Frequently Asked Questions
What is a foundry?
A foundry is a factory that heats metal to a molten state using a furnace and then pours the molten metal into molds to produce metal castings. Aluminum and cast iron are examples of metals commonly processed in foundries. The types of products manufactured in foundries range from cast iron cooking vessels to highly advanced aerospace components. EMSCO offers multiple foundry services, including furnace rebuilds, induction coil repairs, and table mount furnace repair. Call 1-877-77-EMSCO (773-6726) for our foundry services.
What is the process of metal casting?
Metal casting is a manufacturing process performed in a foundry. Liquid metal is poured from a melting furnace into a mold and then allowed to solidify. Once the metal has solidified, it is removed from the mold. The finished piece is a casting.
What is a foundry ladle made of?
Foundry ladles are made from hot rolled steel (HRS) and then rammed or poured with refractory lining to prevent damage when the ladle is used to transport molten metal. Without the refractory lining, molten metal would rapidly melt the ladle upon contact.
What is a sand casting?
Sand casting is a metal casting process where sand is used as the mold material. The mold is made of sand and molten metal is poured from a melting furnace into the mold to make a casting. The term “sand casting” may also refer to an object produced via the sand casting process.
Is molten metal magnetic?
Metal loses its magnetism before reaching melting its temperature. The Curie temperature is the temperature at which certain materials lose their permanent magnetic properties, to be replaced by induced magnetism. Different metals have different Curie temperatures. Click here to learn more about the Curie temperature.
What is slag?
Slag is the by-product left over after a desired metal has been separated (smelted) from its raw ore. Slag is typically comprised of metal oxides and silicon dioxide, but can contain metal sulfides and elemental metals. Beyond simply being a by-product of smelting, slag can help control the temperature of the smelting process and can assist in preventing re-oxidation of the final liquid metal product before the molten metal is poured.
Is there a difference between a foundry and a forge?
Foundries heat metal scrap, turnings, and other similar alloys into a molten liquid state. This molten metal is poured into a mold to create a desired shape. Forges heat metal billets and ingots, but the metal is not heated to the point of melting. The application of thermal and mechanical energy to the metal in forging allows the shape of the metal to be manipulated while in remaining in a solid state.
What is metallurgy?
Metallurgy is the science of forming metal into desired shapes or manipulating a metal’s properties through heating or melting and alloying to achieve the desired finished metal shape and chemistry.
What is smelting?
Smelting is a process. The primary use of smelting is to extract a base metal, such as silver, iron, or copper, from its ore. Secondary smelting is the process of removing impurities from old materials and returning to the original base metal.
What is adiabatic cooling?
EMSCO defines “adiabatic” as the process of evaporation where dry air absorbs moisture, thereby dropping its temperature. This process allows us to precool the air without energy cost and cool the process fluid with a smaller, more efficient system than if we were to use the air at its warmer ambient temperature. Click here to learn more about adiabatic cooling systems.
What areas does EMSCO serve?
EMSCO responds quickly to any foundry crisis from our facilities in Massillon, Ohio; Anniston, Alabama; Pico Rivera, California and Rancocas, New Jersey. We are ready to dispatch mechanics, engineers, and account managers 24/7 to keep your foundry up and you in business with furnace rebuilds, table mount furnace repair, foundry furnace coil repairs, and other foundry services.
What installation and construction services do you provide?
Job Specifying
Project & Construction Management
Electrical, Mechanical & Civil Engineering
Building & Civil Construction
Electrical & Plumbing
Air Handling Systems
Melt Deck Design
Melt Deck Construction
Excavation & Shoring
Cooling Towers & Water Systems
Charge Drying & Delivery
Demolition
Furnace Rigging
High Voltage Electrical
Complex Thermal Processing Systems
Crane Installations
Charge/Scrap Handling
Induction Furnace & Power Supply
Electrical, Hydraulic & Fume Collection
Control Systems
Automatic Pouring Systems
Optimize Heat Rejection Process
Induction Furnace Service FAQs
What is an induction furnace used for?
Induction furnaces are used in foundries to melt iron, steel, copper, aluminum, and precious metals to name a few. Once melted, the metal is poured from the induction furnace into a mold. Once the metal has solidified, it is removed from the mold. This finished product is called a “casting.” The induction furnace can be used in an atmosphere or in a vacuum chamber. Induction furnaces possess a key advantage over gas furnaces due to their ability to convert solid metal to liquid with less contamination (high return). If your business needs foundry services, EMSCO provides furnace rebuilds, induction coil repairs, and more! Request a quote for our foundry services today.
How do I know if I need an induction coil repair?
Signs that you need an induction coil repair include reduced heating efficiency, inconsistent heat distribution, sparks, unusual noises, and visual signs of wear, such as cracks or damage to the coil.
How long does an induction coil repair take?
The time required for induction coil repair depends on the complexity of the repair. Minor induction coil repairs may be completed within a few days, while more extensive repairs might take longer. Contact us or request a quote for your induction coil repair or for other foundry services!
How does an induction coil work?
Induction starts with a coil of conductive material (ex: copper). As electrical current flows through the coil, a magnetic field in and around the coil is produced. The ability of the magnetic field to do work depends on the coil design as well as the amount of current flowing through the coil. The energy from the coil is transferred to the metal inside the crucible, thereby heating the metal to a desired point.
What is a channel induction furnace?
Channel induction furnaces are comprised of a refractory lined upper case which houses the molten metal. An induction unit assembly, called the lower case, is attached to the upper case via a throat to provide the melting or holding power. Together, these components create a transformer in which the molten metal loop forms the secondary and receives the power from the induction coil. The loop generates heat as well as a magnetic field which causes the metal to circulate in the upper case of the furnace. This circulation creates a beneficial stirring action in the molten metal. Typically channel induction furnaces are used for melting, or as a holding unit for various alloys. Call 1-877-77-EMSCO (773-6726) for furnace rebuilds and other metal foundry services.
What are the key features to look for in an OEM induction melting furnace?
When searching for an OEM induction melting furnace, look for features such as efficiency, reliability, ease of operation, safety features, after-sales support, and compliance with industry standards.
What types of induction melting furnaces can an OEM manufacture?
The types of OEM induction melting furnaces vary. Furnaces can be manufactured for melting steel, iron, copper, aluminum, and other metals, with many different capacities and configurations.
Furnace Rebuild FAQs
What is a furnace rebuild?
A furnace rebuild refers to the process of refurbishing or renovating an existing induction furnace to enhance its performance, capacity, efficiency, or to address issues with the furnace. Visit our furnace rebuild page to learn more!
Can I continue production in my facility during a furnace rebuild?
Certainly! EMSCO provides 24/7 foundry services, including furnace rebuilds, induction coil repairs, and more. We will work with you to schedule furnace rebuilds during your facility’s production schedule or after hours. Contact us to learn more!
What are the signs that I need a furnace rebuild?
Common signs of needing a furnace rebuild include decreased performance, increased fuel consumption, frequent breakdowns, uneven heating, and non-compliance with updated environmental or safety regulations. Call 1-877-77-EMSCO (773-6726) for furnace rebuilds and other metal foundry services.
How long does a furnace rebuild typically take?
The duration of a furnace rebuild can vary significantly based on factors such as the extent of refurbishment required and the availability of replacement parts. Furnace rebuilds could take several weeks to several months.
What kind of furnaces can EMSCO rebuild?
EMSCO, Inc. specializes in furnace rebuilds and repairs for induction furnaces by any OEM. To learn more about our foundry services, visit our Induction Melting Furnace Services page!
How often should a furnace be rebuilt?
The frequency of furnace rebuilds varies depending on several factors, including the type of furnace, the intensity of use, the materials processed, and the maintenance practices in place. EMSCO, Inc. can provide a maintenance schedule tailored to your specific furnace rebuild needs. Contact us today to learn more about our foundry services.
Heat Rejection Optimization FAQs
What are your capabilities for optimizing the heat rejection process?
We offer induction melting furnace services such as steel shell furnace rebuilds, vacuum furnace rebuilds, table mount furnace repairs, channel furnace repairs, and steel melting furnace repairs. To learn more about our heat rejection services and other foundry services, please visit our Induction Melting Furnace Services page!
How does EMSCO optimize your heat rejection process?
We optimize the heat rejection process by accessing the abilities of your induction furnace and investigating potential issues through testing. Our professionals will walk you through foundry service recommendations for improving systems in your induction furnace that will optimize the heat rejection process. Our professionals will also let you know if a furnace rebuild is necessary. Contact us today to find out which of our foundry services is right for you!
High Voltage Furnace Installation FAQs
Do you offer high voltage furnace installation?
The experts at EMSCO install high voltage furnaces, and we use high voltage furnace insulation to hold conductors in the correct position.
How should I contact you for high voltage furnace installation?
Call us at 1-877-77-EMSCO (773-6726) for your high voltage furnace installation and other metal foundry services.
What are some safety factors to consider for my high voltage furnace installation?
Safety is a critical concern during high voltage furnace installation. Some safety considerations include ensuring that the furnace is installed in a well-ventilated area, using appropriate safety gear when handling the furnace or its components, ensuring that all electrical connections are properly grounded and insulated, and following all applicable safety codes and regulations.
What kind of power supply is required after a high voltage furnace installation?
A high voltage furnace requires a three-phase AC power supply with a voltage of at least 480 volts. The power supply must be able to provide sufficient current to heat the furnace to the desired temperature.
What kind of insulation is used in high voltage furnace installation?
High voltage furnaces are typically insulated with a combination of ceramic fiber and refractory materials. The insulation must be able to withstand the high temperatures generated by the furnace and must also be able to resist thermal shock and chemical corrosion. Request a quote from EMSCO today for your high voltage furnace installation.
What kind of refractory materials are used in high voltage furnace installation?
High voltage furnaces are lined with refractory materials like alumina, magnesia, and zirconia. These materials are chosen for their high melting points and resistance to thermal shock and chemical corrosion.
How is temperature controlled after a high voltage furnace installation?
Temperature in a high voltage furnace is controlled using a thermocouple or other temperature sensor, which feeds data to a temperature controller. The controller adjusts the power input to the furnace to maintain the desired temperature.
Foundry Service FAQs
What industries use metal foundry services?
Metal foundry services are utilized by various industries, including automotive, aerospace, construction, manufacturing, and art.
What foundry services do you provide?
Steel Shell Furnace Rebuilds
Vacuum Furnace & Coil Rebuilds
European Style Furnace Rebuilds
Table Mount Furnace Repairs
Channel Furnace Repairs
Optimizing the Heat Rejection Process
Induction Furnace Coil Resizing
Furnace Grouting Services
Induction Furnace Field Service & Repair
Furnace Helium Testing
High Voltage Furnace Insulation
How can I request a quote for furnace rebuilds or foundry services?
To request a quote for furnace rebuilds or other foundry services, please visit our Request a Quote page and fill out the form.
Table Mount Furnace Repair FAQs
What can I do to minimize the need for table mount furnace repairs?
To minimize the need for table mount furnace repairs, regularly clean the furnace and keep the area around it free from debris. Furthermore, follow the manufacturer’s guidelines for operation, such as using the furnace within its specified temperature and workload limits to avoid overburdening the unit.
How do I know if I need a table mount furnace repair?
Signs that you may need a table mount furnace repair include performance inefficiency, inconsistent heat distribution, unusual noises, and visual signs of wear, such as damage to the furnace body or insulation.
What kind of maintenance should be performed on a table mount furnace regularly?
To avoid table mount furnace repair, consider regular maintenance, such as checking for signs of wear or damage, cleaning exterior and interior elements, and ensuring controls and sensors function correctly.
Who should I contact for professional table mount furnace repair?
For table mount furnace repair and other foundry services, contact the experts at EMSCO at 1-877-77-EMSCO (773-6726).
How long does a table mount furnace repair typically take?
The duration of table mount furnace repairs can vary widely, from a few hours for minor issues to several days for major repairs involving parts replacement or extensive refurbishment.
Melt Deck Design and Construction FAQs
What are some common maintenance procedures after melt deck construction?
Maintenance procedures after melt deck construction can include:
- Regular inspection and repair of induction furnace refractory lining
- Checking and maintaining induction furnace heating and cooling systems
- Ensuring structural integrity of induction furnace support systems
- Keeping induction furnace ventilation and extraction equipment clean and in good working order
- Examining and testing induction furnace safety features such as emergency stops and spill containment
Does melt deck construction require specialized labor?
Experts are often necessary in melt deck construction due to the technical complexity of constructing a facility that will handle extreme temperatures and potentially hazardous materials. Contact the EMSCO installation experts today at 800.858.7030 for the foundry services you need to get your project started.
Can the melt deck design impact the quality of the finished products?
Yes, the melt deck design can significantly impact the quality of the finished products. An efficient design ensures uniform melting and proper temperature control, which are critical for producing high-quality casts. A well-designed melt deck also minimizes the risk of contamination and allows for effective slag removal.
What safety features should be included in a melt deck design?
Safety features in a melt deck design should include proper ventilation to remove harmful gases, easy access to emergency stops, fire-resistant materials, adequate space around furnaces to prevent accidents, protective barriers, and safety signage. Regular safety training for operators is also essential.
How do I choose the right melt deck design?
Choosing the right melt deck design involves considering the type of metal you plan to melt, your production capacity needs, the space available, and compliance with safety and environmental regulations. It’s also important to consider future expansion plans.
How does the material of the furnace affect a melt deck design?
The furnace material influences the thermal efficiency, durability, and maintenance requirements. For instance, a refractory lining must withstand high temperatures and thermal shocks, and thus affects the structural melt deck design and layout.