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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.
The cakes are heated in a liquation furnace, usually four or five at once, to a temperature above the melting point of lead (327°C), but below that of copper (1084 °C), so that the silver-rich lead melts and flows away. [5] As the melting point of lead is so low a high-temperature furnace is not required and it can be fuelled with wood. [7]
The fuel should have high heat of combustion and produce oxides with low melting point and high boiling point. The oxidizer should contain at least 25% oxygen, have high density, low heat of formation, and produce metal with low melting and high boiling points (so the energy released is not consumed in evaporation of reaction products).
The advantage of the induction furnace is a clean, energy-efficient and well-controlled melting process, compared to most other means of metal melting. Most modern foundries use this type of furnace, and many iron foundries are replacing cupola furnaces with induction furnaces to melt cast iron, as the former emit much dust and other pollutants ...
In making crucible steel, the blister steel bars were broken into pieces and melted in small crucibles, each containing 20 kg or so. This produced higher quality metal, but increased the cost. The Bessemer process reduced the time needed to make lower-grade steel to about half an hour while requiring only enough coke needed to melt the pig iron.
Exothermic welding, also known as exothermic bonding, thermite welding (TW), [1] and thermit welding, [1] is a welding process that employs molten metal to permanently join the conductors. The process employs an exothermic reaction of a thermite composition to heat the metal, and requires no external source of heat or current.
Ideally, the melt rate stays constant throughout the process cycle, but monitoring and control of the vacuum arc remelting process is not simple. [5] This is because there is a complex heat transfer occurring involving conduction, radiation, convection within the liquid metal, and advection caused by the Lorentz force. Ensuring the consistency ...
After the carbon content in the melt had dropped to the desired level, the air draft was cut off: a typical Bessemer converter could convert a 25-ton batch of pig iron to steel in half an hour. In the 1860s development of regenerative furnaces and higher temperature refractory lining allowed to melt steel in an open hearth. That was slow and ...
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