Aluminum Melting 201

Learning Outcomes

  • Describe the principles of transforming solid aluminum to liquid.
  • Describe furnace charging procedures.
  • Identify accurate temperature measurement and control techniques.
  • Describe purposes and methods of alloying.
  • Identify impurities and their causes and handling.
  • Identify melt loss causes and control methods.
  • Describe the purpose of fluxing and common methods of melt treatment.
  • Describe various sampling techniques.
  • Describe pouring techniques.

Course Introduction

This course introduces the principles and best practices of aluminum melting for use in castings. The course will examine furnace charging, furnace temperature and its effect on the melt, and in-furnace treatments to reduce impurities.  Melt sampling, transfer and pouring methods, and the corresponding equipment will be analyzed, with demonstrations of various techniques throughout the course.  Casting defects related to melting, treatment and transfer also will be presented and discussed.

Benefits to Taking the Course

Participants of this course will leave with the knowledge and skills to reduce the overall cost of melting operations by reducing metal spills, waste, dross, and scrap; realize profitability gains by improving energy efficiency through better molten metal handling; improve productivity by applying proper molten metal handling techniques; and demonstrate to all other company employees as well as potential customers that quality begins with proper molten metal operations.

Module 1: Introduction

Module 2: Course Overview

  • Melting and the Final Cast Product
  • Aluminum Melt and Transfer Overview

Module 3: Transforming Solid Aluminum to Liquid

  • Safety Overview
  • Heat Transfer and Efficient Heat Supply
  • Melting Furnace Operations
  • Temperature Measurement and Control

Module 4: Impurities and Melt Loss

  • Oxidation
  • Hydrogen
  • Dross Formation and Melt Loss

Module 5: Fluxes, Degassing, and Filtration

Module 6: Sampling Procedures

Module 7: Pouring Techniques and Practices

  • From Furnace to Transfer Ladle
  • Pouring Molds
  • Automated Pouring Devices and Techniques

Module 8: Conclusion


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