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Arc Furnace Melting and Sand Casting of Aluminum and Copper

James Bonnell James O’Brien Engr 45 Dec 8, 2004. Arc Furnace Melting and Sand Casting of Aluminum and Copper. Arc Furnace Typical Uses. Metal Recycling Used to reclaim iron, nickel and cobalt alloy Scrap is generally 100% of the charge

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Arc Furnace Melting and Sand Casting of Aluminum and Copper

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  1. James Bonnell James O’Brien Engr 45 Dec 8, 2004 Arc Furnace Melting and Sand Casting of Aluminum and Copper

  2. Arc Furnace Typical Uses Metal Recycling Used to reclaim iron, nickel and cobalt alloy Scrap is generally 100% of the charge With computer control is used to separate various mixed scrap to specific compositions

  3. Arc Furnace Source: http://tristate.apogee.net/et/ Benefits: • Cost per ton of final product is less (taking into account all expendables) • Can melt almost any type of metallic scrap • Good for smaller production runs requiring less capacity.

  4. Power Consumption Source: http://tristate.apogee.net/et/

  5. Cost Per Ton of Steel Source: http://tristate.apogee.net/et/

  6. Basic Electric Arc Furnace

  7. DC Electric Arc Furnace www.jfe-21st-cf.or.jp

  8. Current Carrying Capacity Nominal Diameter Electrode Type mm inch Regular Power High Power Ultra High Power 75 3 1,000 ~ 1,400 100 4 1,500 ~ 2,400 Source: www.foundrytraders.com 150 6 3,000 ~ 4,500 200 8 5,000 ~ 6,900 5,400 ~ 9,000 250 10 7,000 ~ 10,000 8,000 ~ 12,000 300 12 10,000 ~ 13,000 13,000 ~ 17,400 18,000 ~ 22,000 350 14 13,500 ~ 18,000 17,400 ~ 24,000 20,000 ~ 30,000 400 16 18,000 ~ 23,500 21,000 ~ 31,000 25,000 ~ 40,000 450 18 22,000 ~ 27,000 25,000 ~ 40,000 32,000 ~ 45,000 500 20 25,000 ~ 32,000 30,000 ~ 48,000 38,000 ~ 55,000

  9. Our Arc Furnace • Started as a standard arc lamp used for exposing photographic emulsions.

  10. Modified Arc Lamp • Moved the bottom electrode to be parallel with the top electrode • Added: • Platform • Crucible

  11. Attempted Arc Start with Steel

  12. Arc Start with Carbon Rod

  13. Sand Casting Mold and Products www.birt1.demon.co.uk www.simmons.com

  14. Sand Casting Suitability Advantages: Least Expensive Casting Process Castings can be up to Several Tons Less Expensive than Machining Shapes from Bar Stock Can Cast Intricate Shapes Can be Used with Most Pourable Metals and Alloys Disadvantages: Can Only Cast Basic Part Shape Castings Require Secondary Machining Rough Surface Finish www.casting-source.com

  15. Casting Sand Types Basic casting sand consists of bentonite clay and sand (usually 120 grit) Chromite sand: a high quality refractory molding sand,with high chilling effect and stability Zircon sand: particularly suitable for higher melting point alloys Source: http://www.foundrytraders.com

  16. Basic Tools

  17. Shrinkage Consideration Shrinkage Rate for Small Castings Iron - 1/8" per foot Steel - 1/4" per foot Aluminum - 5/32" per foot Brass - 3/16" per foot www.casting-source.com

  18. General Setup www.lethbridgeironworks.com

  19. Our setup and mold

  20. Disappointing Results Insufficient input heat to maintain molten state Worked to melt small samples Crucible broke from thermal shock when the sample melted

  21. Final Castings Used Oxyacetylene Torch to heat steel crucible that would not suffer thermal shock. Cast aluminum and copper alloys (not quite enough heat input for copper) Original

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