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Primary casting facilities melt iron ore in massive blast furnaces.

Iron Melting Fundamentals

Iron Melting Fundamentals is an introduction to iron casting processes, including the raw materials, charge preparation, and melting equipment used in modern foundries. Ready to take the next step? Explore the course details and see everything we’ve packed into this program!

Learning Hours: 2

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Course Description

Iron Melting Fundamentals is an introduction to iron casting processes, including the raw materials, charge preparation, and melting equipment used in modern foundries. Presented in THORS’ highly visual and interactive learning format, this course will help foundry employees become familiar with the important equipment and terminology associated with their profession.

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Who will benefit from this Iron Melting course?

Companies, individuals, or educational institutions that produce or require an understanding of cast iron.

Course Classification

This manufacturing course by THORS eLearning Solutions covers identification of key terms and understanding of key concepts.

*THORS uses the Bloom’s Taxonomy Methodology for our course development.

Certificate Awarded for Iron Melting Fundamentals

Example of certificate awarded upon successful completion of the course.

*upon successful completion

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Learning Objectives

  1. Recognize some of the basic equipment used in cast iron foundries.
  2. Recall basic terminology and phrases associated with foundry processes.
  3. Distinguish between the common furnaces used for melting iron.
  4. Recognize the unique traits and properties of prominent cast irons.
  5. Understand the primary tests and analyses applied to molten iron.
A graph tracking the increase in temperature as the metal in the furnace is heated changing the metal from a solid to a liquid.
Iron Melting Fundamentals

Table of Contents

  1. Iron Casting Processes
  2. Cast Irons
    1. Properties
      1. Hardness
      2. Tensile Strength
      3. Elongation
      4. Machinability
      5. Vibration Damping
      6. Corrosion Resistance
      7. Oxidation Resistance
      8. Fatigue Resistance
    2. Types of Cast Iron
      1. Gray Iron
      2. Malleable Iron
      3. Ductile Iron
      4. Compacted Graphite (CG) Iron
      5. White Iron
      6. Austenitic Iron
  3. Melting Equipment
    1. Charge Materials
    2. Protective Gear
    3. Hand Tools
      1. Air Hammers
      2. Oxygen Lances
      3. Sampling Spoons
      4. Slag Skimmers
    4. Preaheaters
    5. Melting Furnaces
      1. Induction Furnaces
      2. Cupola Furnaces
    6. Ladles
      1. Lip Pouring Ladles
      2. Tea Pot Ladles
      3. Transfer Ladles
      4. Treatment Ladles
  4. Molten Metal Testing and Additions
    1. Temperature Control
    2. Chemistry Testing
      1. Spectrometer Analysis
      2. Thermal Analysis of Base Iron
      3. Combustion Analysis
      4. Chill Wedge Analysis
  5. Additions
    1. Alloying Elements
    2. Inoculation

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