There are various types of induction furnaces from induction furnace inductotherm that can melt metals of different types and quantities. There are metal melting furnaces for virtually every application, and they are designed with the end-user in mind.
For applications that require melting copper, induction furnace inductotherm are used. That is because Copper has a high melting point of 10830C. We’ll look at the two main types used, from small scale and large scale copper rotor die-casting, as well as the applications and advantages.
Double Push-up Furnaces
Double push up copper melting furnaces uses the single-shot melting technique. Pieces of chopped copper wire rods are placed in the crucible. The furnace melts one shot, after which other quantities are added progressively.
By using the single-shot melting technique, the metals can be added in small quantities at every stage. For this reason, the double push-up process is recommended for small scale applications and for prototyping.
It is referred to as a double push up furnace, since there are two crucibles that work interchangeably. The crucibles have an induction coil around each of them. When the metal in the first crucible melts, it is pushed out of the way, and the next batch of metals is ready to be heated. Meanwhile, the molten metal in the first crucible is allowed to drain into the die casting machine.
In small scale applications, pieces of the chopped copper rod are used for the crucible. Sheared cathode does not provide the required surface area and ends up crowding the induction forging furnace. Chopped copper rods are recommended even though they are marginally more expensive. However, they create a greater surface area that allows for rapid melting and has a more practical packing density.
Another advantage of the double push up process is that due to the size of the copper metals used and the time, you may not be required to prevent oxidation of the molten copper by using a cover gas. But in applications where protection against oxidation has been deemed necessary, you could use nitrogen or another inert gas can be incorporated to cover the crucible.
Tilting induction furnace from induction furnace inductotherm are recommended for large scale copper melting applications. They are ideal for applications where a large quantity needs to be produced continuously.
Tilting furnaces have large crucibles which allow for melting large amounts of copper. Additionally, the dimensions of the crucible can handle different types of charge materials. You can use copper cathodes or low-grade copper scraps in a single unit.
A metal or ceramic cover is placed over the crucible to prevent oxygen pick up. A cover gas containing nitrogen and 5% hydrogen is placed over the liquid bath during the process. When the temperature in the copper melting furnace gets to the desired temperature, it is transferred by tilting the crucible to pour liquid copper into the die casting machine.
Some of the advantages of the tilting induction furnace include:
- Uses an efficient process that can produce high-quality output due to better monitoring and control of the process.
- Tilting furnaces increase the flexibility of the process.
- It can yield fast rates for continuous melting and charging of metals.
- Using induction furnaces as opposed to electric furnaces reduces energy costs.
- High efficiency and ease of operation reduces the operating costs for the business.
- They can use clean fuels such as natural gas, which results in less pollution and is environmentally-friendly.
Induction furnaces are best suited for melting copper, which has a high melting point of 10830C. The two main types of induction furnaces from induction furnace inductotherm. They are double push up, and the tilting furnace. The choice of the furnace will depend on the size of applications, as well as the nature of operations suitable for your industrial setting. The process has several advantages, which makes them suitable for copper melting. It is highly efficient, easy to operate, and can use clean and affordable fuels like natural gas.