MANUFACTURING SCIENCE

INTRODUCTION

Presented By
SRIKUMAR BIRADAR

DATE: 05-JANUARY-2022

01/05/22 1
 Melting Equipments
• In order to obtain the proper pouring and
melting temperature of the metal several
furnaces are used:
• For ferrous metals:
– Cupola furnaces
– Open hearth furnaces
– Electric furnaces
• For non-ferrous metals:
– Pit Type
– Stationary type
– Tilting Type
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Cupola Furnace
• Used only for melting cast irons.
The iron is usually a mixture of
pig iron (crude iron) and scrap.
• Coke is the fuel used to heat the
furnace.
• Forced air is introduced through
openings near the bottom of the
shell for combustion of the
coke.
• Coke is a fuel with few
impurities and a high carbon
content, usually made from coal.
• Flux is the carbonate of coal.

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 Open Hearth Furnace
• In this the excess carbon and other impurities are burnt out of pig iron to produce
steel.
• Since steel is difficult to manufacture due to its high melting point, normal fuels and
furnaces were insufficient and the open hearth furnace was developed to overcome
this difficulty.
• Once all the steel has melted, slag forming agents, such as limestone, are added.
• The oxygen in iron oxide and other impurities decarburize the pig iron by burning
excess carbon away, forming steel. To increase the oxygen contents of the heat, iron
ore can be added to the heat.

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 Indirect Electric Arc furnace
• Arc is struck between two carbon or graphite
electrodes and heating of the charge takes place due
to radiation from the arc and contact with the furnace.
• It consist of a horizontal barrel shape steel shell lined
with refractories. Melting is effected by the arcing
between two horizontally opposed carbon electrodes.
• The barrel shaped shell is designed to rotate and
reverse, in order to avoid excessive heating of the
refractories above the melt .

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 Direct Electric Arc furnace
• An arc is maintained between electrode and the metal
being melted.
• The gap between the electrode and the charge is
adjusted continuously so that a steady state arc can
be maintained.
• The furnace can be tilted for pouring the molten
metal through the metal hole. It is used for melting
steel, but occasionally cast irons are also melted.

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 Rotary furnace
• The barrel is kept horizontal and revolved around its
axis at about 1 rpm.
• The fuel is burnt at one end of the barrel by a burner
and the hot flue gases pass through the other end.
• The molten metal is tapped through hole on the
cylindrical surface at the middle of the furnace. It is
used for melting grey and malleable irons in many
locations.

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Crucible furnace

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 Crucible furnace
• Employed for melting small quantities of nonferrous
metals.
• Crucibles are made of clay, graphite or silicon carbide
and it is kept in a cylindrical shell limited with
refractory bricks.
• Tilting furnace is tilted to transfer the molten metal to
the ladle.
• In non-tilting crucible is lifted out and taken to the
moulds for pouring the metal.

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 Reverberatory furnace
• A furnace in which the
material under treatment is
heated indirectly by means of
a flame deflected downward
from the roof.
• It is used in the production of
copper, tin, nickel and
aluminum.
• It heats the metal to melting
temperatures with direct fired
wall-mounted burners.

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 Reverberatory furnace
• The primary mode of heat transfer is
through radiation from the refractory
brick walls to the metal, but convective
heat transfer also provides additional
heating from the burner to the metal.
• Advantages:
– High volume processing rate
– Low operating & maintenance cost
• Disadvantages:
– High metal oxidation rates
– low efficiencies & large floor space
requirements. 

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Pit type furnace

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Pit type furnace

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 Solidification of Metals
• The process of becoming hard or solid by
cooling or drying or crystallization
• Solidification involves the transformation of the
molten metal back into the solid state.
• The solidification process differs depending on
whether the metal is a pure element or an alloy.

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Cooling curve for a pure metal during casting

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 Pure Metal
• A pure metal is metal that does not contain any
other material in it. A pure metal is mostly soft,
bristle or chemically reactive.

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 Pure Metal
• A pure metal solidifies at a
constant temperature equal
to its freezing point, which
is the same as its melting
point.
• The actual freezing takes
time, called the local
solidification time in
casting, during which the
metal’s latent heat of
fusion is released into the
surrounding mold. 25
 Pure Metal
• The total solidification
time is the time taken
between pouring
temperature and complete
solidification.
• After the casting has
completely solidified,
cooling continues at a rate
indicated by the downward
slope of the cooling curve.
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 Pure Metal
• Due to chilling action of mold
wall, a thin skin of solid metal is
initially formed at the interface
immediately after pouring.
• Thickness of the skin increases to
form a shell around the molten
metal as solidification progresses
inward toward the center of the
cavity.
Characteristic grain structure in a
casting of a pure metal, showing
randomly oriented grains of small size
near the mold wall, and large
columnar grains oriented toward the
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center of the casting.
 Pure Metal
• The metal which forms the initial
skin has been rapidly cooled by the
extraction of heat through the mold
wall.
• Cooling action causes the grains in
the skin to be fine and randomly
oriented.
• As cooling continues, further grain
formation and growth occur in a
direction away from the heat Characteristic grain structure
transfer. Since the heat transfer is in a casting of a pure metal,
showing randomly oriented
through the skin and mold wall, the grains of small size near the
grains grow inwardly as needles. mold wall, and large columnar
grains oriented toward the
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center of the casting.