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Melting & Pouring of Steel Castings

This document discusses the process of melting and pouring metals using an induction furnace. It describes the main components of the furnace including the transformer, crucible, and cooling units. It provides details on furnace capacity and operating parameters for different tonnage furnaces. The document outlines the steps for furnace lining, melting process, charging materials, slag removal, bath analysis, ladle preparation, and pouring process. It specifies ladle and pouring capacities and provides an example pour record for grade SC450W steel.

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Gokul K
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332 views18 pages

Melting & Pouring of Steel Castings

This document discusses the process of melting and pouring metals using an induction furnace. It describes the main components of the furnace including the transformer, crucible, and cooling units. It provides details on furnace capacity and operating parameters for different tonnage furnaces. The document outlines the steps for furnace lining, melting process, charging materials, slag removal, bath analysis, ladle preparation, and pouring process. It specifies ladle and pouring capacities and provides an example pour record for grade SC450W steel.

Uploaded by

Gokul K
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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MELTING AND POURING

UNIT 2

Presented By
THAMARAIKANNAN M (MTK1)
GET-METALLURGY

1
S R SESHADRI TRAINING INSTITUTE
MELTING FURNACE
• Melting process is done by using induction furnace.
• Induction furnace works on the principle of
electromagnetic induction by using AC power supply.

2
S R SESHADRI TRAINING INSTITUTE
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
3
S R SESHADRI TRAINING INSTITUTE
UNITS OF FURNACE

Units of induction furnace are,


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

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S R SESHADRI TRAINING INSTITUTE
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

S R SESHADRI TRAINING INSTITUTE 5


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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S R SESHADRI TRAINING INSTITUTE
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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S R SESHADRI TRAINING INSTITUTE
CHARGE MATERIALS SLAG REMOVAL

POURING

8
S R SESHADRI TRAINING INSTITUTE
CHARGING MATERIAL
SCRAP RETURNS

9
S R SESHADRI TRAINING INSTITUTE
CHARGING MATERIAL
PU.MN HC FE MN FE AL FE SI CAL

MET COKE

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S R SESHADRI TRAINING INSTITUTE
BATH ANALYSIS
Used for adding alloying elements,

Bath analysis Formula:

(Aim-Actual chemistry)*Liquid metal weight


Recovery rate

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S R SESHADRI TRAINING INSTITUTE
LADLE

S R SESHADRI TRAINING INSTITUTE 12


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

S R SESHADRI TRAINING INSTITUTE 14


UNIT- 2 Pouring

S R SESHADRI TRAINING INSTITUTE 15


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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S R SESHADRI TRAINING INSTITUTE
UNIT- 2 [Pouring capacity]

No of plates in single path way: 30


Path ways: 5
Total= 150 plates

S R SESHADRI TRAINING INSTITUTE 17


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


S R SESHADRI TRAINING INSTITUTE 18

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