.582 * 1.04)/surface load = 16.1

surface load = 13.735W/sq.inch = 2.129W/sq.cm

the surface load is well within safe limits and hence the element size is 15SWG is selected.

4.3 HEATING ROD SPECIFICATION

Specifications of Silicon Carbide Heating Rods used in the Furnace.
Operating Current Range : 25 to 30 Amps.

Operating Voltage : 90 to 120 Volts

No. of Heating Rods : 6 Nos.

Resistance per heating Rod : 1.2 ohms

Diameter : 14 mm

Hot Zone : 150 mm

Total Length : 550 mm

The most important advantages of Silicon Carbide Heating Rods

 Higher maximum element temperature of 1425oC and compare 1250OC.

 Durability and Uniformity
 Higher surface load.
 Higher resistivity.
 Lower density
 No spalling oxide, which may contaminate the goods and the furnace and also cause
short circuit or failure of elements.

Ceramic Fibre Board-Features.

 Withstand high temperature and sudden changes

 Withstand action of molten slag, glass, hot gases etc.
 Withstand load at service conditions
 Withstand abrasive forces
 Conserve heat
 Have low coefficient of thermal expansion
 Will not contaminate the load
Some of the important properties of Insulation Materials / Ceramic Boards are:

Melting point: Pure substances melt instantly at a specific temperature. Most Ceramic Board
materials consist of particles boned together that have high melting temperatures. At high
temperatures, these particles melt and form slag. The melting point of the Ceramic Board is
the temperature at which a test pyramid (cone) fails to support its own weight.

Size: The size and shape of the Ceramic Board is a part of the design of the furnace, since it
affects the stability of the furnace structure. Accurate size is extremely important to properly
fit the chamber shape inside the furnace and to minimize space between construction joints.

Bulk density: The bulk density is useful property of Ceramic Boards which is the amount of
Ceramic material within a volume (kg/m3). An increase in bulk density of a given Ceramic
Board increases its volume stability, heat capacity and resistance to slag penetration.

Thermal conductivity: Thermal conductivity depends on the chemical and mineralogical

composition and silica content of the refractory and on the application temperature. The
conductivity usually changes with rising temperature. High thermal conductivity of a
refractory is desirable when heat transfer though insulation is required. Additional insulation
conserves heat but at the same time increases the hot face temperature and hence a better
quality insulation is required.

Insulating materials:

Insulating materials greatly reduce the heat losses through walls. Insulation is achieved by
providing a layer of material with low heat conductivity between the internal hot surface of
furnace and the external surface, thus keeping the temperature of the external surface low.
Insulating materials owe their low conductivity to their pores while their heat capacity
depends on the bulk density and specific heat. Air insulating materials consists of minute
pores filled with air, which have a very low thermal conductivity. Excessive heat affects all
insulation material adversely, but at what temperatures this takes place varies widely.
Therefore the choice of an insulating material must be based on its ability to resist heat
conductivity and on the highest temperature it will withstand.
In our project,ceramic fiber blankets and Ceramic Board are used for insulation purpose due
to ease of availability and inexpensive.
CERAMIC FIBER BLANKET:

Ceramic Fiber Blanket is made of high purity Aluminum Silicate fibrous wool. Process of
mechanically needled to increase tensile strength. Without any asbestos and organic binders.
They are lightweight and flexible for handling and installation. Widely used in high
temperature environment.

 Low thermal conductivity.

 No curing or dry out time, lining can be fired to operating temperature immediately.
 Very low heat storage.
 Resist most chemical attack.
 Thermal shock resistant.
 Easy, quick installation and repair.
 Unaffected by steam.
 Excellent sound absorption.
 Asbestos free.
 Resilient.
 Light weight.

Properties Unit Values

Percentage of A12O3 % 47-49
Percentage of Silica % 51-53
Percentage of Ferric Oxide % 0.1
Service temperature 1250(max)
Specific gravity 2.65
Blanket tensile strength KPa 55
Colour White

4.4 PROCESS OF FABRICATION

 Step-1: The Outer Casing is made out of Mild Steel Sheets 16 swg with adequate
reinforcement by means of M.S.Angles vertically and horizontally to avoid stress and
strain during operation. M.S. Plate 4 mm thick is provided on the top with necessary
cavity to insert the graphite Crucible. Provision is made on the shell for inserting
thermocouple.
 Step-2: Once the outer casing is ready, Ceramic Fibre lining is done with sufficienht
thickness to minimize heat loss. The chamber will be constructed out of high density
 Ceramic Board to withstand the temperature. Necessary provisions are made in the
chamber insert the Silicon Carbide Heating Rods.
 Step-3: Silicon Carbide Heating Rods are provided horizontally i.e. 3 Nos. each side
which are grouped together with necessary Baids and Clamps. . Terminals are taken
outside to connect to the main supply.
 Step-4: Internal wiring is done with Furnace and Control Panel with heat resistant
Fibre Glass Cable.
 Step-5. The Furnace and Control Panel is finished with Painting/powdercoating.

4.5 CASTING PROCESS

Cast material: Here we used general aluminium , i.e., A356.1 as the casting material to now
the properties of cast product obtained by stir casting.

The chemical composition of A356.1 is as below

A356.1 (Al 92.5% ; Si 7% ; Fe 30%)

That means, it has 92.5% Aluminium as the base composition with silicon and iron as the
alloying materials with 7% & 0.30% respectively

Steps followed :

1. Preheat the metal to remove moisture content

2. Make sure of proper electrical connections and switch on the console of the furnace
3. Set the furnace temperature to 900℃
4. Place the metal inside the crucible and close the lid
5. Once we know that mixing is completed, the resulting slag is slimmed off
6. The final molten metal is then poured into die to obtain the cast product
7. The cast product is then machined to the dimension and subjected to test.

4.6 BRINELL HARDNESS TEST

For Brinell test of Al a carbide ball indenter is used. He test procedure is as follows:

 The indenter is pressed into the sample by an accurately controlled test force
 The force is maintained for a specific dwell time, normally 10 – 15 seconds
 After the dwell time is complete, the indenter is removed leaving a indent in the
sample
 The size of the indent is determined optically by measuring 2 diagonals of the
indent using a either a portable microscope or one that is integrated with the load
application device
 The Brinell hardness number is a function of the test force divided by the curved
surface area of the indent. The identification is considered
to be spherical with radius equal to half the diameter of the ball.

Load applied Diameter of Diameter of BHN

F in kgf indenter indentation
D in mm Di in mm
187.5 2.5 1.41 109.97
187.5 2.5 1.38 113.18
187.5 2.5 1.4 111.27
 Calculation

2∗187.5
BHN =
π∗2.5 ( 2.5−√ 2.52.−1.4 2 )

4.7 COST ANALYSIS

SL.NO PARTICULARS APPROXIMATE

COST IN Rs
1 Casing fabricated with mild steel 18850
2 Thermal insulation 13400

3 Heating elements 6000

4 Temperature control system 6000
5 Electrical control system 3000
6 Crucible 250
7 Miscellaneous 500
Total cost 48000

Chapter 5
Observation and result
 Conclusion

 From the graph it is observed that temperature increases exponentially

with time
 The designed maximum temperature (1000℃ ) is attained successfully
 The set temperature is maintained successfully without any dropping
  Electric resistance crucible furnace are used for direct melting of high
grade Al casting
 The cast product of Aluminium356.1 is subjected to hardness test under
Brinell scales and the resulting hardness number is 111.414 HB

Appendix-1
SAFETY PRECAUTIONS

SAFETY PRECAUTIONS
To avoid personal injury:
1. Do not stand directly in front of the chamber without wearing a heat resistance face
shield, gloves and apron.
2. Do not operate or clean furnace without proper eye protection.
3. Do not use in the presence of flammable or combustible materials; fire or explosion
may result. This device contains components which may ignite materials.
4. Refer servicing to qualified personnel.
5. Caution: Hot Surface. Avoid Contact.
6. To AVOID EYE DAMAGE in operating or cleaning furnace, proper eye protection
must be worn.
7. To AVOID BURNS, do not stand directly in front of the chamber without wearing a
heat resistant faceshield, gloves and apron.
8. To AVOID FIRE, do not place combustible materials where exposed to heat from
open door.
9. Always be disconnected from the electrical supply prior to maintenance and servicing.

Appendix-2

WARNING
This furnace contains ceramic fiber or fiberglass insulation, which can produce
respirable dust or fibers during disassembly. Dust or fibers can cause lung damage
(silicosis). The international Agency for Research on Cancer (IARC) has classified
refractory ceramic fiber and fiberglass as possibly carcinogenic (Group 2B), and
crystalline silica as carcinogenic to humans (Group 1).

The insulating materials can be located in the door, the hearth collar, in the chamber
of the product or under the hot plate top. Tests performed by the manufacturer
indicate that there is no risk of exposure to dust or respirable fibers resulting from
operation of this product under normal conditions. However, there may be a risk of
exposure to respirable dust or fibers when repairing or maintaining the insulating
materials, or when otherwise disturbing them in manner which causes release of dust
or fibers. By using proper handling procedures and protective equipment you can
work safely with these insulating materials and minimize any exposure. Refer to the
appropriate Material Safely Data Sheets (MSDS) for information regarding proper
handling and recommended protective equipment.
Please strictly follow the warning, or you may get a very bad injury.
 Do not place any vase with water around the furnace.
 No water around the furnace.
 Do not place anything on the cover of the furnace.
 Do not damage or bend the power cable.
 Do not let the child touch the furnace.
 Do not place any flammable stuff around the furnace.
 Wear gloves when the temperature is high.
 Open the case after the temperature cooling to room temperature.

Appendix-3
MAINTENANCE

1. Leave nothing around the furnace within 30 cm.

2. Do not open the cover when furnace in operation, especially at high temperature.
 3. Please fully dry the sample before put it into the furnace.
4. Never use furnace to heat halogen, sulfur and ammonia.
5. Heat the furnace for 1 hour at 120 oC and 2 hours at 300 OC to warm up if first
time use or use after leave it a long time idle.
6. Do not affuse any liquid or solution.
7. Keep the heating rate low in low temperature segment.
8. Regularly check the wire contact, especially connecting point.\
9. Working environment
a. Circumstance temperature:- 10-75 oC
b. Relative humidity: 85%
c. Keep from electric dust, explosive and corrosive gas.
d. Keep stable position when working.

BIBLIOGRAPHY
[1] F Ostler , vol5.no, 2-4 , June –julyb1995 published by Elsevier Science B.V.
Amsterdam.

[2] Jaroslav bublik, Matej Abraham, School of materials science and

engineering, university of aeronautics, Thailand
[3] Rehren. T & Thornton C.P, 2009, A truly refractory crucible from fourth
millennium Tepe Hissar, northeast Iran , journal of Archaeological science.

[4] F.King Aluminium and its alloys 1987

[5] Vivek R. Gandhewar et a./ International journal of engineering and

technology 2011

[6] David J. Gingery

[7] D.A.Fod 1981, Casting technology, pp147-176

[8] KANTHAL HANDBOOK – resistanc heating alloys and system for

industrial furnances by KANNTHAK AB SWEDEN, 1994