In this article, we will go over the requirements that must be met before beginning the smelting process in metal casting. What are these smelting process conditions? Let’s take a look!
Smelting is the process of melting metal until it reaches the pouring temperature by utilizing the thermal energy produced by the furnace. A furnace is a tool used to melt metal, after which the liquid in the furnace that has reached the pouring temperature is poured into the ladle and the pouring process (pouring liquid into the mold) is carried out so that a cast product is formed.
Smelting is the most important aspect of metal casting because it has a direct impact on the quality of cast products. Additionally, the addition of alloying elements has an impact on the microstructure and product quality if it is integrated into an appropriate composition.
Silicon (Si), Manganese (Mn), Phosphorus (P), Sulfur (S), Nitrogen (N 2), Copper (Cu), Nickel (Ni), Chrome (Cr), Oxygen (O 2), Aluminum (Al), Hydrogen (H 2), and other minor elements are used as alloying elements.
Before the smelting process can begin, a number of conditions must be met, including:
1. Pay Attention to Occupational Health and Safety
Occupational health and safety are critical components in efforts to improve employee well-being and productivity. Accidents that cause illness, disability, and death can be reduced to a minimum if occupational safety is high.
Why is Occupational Health and Safety required in a business? Because it is directly related to the manufacturing process. The point is that by implementing Occupational Health and Safety, the manufacturing process will run smoothly. Consider that if the company does not implement Occupational Health and Safety, it will cause a high number of work accidents, which will impede the production process and result in losses.
2. Understand the smelting process flow
Because smelting is the most important stage in casting, understanding the flow of the smelting process is critical to the smooth operation of the production process.
3. Check the tools to be used on a regular basis
The tools used must meet the standards and must be inspected on a regular basis. Especially on the furnace lining walls that are in direct contact with the metal liquid. If the diameter of the furnace lining wall is still 60% of its original thickness, the furnace must be disassembled (re-lining).
4. The metal is free of impurities
Impurities are typically caused by low-quality raw materials. Poor raw materials consist of a large amount of dirt that adheres to raw materials such as oil, soil, and so on. These impurities will form slags, and because slags cannot unite with metal, if slag enters the product, it will cause defects.
5. The furnace used must meet the metal casting process’s requirements
Furnaces or furnaces used for smelting must also meet certain conditions, that is:
- High-temperature resistance.
- Load and abrasion resistance.
- The coefficient of heat expansion is low (discharge due to temperature increase).
These are the conditions that must be met before beginning the smelting process in metal casting in order to produce high-quality products while keeping metal foundry workers safe. Professional operators who understand the expected smelting, furnace, material, and alloying elements are also required in metal casting.