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  • Metal Melting Furnace - 1991

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    21 vistas23 páginas

    Metal Melting Furnace - 1991

    Cargado por

    angel123
    fundicion metales libro completo

    Copyright:

    © All Rights Reserved
    Descargue como PDF o lea en línea desde Scribd
    Marcar por contenido inapropiado
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    HOW TO BUILD A METAL MELTING FURNACE Published by: ‘TRENDLINE PUBLISHING COMPANY (A Division of Trendline International Pty. Ltd.) G.P.0. Box 1889, Sydney, 2001. Australia, © Copyright 1991. Trendline international Pty. Ltd. Reproduction prohibited by any method without prior permission in writing from the Publishers. This manual is compiled from a special projact headed by J.T. Allowyn and commissioned by Trendline International Pty. Ltd. for adapting the patented design into a compact iow cost unit capable of being built and used in the home workshop. The information contained herein is believed to be accurate, butis sold as information only, and no liability is aecepted by either the Publishers or Research analysts. PUBLISHER'S NOTE ‘This units prowected by patont administered by our parent company, Trendine Intemational Ply. Lid. We have fal pubishing rights, ‘andthe purchase otis manual entes you to buld one or Your own Us. Howove, I You itond manufacturing tr rea, asall royal apples and you should wie to Trendine Ietrnatonal Py Li. ae ask for @Royaly Agreement frm to be posiod to you. WARNING Metal melting is dangerous. Wear protective clothing and pay particular attention to all safety procedures, INTRODUCTION, ‘The design of this furnace is relatively simple and straightforward, but never the less is highly efficient and capable of industrial quality output, and will give you many years of lasting plea ‘re and trouble free service. This \ ce ds small enough for the home workshop, but big enough for small scale comercial produetion.It is capable of producing very high quality castings in all types of comsonly known casting metals, and will take up to a size Al0 melting erucible.(Melting pot). An Al0 crucible holds 2 litres, and is a big capacity for backyard use-It is as big as can be safely handled by one man as far as aluminium output is concerned. (Tt is advisable to have an assistant helping if you are melting a full charge of cast iron due to the extra weight, and the fearful searing heat of this waite hot molten metal.) We have designed the furnace at this size because a lot of the castings that you might want to do require this amount of molten metal to form one casting. Items such as machinery casings,- mounting plates, and other specialised and custom designed equipment such as lathes and milling machines which you can build yourself. Also, if you take up small scale production runs such as supplying car clubs with custom castings or reproductions of hard to get parts, you can pour all the small separate castings in one melt, thereby saving considerably on time, fuel and effort. This type of furnace is best described as a solid fuel, cructble furnace. This means the fuel used is solid such as coke, coal or char.(Char is a type of compressed coke. It is often used instead of wood for stoves and heaters.) The term "Crucible Furnace” means the metal is melted in a crucible, ie. a melting pot rather than melting in direct contact with the coke as is the case with the more popular cupola type furnace. The cupola type furnaces were more popular for continuous melting because the coke and metal is shoveled in on an alternating layer basis with the burning coke in direct contact with the metal. The molten metal flowe to the base of the furnace where it is periodically tapped off. While this type of furnace is better sufted to continuous melting it does not produce the purity and quality of the standards which are possible in the crucible furnace. In the cupola, the molten metal tends to absorb impurities from the burning coke. An additional disadvantage is the difficulty in experimenting with chemical additives and steel alloys..... the problem being that the chemicals will either change or vaporize with the direct flame contact, and steel will oxidize and actually burn when exposed to the combination of intense heat and the air blast. However, in the crucible furnace the molten metal 1s protected inside the melting pot, and in-simplified terms ‘what you put in is what you get out". It has been designed so that you can melt and cast all types of common metals ranging from the low melting point metals such as lead, zinc and aluminium up to the highest range which includes cast iron, stainless ‘steel, carbon stecl, mild steel and cast iron / steel alloys where the pouring temperature reaches 1550°C. At this temperature the colour of the furnace interior, the melting pot and the molten metal has gone beyond bright red and light yellow to tura into a brilliant dazzling white. The construction of the furnace is relatively elaple, and can easily be built by the average hone handyman. Tt is basically a 60 litre (12 gallon) ofl drum forming an outside casing which holds the furnace lining and internal components. ‘The material used in the construction 1s high quality industrial refractory cement, known in the trade as "Refractory Castable”. This forms the main lining of the furnace, and incorporates the air blast grates, and an adjustable centre post to support the melting pot. A sheet of 25mm ceramic fibre is 2. fri 88 additional insulation between the refractory cenent and the drum wall. fhis particular type of refractory material is quite common in the furnace industry, and can be purchased from most furnace equipment suppliers. The refractory cement is called “Duracast 1650", and the insulating fibre 1s called 25nm Ceramic Fibre, LT900 grade. ( This ceramic fibre is the same grade as is used in the portable stove ). If you have difficulty getting this material from your local suppliers, you can buy it direct from Field Furnace Refractories Pty. Ltd. Crescent St. Granville, 2142 (Sydney). Ph. (02) 637-1001.They are in Goodlet & Smith brickworks in Crescent St. Granville.. They will supply you direct at discounted industry prices. Ask for Alan Jones. He will give you an up to date price, and will organise freight and delivery to anywhere in Australia. The prices as at the date of publishing this manual is $32-50 for a 25kg bag of the Duracast 1650. (You will need 5 bags ), and the ceramic fibre sheets measuring 600mm x 900mm are $8-00 each. ( You will need 2 of these). This particular combination of materials has been chosen because it is easy to use, and will withstand around the clock working temperatures of up to 1650°C. Although this cenent is considerably more expensive than the lower temperature grades, it is essential that you use the Duracast 1650. This furnace reaches temperatures in excess of 1550°C, and cement below the 1650°C grade are likely to soften, in some cases nelt into a black treacle like substance which will ruin your furnace and necessitate a partial rebuild. Note; It may be your intention only to melt low temperature metals such as aluminium. Even in circumstances such as this it is still essential that you use the 1650°C. The reason being that tt takes a while for the temperature in the melting pot to reach it's proper pouring temperature. During this heat build up, the temperatues in the furnace, particularly around the centre post may be up around 1500-1550°C. This 1s particularly so when you are doing quite a lot of melts, and the furnace temperature is well up, and a cold pot of aluminium is put ia. The pot will be comparatively cool, yet when the air blast is turned on the centre post with its retained heat content will be glowing bright red or even light yellow within a few minutes. (Light yellow is around 1350°C), and as the aluminium reaches its pouring temperature of around 760°C, the lower portion of the centre post will be up around 150°C. BASIC CONSTRUCTION DETAILS . This furnace is designed for easy low cost construction using readily available parts. Apart from the refractory cement all other parte can be obtained for very Little cost, and in some cases no cost at all. Basically the furnace is a 60 litre ofl drum lined with refractory cement, and Tunning on either charcoal, barbecue heat beads, coke, coal or any similiar type of solid fuel. It is a forced draught unit, with the air being supplied by either an old vacuum cleaner in reverse cycle, te. blowing air, or any other air blowing device. The lid mechanism is made using old water plpe or steel tube. The trolley is optional. We have made up this trolley using old scrap angle iron, (see photo) with the wheels being salvaged from a garbage throw out, and the sand and tool trays made from the sides of an old washing machine. It could have been all screwed, rivetted or bolted together, but we have welded it simply because it was quicker and easier. The trolley is useful for wheeling it in and out of the shed. However if you have 3. a well ventilated weatherproof area to position and use the furnace as a permanent fixture, then the trolley is of no value. Tn fact, a permanent fixture is more desireable because you can set up your sand area and molding trays for an efficient work output, and have all your refined ingots stacked and labelled for quick reference and selection. This furnace is designed for ease of construction. In accordance with our usual criteria of design, serap material is used extensively in our projects. In this particular project, the design is quite flexible. This means you can use whatever scrap material will do the job in whatever layout you prefer to sult your shed, and your style of work. However, there are certain essential requirements are far as design and material are concerned. eg. The furnace interior design and specified material. Throughout this manual, alternatives in materials and design are given. This enables you to look around your shed and pick out a likely piece of scrap and use it. This ts much more convenient than running around the shops chasing up new parts., and of course the big advantage {s old scrap pleces cost you nothing. Where a specific design or procedure is required, then no options or alternative ideas are given, and in this case it is essential that our specifications are followed. Sand tray d Fo way binge

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