This chapter highlights the different melting, holding, and dosing furnaces that are available for the alternative casting processes used for the production of aluminum castings. Melting furnaces are grouped into four broad categories: crucible furnaces; reverberatory furnaces (or reverbs); stack melting furnaces (also called stack melters), tower melting furnaces, or jet melting furnaces; and electric coreless induction furnaces are detailed in this chapter. Factors influencing the choice of the melting, holding, and dozing equipment are presented. Equipment for recycling machined chips is also addressed.

This chapter provides a brief overview of iron and steel manufacturing and the major equipment involved in the process as well as identifying where casting fits into the overall process. In addition, it provides an overview of cast iron manufacturing, including the processes involved in converting pig iron into cast iron and steel.

The melting furnace is a critically important piece of equipment in a foundry; it influences the balance between the metal required by molding machines and the melting capacity. This chapter presents the features, types, advantages, and applications of furnaces suitable for iron and steels such as cupolas, induction furnaces, and arc furnaces.

This chapter provides an overview of the types of melting furnaces and refractories for steel casting. It then presents information about arc furnace melting and induction melting cycles. The chapter also describes methods for the removal of phosphorous, the removal of sulfur, and the recovery of elements from slag. It then presents an overview of argon-oxygen-decarburization (AOD) refining and types of ladles. The chapter describes chemical analysis that is performed using either optical emission or x-ray spectrographs.

The detailed heating requirements for specific applications must be considered before construction and implementation of any induction heating process. These requirements may include considerations such as type of heating, throughput and heating time, workpiece material, peak temperature, and so forth. The major applications of induction technology include through heating, surface heating (for surface heat treatment), metal melting, welding, brazing, and soldering. This chapter summarizes the selection of equipment and related design considerations for these applications.

Electromagnetic induction, or simply "induction," is a method of heating electrically conductive materials such as metals. It is commonly used for heating workpieces prior to metalworking and in heat treating, welding, and melting. This technique also lends itself to various other applications involving packaging and curing of resins and coatings. This chapter provides a brief review of the history of induction heating and discusses its applications and advantages.

Malleable iron has unique properties that justify its application in the metal working industry. This chapter discusses the advantages, limitations, and mechanical properties of malleable iron; provides a description of the malleabilization process; and presents manufacturing guidelines for malleable iron castings.

This chapter covers the practices and procedures used for shape casting metals and alloys. It begins with a review of the factors that influence solidification and contribute to the formation of casting defects. It then describes basic melting methods, including induction, cupola, crucible, and vacuum melting, and common casting techniques such as sand casting, plaster and shell casting, evaporative pattern casting, investment casting, permanent mold casting, cold and hot chamber die casting, squeeze casting, semisolid metal processing, and centrifugal casting.

This chapter describes some of the technological milestones of the early 20th century, including the invention of tungsten carbide tool steel, the use of age-hardening aluminum in the Wright Flyer , the development of a new heat treating process for aluminum alloys, and Ford’s pioneering use of weight-saving vanadium alloys in Model T cars. It explains how interest in chromium alloys spread throughout the world, spurring the development of commercial stainless steels. The chapter concludes with a bullet point timeline of early 20th century achievements and a brief assessment of more recent innovations.

This chapter provides an overview of key elements in controlling the casting process, systems to confirm the quality of outgoing components, and the steps needed to launch a novel product. The discussion also provides information on process control tools and techniques; incoming material control; process control of sand preparation and system maintenance; metallic charge materials; product quality control; and melting, metallurgical, and mechanical testing.

Because of its speed and ease of control, induction heating can be readily automated and integrated with other processing steps such as forming, quenching, and joining. Completely automated heating/handling/control systems have been developed and are offered by induction equipment manufacturers. This chapter deals with materials handling and automation. First, it summarizes basic considerations such as generic system designs, fixture materials, and special electrical problems to be avoided. Next, it describes and provides examples of materials-handling systems in induction billet heating, bar heating, heat treatment, soldering, brazing, and other induction-based processes. The final section discusses the use of robots for parts handling in induction heating systems.

This chapter describes the processes involved in alloy production, including melting, casting, solidification, and fabrication. It discusses the effects of alloying on solidification, the formation of solidification structures, supercooling, nucleation, and grain growth. It describes the design and operation of melting furnaces as well as melting practices and the role of fluxing. It also discusses casting methods, nonferrous casting alloys, and atomization processes used to make metal powders.

This chapter presents a glossary of foundry terms.