Foundry Melt Department
In a foundry’s melt department system, equipment melts solid scrap and ferrous/non-ferrous metal alloys, which are loaded into a furnace to be transformed into liquids for pouring into molds.
The melt department is an essential part of any foundry system because the melting process heavily influences the quality of the final casting. If done incorrectly, casting defects may occur, wasting precious metal and reducing your foundry’s profit margins. Depending on the type of metal you’re working with, you’ll have different material, temperature, and equipment requirements to get a clean pour. Therefore, it is important to design your melt department to be as streamlined as possible.
Melt Department Process
Materials like alloys and scrap metals are held in raw material storage until they’re needed for processing. The materials are loaded and weighed into equipment like weigh hoppers and prepared to meet the chemical requirements for high-quality castings. A furnace (such as an electric arc furnace) is charged with metals using a furnace charger, then heats and melts the charged metals. The furnace is chosen based on several factors, such as the type of metal (scrap, alloy, pure) used and production requirements.
Once melted, the molten metal is treated using methods like degassing or alloying to refine it and eliminate defects before being used in castings. The treated metal is then transferred from furnaces and into ladels, which are transported to designated casting areas.
Common Melt System Equipment
Charge Feeders: Charge furnaces (electric, arc, holding, etc.) with metal. Charge feeder systems give you precise automated batch control and improve worker safety. They control fumes and direct the charge into the center of your furnace.
Furnaces: One of the primary elements of a melt department, furnaces melt scrap and alloy metals. Depending on the type of metal you’re working with, different types of furnaces may be used, such as crucibles, electric arcs, induction, cupola, or blast furnaces.
Overhead Rail Systems: Allow for easy and safe transport of molten metals, alloys, casting materials, and more. They help keep the foundry floor clear, improving safety by moving hazardous material overhead. They also save ground space by moving transport equipment off the floor.
Ladles: Ladles are used to hold molten metal for transport and for pouring the molten metal into molds.
Automating Melt Systems
Automation is an important consideration when designing melt department systems. It saves money and makes work environments safer by moving people further away from hazards such as molten metal and silica dust. When designing melt department systems, GK Systems will typically include equipment designed to automate melt deck processes such as:
Alloy Addition Systems: Alloy bins receive and store alloy addition materials, then release them via a vibratory feeder to weigh units for batch make-up. Delivery barrels and a monorail/hoist assembly deliver the final batches to charge areas and integrate directly with charge feeders that accept and gradually distribute alloy batches with the main charge.
Inoculant Systems: Prepare and add inoculants and other materials into ladels before pouring. These systems include material bins, feeders, weighing rollovers, and charge make-up feeders.
Charge Feeder Systems: GK’s charge systems offer precise automated batch control, optional scrap drying, and other charge enhancement capabilities. Designed with automation in mind, these systems help improve worker safety. They can also be mounted on carriers and rails for transport, making them mobile.
Optimize Your Foundry’s Melt Department with GK Systems
GK Systems designs and implements your melt system from concept to startup. We provide services like melt system layout design, installation, startup, manufacturing, and more. Contact us today, and we’ll help you design a streamlined melt department.