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Melting metal in a crucible for casting A metal die casting robot in an industrial foundry. Melting is performed in a furnace. Virgin material, external scrap, internal scrap, and alloying elements are used to charge the furnace. Virgin material refers to commercially pure forms of the primary metal used to form a particular alloy.
Vacuum arc remelting (VAR) is a secondary melting process for production of metal ingots with elevated chemical and mechanical homogeneity for highly demanding applications. [1] The VAR process has revolutionized the specialty traditional metallurgical techniques industry, and has made possible tightly controlled materials used in biomedical ...
Aluminium smelting is the process of extracting aluminium from its oxide, alumina, generally by the Hall-Héroult process. Alumina is extracted from the ore bauxite by means of the Bayer process at an alumina refinery .
Permanent mold casting is a metal casting process that employs reusable molds ("permanent molds"), usually made from metal. The most common process uses gravity to fill the mold. However, gas pressure or a vacuum are also used. A variation on the typical gravity casting process, called slush casting, produces hollow castings.
Toy road roller cast from zinc. Pot metal (or monkey metal) is an alloy of low-melting point metals that manufacturers use to make fast, inexpensive castings. The term "pot metal" came about because of automobile factories' practice in the early 20th century of gathering up non-ferrous metal scraps from the manufacturing processes and melting them in one pot to form into cast products.
Smelting involves more than just melting the metal out of its ore. Most ores are the chemical compound of the metal and other elements, such as oxygen (as an oxide), sulfur (as a sulfide), or carbon and oxygen together (as a carbonate). To extract the metal, workers must make these compounds undergo a chemical reaction.
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Reverberatory furnaces are widely used to melt secondary aluminium scrap for eventual use by die-casting industries. [4]The simplest reverberatory furnace is nothing more than a steel box lined with alumina refractory brick with a flue at one end and a vertically lifting door at the other.