Frequently Asked Questions

What is an induction furnace used for?

Induction furnaces are used in foundries to melt iron, steel, copper, aluminum, and precious metals to name a few. Once melted, the metal is poured from the induction furnace into a mold. Once the metal has solidified, it is removed from the mold. This finished product is called a “casting.” The induction furnace can be used in an atmosphere or in a vacuum chamber. Induction furnaces possess a key advantage over gas furnaces due to their ability to convert solid metal to liquid with less contamination (high return).

How does an induction coil work?

Induction starts with a coil of conductive material (ex: copper). As electrical current flows through the coil, a magnetic field in and around the coil is produced. The ability of the magnetic field to do work depends on the coil design as well as the amount of current flowing through the coil. The energy from the coil is transferred to the metal inside the crucible, thereby heating the metal to a desired point.

What is a foundry?

A foundry is a factory that heats metal to a molten state using a furnace and then pours the molten metal into molds to produce metal castings. Aluminum and cast iron are examples of metals commonly processed in foundries. The types of products manufactured in foundries range from cast iron cooking vessels to highly advanced aerospace components.

What is a coreless induction furnace?

The primary component of a coreless induction furnace is its coil. The coil is fabricated from high conductivity copper tubing and housed within a steel shell. To prevent overheating, the coil is water-cooled with a cooling system, such as our own HyprCool® Hybrid Process Cooling Systems. Coreless induction furnaces offer a high level of control over the temperature and chemistry of the metal, as well as even heat distribution courtesy of the induction coil. These characteristics make coreless induction furnaces ideal for melting all grades of steels and irons, many non-ferrous alloys, and re-melting.

What is a channel induction furnace?

Channel induction furnaces are comprised of a refractory lined upper case which houses the molten metal. An induction unit assembly, called the lower case, is attached to the upper case via a throat to provide the melting or holding power. Together, these components create a transformer in which the molten metal loop forms the secondary and receives the power from the induction coil. The loop generates heat as well as a magnetic field which causes the metal to circulate in the upper case of the furnace. This circulation creates a beneficial stirring action in the molten metal. Typically channel induction furnaces are used for melting, or as a holding unit for various alloys.

What is the process of metal casting?

Metal casting is a manufacturing process performed in a foundry. Liquid metal is poured from a melting furnace into a mold and then allowed to solidify. Once the metal has solidified, it is removed from the mold. The finished piece is a casting.

What is a foundry ladle made of?

Foundry ladles are made from hot rolled steel (HRS) and then rammed or poured with refractory lining to prevent damage when the ladle is used to transport molten metal. Without the refractory lining, molten metal would rapidly melt the ladle upon contact.

What is a sand casting?

Sand casting is a metal casting process where sand is used as the mold material. The mold is made of sand and molten metal is poured from a melting furnace into the mold to make a casting. The term “sand casting” may also refer to an object produced via the sand casting process.

Is molten metal magnetic?

Metal loses its magnetism before reaching melting its temperature. The Curie temperature is the temperature at which certain materials lose their permanent magnetic properties, to be replaced by induced magnetism. Different metals have different Curie temperatures. Click here to learn more about the Curie temperature.

What is slag?

Slag is the by-product left over after a desired metal has been separated (smelted) from its raw ore. Slag is typically comprised of metal oxides and silicon dioxide, but can contain metal sulfides and elemental metals. Beyond simply being a by-product of smelting, slag can help control the temperature of the smelting process and can assist in preventing re-oxidation of the final liquid metal product before the molten metal is poured.

Is there a difference between a foundry and a forge?

Foundries heat metal scrap, turnings, and other similar alloys into a molten liquid state. This molten metal is poured into a mold to create a desired shape. Forges heat metal billets and ingots, but the metal is not heated to the point of melting. The application of thermal and mechanical energy to the metal in forging allows the shape of the metal to be manipulated while in remaining in a solid state.

What is metallurgy?

Metallurgy is the science of forming metal into desired shapes or manipulating a metal’s properties through heating or melting and alloying to achieve the desired finished metal shape and chemistry.

What is smelting?

Smelting is a process. The primary use of smelting is to extract a base metal, such as silver, iron, or copper, from its ore. Secondary smelting is the process of removing impurities from old materials and returning to the original base metal.

What is adiabatic cooling?

EMSCO defines “adiabatic” as the process of evaporation where dry air absorbs moisture, thereby dropping its temperature. This process allows us to precool the air without energy cost and cool the process fluid with a smaller, more efficient system than if we were to use the air at its warmer ambient temperature. Click here to learn more about adiabatic cooling systems.

What are your heat rejection services?

We offer heat rejection services such as steel shell furnace rebuilds, vacuum furnace rebuilds, table mount furnace repairs, channel furnace repairs, steel melting furnace repairs, and automatic pouring system rebuilds.

How do you optimize the heat rejection process?

We optimize the heat rejection process by accessing the abilities of your furnace and investigating potential issues through testing. Our professionals will walk you through recommendations for improving systems in your furnace that will optimize the heat rejection process.

Do you offer high voltage furnace installation?

The experts at EMSCO install high voltage furnaces, and we use high voltage furnace insulation to hold conductors in the correct position.

How should I contact you for high voltage furnace installation?

Call us at 1-877-77-EMSCO (773-6726) for your high voltage furnace installation.

What are some safety factors to consider for my high voltage furnace installation?

Safety is a critical concern during high voltage furnace installation. Some safety considerations include ensuring that the furnace is installed in a well-ventilated area, using appropriate safety gear when handling the furnace or its components, ensuring that all electrical connections are properly grounded and insulated, and following all applicable safety codes and regulations.

What kind of power supply is required after a high voltage furnace installation?

A high voltage furnace requires a three-phase AC power supply with a voltage of at least 480 volts. The power supply must be able to provide sufficient current to heat the furnace to the desired temperature.

What kind of insulation is used in high voltage furnace installation?

High voltage furnaces are typically insulated with a combination of ceramic fiber and refractory materials. The insulation must be able to withstand the high temperatures generated by the furnace and must also be able to resist thermal shock and chemical corrosion.

What kind of refractory materials are used in high voltage furnace installation?

High voltage furnaces are lined with refractory materials like alumina, magnesia, and zirconia. These materials are chosen for their high melting points and resistance to thermal shock and chemical corrosion.

How is temperature controlled after a high voltage furnace installation?

Temperature in a high voltage furnace is controlled using a thermocouple or other temperature sensor, which feeds data to a temperature controller. The controller adjusts the power input to the furnace to maintain the desired temperature.

What industries use metal foundry services?

Metal foundry services are utilized by various industries, including automotive, aerospace, construction, manufacturing, and art.

What are the signs that I need a furnace rebuild?

Common signs of needing a furnace rebuild include decreased performance, increased fuel consumption, frequent breakdowns, uneven heating, and non-compliance with updated environmental or safety regulations.

How long does a furnace rebuild typically take?

The duration of a furnace rebuild can vary significantly based on factors such as the extent of refurbishment required and the availability of replacement parts. It could take several weeks to several months.

What are the key features to look for in an OEM induction melting furnace?

When searching for an OEM induction melting furnace, look for features such as efficiency, reliability, ease of operation, safety features, after-sales support, and compliance with industry standards.

What types of induction melting furnaces can an OEM manufacture?

The types of OEM induction melting furnaces vary. Furnaces can be manufactured for melting steel, iron, copper, aluminum, and other metals, with many different capacities and configurations.