Castings: Aluminum Melting Fundamentals

Aluminum Melting Fundamentals examines the equipment, processes, and general terminology associated with aluminum melting and casting foundries. Presented in THORS’ highly visual and interactive format, this course provides learners with a variety of important topics for this expanding industry. From learners who are new to aluminum casting industries, to seasoned veterans, there is relevant knowledge for everyone in this course.


Learning Objectives

  • Recognize some of the basic equipment used in aluminum foundries.
  • Distinguish between the common furnaces used for melting aluminum.
  • Identify some of the prominent tests applied to molten aluminum.
  • Differentiate between metallic and non-metallic additions for aluminum.
  • Understand the primary steps involved in molten aluminum processing.
Course Length: 2 HRS

Table of Contents

Foundry Terminology

  • Foundry Equipment
    • Ladles
    • Crucibles
    • Skimmers
    • Refractory Materials
    • Resistance Elements
    • Molds
  • Protective Gear
  • Charge vs. Melt
  • Charge Materials
  • Mechanical Properties
    • Hardness
    • Strength
    • Elongation
    • Machinability
    • Conductivity
    • Corrosion Resistance
  • Melting and Solidification
  • Mold Example
  • Casting Processes
  • Filling vs. Feeding
  • Cast Alloy Designations

Furnaces and Molten Metal Testing

  • Crucible Furnaces
    • Fuel-Fired Furnaces: Stationary Furnaces
    • Fuel-Fired Furnaces: Tilting Furnaces
    • Fuel-Fired Furnaces: Lift-Out Furnaces
    • Resistance Furnaces
    • Induction Furnaces
  • Reverberatory Furnaces
    • Wet Bath Furnaces
    • Dry Hearth Furnaces
  • Molten Metal Testing
    • Temperature Checking
    • Spectrometer Analysis
    • Reduced Pressure Testing (RPT)
    • Density Evaluation

Additions and Molten Metal Processing

  • Additions
    • Metallic Additions
    • Non-Metallic Additions: Fluxes
    • Non-Metallic Additions: Inert Gases
    • Non-Metallic Additions: Active Gases
  • Molten Metal Processing
    • Degassing
    • Fluxing
    • Dross Removal
    • Grain Refinement
    • Silicon Modification

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