MELTING AND POURING

UNIT 2

Presented By
THAMARAIKANNAN M (MTK1)
GET-METALLURGY

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 MELTING FURNACE
• Melting process is done by using induction furnace.
• Induction furnace works on the principle of
electromagnetic induction by using AC power supply.

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MELTING FURNACE
Nos Parts Name
1 Molten Metal
2 Refractory Lining
3 Former
4 Mill board
5 Power coil
5a Cooling coil
6 Furnace top
6a Pouring spout
7 Furnace body
8 GLD
9 Hydraulic unit
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 UNITS OF FURNACE

Units of induction furnace are,

1.Transformer unit
2.Crucible unit
3.Cooling unit
4.Hydraulic unit

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 UNIT- 2 [Furnace capacity]
3 Ton 6 Ton 8 Ton
CAPACITY 2 3 1
Frequency MIN 200 200 200

MAX 450 450 450

Voltage MIN 1000 1000 1000

MAX 2400 2400 2400

Power MIN 500 500 500

MAX 1400 3000 3000

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 FURNACE LINING
Need to clean furnace

Place Mill Board/ Asbestos sheet near coil

Place the former inside the furnace

Refractory lining is rammed in between

Lining Vibratory is used

Slowly start the furnace with charge

Sintering process is take place

Lining is complete after the first heat

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 MELTING PROCESS FLOW
Released Melt plan Check the condition
Weight the scrap
of furnace

Slag removal Melt the charge Materials Charge Raw Materials

Bath analysis Check Chemistry

No
Yes

Correct chemistry by Check the temperature and Tap

adding alloying elements metal and add deoxidant into ladle

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CHARGE MATERIALS SLAG REMOVAL

POURING

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CHARGING MATERIAL
SCRAP RETURNS

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 CHARGING MATERIAL
PU.MN HC FE MN FE AL FE SI CAL

MET COKE

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 BATH ANALYSIS
Used for adding alloying elements,

Bath analysis Formula:

(Aim-Actual chemistry)*Liquid metal weight

Recovery rate

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 LADLE

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 UNIT- 2 [Ladle capacity]

Teapot spout ladle Bottom pouring ladle

3 Ton 6 Ton 8 Ton 3 Ton 6 Ton 8 Ton

6 - - 2 5 3

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 UNIT- 2 [Ladle Pre heating]
For fresh ladle;
• Heat at 850°C
• 48hrs for air curing
• preheat for 6hrs
• air curing for 2hrs
• preheat for 2 to 3hrs before
metal collection
For cold ladle;
• Heat at 850°C
• preheat for 2 to 3hrs before
metal collection
For Reused ladle;
• Heat at 850°C
• preheat for 20 to 40min
before metal collection

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UNIT- 2 Pouring

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 POURING PROCESS FLOW
Preheat the ladle

Check Weight and temperature of Transfer Liquid metal

liquid metal to ladle

Clamp the cope and drag using Check mould quality

steel clamp and metal support

Pour the liquid metal to closed Provide heat no strip

moulds, Sample cup and keel blocks

Move to knockout Provide cooling time

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 UNIT- 2 [Pouring capacity]

No of plates in single path way: 30

Path ways: 5
Total= 150 plates

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 GRADE- SC450W

• Heat No : 2 (06/09/2022)
• Start Time : 09:35am

• Metal ready time : 10:55pm , Metal Tap time : 11:05pm

• Capacity :6600kg

• Bath sample taken in 1558°C

• Tapped at 11:05pm in 1608 °C

• Poured at 11:15pm in 1597 °C

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