The world relies on different types of metal for varying uses, from mechanical equipment to manufacturing. However, melting is the first step to producing valuable aluminum in many industries. An induction furnace for aluminum melting is usually preferred for this process because it provides fast melting rates without compromising efficiency. This allows you to get the best metal quality for your desired purpose. The capacity of an induction furnace for aluminum melting ranges from two pounds to one hundred tons, making them ideal for melting large volumes of metal.
As the world takes an eco-friendlier approach to metal melting, many industries are switching to induction furnaces due to their energy-efficient, clean and well-controlled melting process. You will find this type of furnace in many modern foundries, replacing cupola furnaces that emit pollutants such as dust. Unlike a blast or electric arc furnace that requires an arc, an induction furnace for aluminum melting doesn’t rely on an angle. As a result, the temperature does not exceed the alloy’s melting point, preventing the loss of alloying elements.
While aluminum might be a light metal, you need the industry heavyweight, induction furnace when melting it. Whether you are an aluminum foundry, caster, recycler or alloy supplier – an induction furnace for aluminum melting is an industry that has proven and is highly efficient for alloying and remelting. Induction melting systems can also be customized to suit any aluminum application.
Coreless Induction Furnace for Aluminum Melting
As mentioned, aluminum is a low-density metal, and an induction furnace for aluminum melting is explicitly designed for lightweight metal. These systems employ the right temperature and evenly distribute the heat, which is crucial when handling metals such as aluminum, preserving quality and durability. Aluminum casting became increasingly important in the early 20th century when the British employed an induction furnace for aluminum melting, popularizing the processing technique until today.
The induction furnace for aluminum melting uses alternating current to melt the metal, whereby the heavy, pure aluminum sinks to the bottom, and the impurities rise. This makes it easy for the top layer containing the contaminants to be removed using the tilting mechanism, leaving pure aluminum. The induction furnace also has a cooling water system that keeps the coil from overheating, allowing for more precise temperature control and faster metal melting. The circulating water is also crucial to prevent the metal from overheating.
An induction furnace for aluminum melting offers an approximate 75% efficiency rate, low emission, reduced losses due to oxidation, and enhances the final product’s degree of uniformity and purity. The key benefit of using an induction furnace for aluminum melting is that the metal does not come into contact with the heat source, making it ideal for mixing when aluminum alloys are being produced. The electric field passes through the molten aluminum, stirring it as it melts.
These are some reasons why an induction furnace for aluminum melting is considered the best option for recycling to create cast aluminum alloys or extract the pure aluminum element. This process uses far less energy than other types of furnaces. Induction furnaces are custom-built to meet the aluminum capacity needed for various industries.
Core-Type Channel Induction Furnace for Aluminum Melting
While coreless induction furnaces are more flexible, core-type channel furnaces are more efficient and knowing the difference between the two helps you choose the most ideal for your needs. The enhanced efficiency over the former is that the iron core is designed to concentrate magnetic flux in the molten loop, guaranteeing optimal power transfer from primary to secondary. This boosts power efficiency to 98%, making it a suitable induction furnace for aluminum melting.
When high production of aluminum products, channel furnaces are the most effective; with a core-type channel induction furnace, you are guaranteed a multi-shift and continuous casting schedule, holding capacity for shift melting operations for off-peak energy savings, few allow changes and power demand limiting. A channel furnace is practically the most economical way to have a large quantity of molten metal for a long time to produce a continuous supply of metal that is ready to pour.
You can use a coreless induction furnace for aluminum melting during off-peak energy demand periods and store the molten metal in a channel furnace, making it easy to be tapped for production during on-peak hours. If you intend to use a channel furnace to melt aluminum, a metal loop must be maintained continuously to avoid circuit disruption and rupture when it’s allowed to freeze. This usually calls for extensive work restoring the circle, or you risk disassembling and realigning the entire system. Consequently, this type of induction furnace for aluminum melting is rarely allowed to cool, preventing alloy changes when a heel of molten metal is always needed.
Another consideration with a channel furnace is keeping narrow melting channels clean, preventing slag accumulation on the walls. This ultimately results in the restriction of metal from flowing freely and overheating. This furnace’s operating characteristics are constant, making them suitable for refractory lining due to the consistent temperature. Since aluminum is a low-density metal with proper maintenance, the uppercase lining extends for several years, allowing millions of pounds of molten metal. Channel furnaces are preferred for melting single alloys, acting as a holding vessel or a pressure-pour furnace.
New to Induction? Here’s What You Need to Know
Current flows through an induction coil, forming a magnetic field. When an alternate current is passed through the coil, it creates a magnetic field that changes in direction at the same rate as the frequency of the alternate current. When added aluminum charged material, the induced voltage results in the flow of current through the material in the magnetic field. The current flowing creates resistance to the flow of electrons, giving off more heat transferred through the material via thermal conduction. Water cooling systems keep the coils cool, but since aluminum is a low-temperature metal, some systems can be air-cooled.
Numerous options can be added to an induction furnace for aluminum melting, making operation more accessible and user-friendly. For more information about induction furnaces, reach out to our representatives for more information.