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Copper Melting 201
This laboratory course introduces the principles and best practices of copper melting and pouring for producing premium quality castings. The various processes involved in melt protection, oxidation, deoxidation and degassing will be examined. Topics include: furnace types and uses, charge materials, melting practices and tests for melt quality.
Participants will complete the course with a broader knowledge on improved energy efficiency during melting due to reduced gas pickup and improved melt cleanliness. They will also learn about improved productivity and quality control along with reduced production costs resulting from appropriate oxidation-deoxidation and degassing practices. Maintenance of proper furnace atmospheres, minimization of porosity and inclusions, and use of the correct melt quality assessments will also be addressed.
Participants will learn to:
- Describe the advantages/disadvantages of the various furnaces used for copper melting.
- Explain the effects of various charge materials on copper melting.
- Discuss oxidation-deoxidation and degassing practices for copper melting.
- Identify proper Personal Protective Equipment (PPE) used in copper melting and pouring practices.
- Describe the tests used for melt quality.
- Explain considerations for making quality, high-conductivity copper castings.
Course Length2.0 days
CEU Units1.00 CEU
Module 1: Introduction
Module 2: Furnace Types and Uses
• Furnace Types
• Furnace Uses
Module 3: Charge Materials
• Charge Material Types
• Charge Material Effects
• Safety in Melting and Casting
Module 4: Melting Practices
• Furnace Atmosphere
• Additions for Various Alloys
• Oxidation/De-oxidation/Gassing/De-gassing Techniques
• Effects of Gas and Melt Contamination on Structure
• High Conductivity Copper Castings
Module 5: Tests for Melt Quality
• Melt Quality Test Types
• Mechanical Properties
• Chemical Analysis
• Tests for Gas
• Fracture Testing
• Temperature Control
Module 6: Conclusion
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