Questions You Should Know about Electric Aluminum Melting Furnace

There will be various problems with the use of an electric smelting furnace. These issues can affect the quality of the final casting product. Today, Luoyang Judian will introduce the 5 most common problems and solutions when using electric melting furnaces.

If you are looking for more details, kindly visit Foshan Osno.

Element Burning Loss Is Too Large When Using an Electric Smelting Furnace

The burning loss of Si, Mn, Cr, and other easily oxidized elements in the induction furnace is mostly 3%~5%. An excessive burning loss will cause fluctuations in the chemical composition of castings, which will inevitably lead to a series of organizational and performance problems. The burning loss of elements is large, which generally occurs when the smelting time is too long and slagging protection is not paid attention to. If the amount of scrap steel is large, there are many light and thin materials, and the furnace charge is watery and rusty, the problem will be aggravated.

Ways to Avoid Excessive Burning of Elements

1. The furnace charge should be as clean as possible, the shape should not be branched, and the size should not be too large or too thin.

2. Put an end to racking materials and create conditions for fast melting.

3. In the early stage of smelting, slag should be formed in time, and in the later stage, there will be slag covering under high temperatures. Give full play to the protective effect of slag.

4. If the factory has a swarf to be used, some can be spread on the bottom of the furnace, and some of the melt can be added to the molten pool in batches.

High Oxygen Content in Molten Iron

The electric smelting furnace does not have the oxidizing atmosphere of the cupola. And, because the O and FeO in the molten iron react with C, the dissolved oxygen is not too much. However, in the later stage of smelting, in order to promote the dissolution and absorption of the C enhancer, the electric frequency is often lowered to strengthen the agitation of the molten pool. If the "hump" is too high and the frequency modulation time is too long, the probability of contact between the molten iron and the atmosphere will increase, and the dissociated O ions will enter the molten iron. Adding materials in the later stage of smelting without baking will also increase O and H.

Ways to prevent high oxygen content

1. Do not over-modulate the frequency in the later stage of smelting.

2. Do not use wet materials and tools in the later stage.

3. The overheating temperature should not be too high. Additionally, it is forbidden to keep warm for a long time at high temperatures.

Lower Amount of C in the Molten Iron

When the temperature of molten iron exceeds the equilibrium temperature, the reaction SiO2+2C=Si+2CO proceeds to the right, causing the molten iron to decrease C and increase Si. So don't forget to add C when ingredients. It is necessary to grasp the C reduction in the factory and make up the full amount of C. It should also be reminded that the composition of gray cast iron should be adjusted in the order of Mn first, then C, and then Si.

There Are Cracked Pores In the Castings

Fissure-like pores are characteristic of nitrogen pores, which mostly appear when the nitrogen content in molten iron exceeds the limit. There are many non-metallic inclusions in molten iron, and the probability of occurrence is higher. Therefore, it is necessary to limit the amount of scrap steel used in electric smelting furnaces and to prevent mixing scrap alloy steel materials with high nitrogen content, such as high manganese steel, heat-resistant high-chromium ferritic steel, chromium-manganese-nitrogen steel, and austenitic steel. The nitrogen content of different recarburizers varies greatly, so they should be treated differently. If we found the nitrogen content is high, use Ti (Fe), Al, Zr (Fe), etc. for solid N treatment.

Long Melting Time and High Power Consumption of An Electric Smelting Furnace

During the use of the electric melting furnace, if the melting time is too long and the power consumption is too high, it may be caused by the following two reasons.

1. The design defect of the furnace itself: With the development of thyristor technology and power capacitor technology, a series of energy-saving intermediate frequency furnaces have sprung up. The concept of "one drag two operations of thyristor series connection" is deeply rooted in the hearts of the people. The power consumption per ton of ductile iron can be lower than 570kW·h. However, the traditional parallel intermediate frequency furnace consumes more than 800kW·h of electricity per ton.

2. Transmission line loss: from the substation to the intermediate frequency power supply, and then through the copper bars and cables to the furnace system, there is unnecessary waste of electric energy on each link. If it is the cause of circuit loss, the original circuit needs to be upgraded.

The above are the most common questions and solutions for an electric smelting furnace. If you have any questions about the electric smelting furnaces, please contact us right now. We will do our best to solve your problems.

Are you interested in learning more about Electric Aluminum Melting Furnace? Contact us today to secure an expert consultation!

To make an informed decision when buying an aluminum melting furnace, there are several key factors to consider. Here are some important points to keep in mind.

Purpose and Application of the Aluminum Melting Furnace: Determine the specific purpose for which you need the aluminum furnace. Are you planning to use it for smelting, casting, recycling, or other applications? Different furnace types and specifications are suitable for various purposes.

Aluminum Melting Furnace Type

There are different types of aluminum furnaces available, such as crucible furnaces, induction furnaces, reverberatory furnaces, and rotary furnaces. Each type has its advantages, disadvantages, and specific applications. Research and select the furnace type that best suits your requirements.

You can check the article Aluminum Melting Furnace Types and Their Features to get more professional information to help you make the decision.

Capacity of Aluminum Melting Furnace

Determine the desired capacity or volume of aluminum that you intend to process in the furnace. The capacity usually affects the furnace size, power requirements, and overall cost.

Generally, the capacity of the aluminum melting furnace ranges from hundred kilograms to tens of tons, such as 100kg, 500kg, 1 ton, 5 tons, 15 tons, etc. Ensure that the furnace capacity aligns with your production needs.

Energy Efficiency

Consider the energy efficiency of the furnace. Look for models that optimize energy consumption and minimize heat loss. Energy-efficient furnaces can help reduce operational costs in the long run.

Temperature Range

Check the temperature range that the furnace can achieve. Aluminum has a relatively low melting point of around 660 degrees Celsius ( degrees Fahrenheit), so most aluminum furnaces should be capable of reaching and maintaining temperatures above this threshold.

What's more, to avoid metal loss as possible as we can, we need to precisely control the temperature. Therefore, the temperature control system is essential for the aluminum melting furnace.

Safety Features

Safety should be a priority when working with furnaces. Look for features such as temperature controls, emergency shut-off systems, and protective measures to ensure the safety of operators and the surrounding environment.

An aluminum melting furnace should contains multiple safety-protection systems, such as self-test function, real-time detection of water temperature, water pressure, over-current, over-voltage, lack phase, etc.

Manufacturer Reputation

Research the reputation and track record of the furnace manufacturer. Check customer reviews, testimonials, and industry reputation to gauge the reliability, durability, and performance of the furnace models they offer.

Support and Service

Evaluate the after-sales support and service provided by the manufacturer or supplier. Consider factors such as warranty, availability of spare parts, technical assistance, and maintenance support.

For a great aluminum melting furnace manufacturer, it is far from over after selling the products to customers. Comprehensive and thoughtful after-sale services, quick response, and professional solutions to questions from customers are much more important than selling the product.

Budget

Consider your budgetary constraints. Aluminum furnaces come in a wide range of prices depending on their size, features, and quality. Determine your budget range and explore options that provide the best value for your investment.

Regulatory Compliance

Ensure that the furnace you purchase complies with relevant safety and environmental regulations in your region or country. Compliance with standards such as those set by Occupational Safety and Health Administration (OSHA) and environmental protection agencies is crucial.

Want more information on Rice Cooker Accessories? Feel free to contact us.