308 1313, ELECTRIC FURNACES (1) Introduction (©, Blectric furnaces are employed forthe production of castings, because: ‘= the furnace atmosphere ean be more closely — losses by oxidation can be eliminated, — alloying elements ean be added without fear of (due to oxidation) composition of the melt and its temperature can rately controlled, i) Electricfurnaces are used for melting steels (neh ‘ce, tool steels and stainless stels)high-test and alloy east ete (ii)_As compared to other furnaces, the cost of oper clectric furnace is high; however this has to be borne when finest quality are demanded. (Gv) Capacity of electri furnaces ranges from 250 kg 1010 (») More than 30% of the yearly tonnage of castings in Uy produced in electric ate furnaces. 13.4, DIRECT ARC FURNACE Introduction (©, Wisthe most widely used remelting unit in steel f Gi). Ieremelts steel of widely differing compositions. (if) The largest direct are furnaces have capacities of about (iv) Direct are furnace as its diameter up to 6 metees. (®)_ Rating of the transformers supplying power to the from 800 kVA to 4,000 kVA. (vi) A S0ton direc are furnace may require arc current of ‘f 25000 Amps and are voltage of about 250 volts, FURNACES AND PRACTICE 309 ‘A ticect are furnace consists of a heavy steel shell fined with ick and silica for acid lined furnaces and magnesite for basic Acid ning is prefered when good steel serap low in sulphur ‘and phosphorus is available so that removal of these two clementsis not required; the heats are produced much faster, =A basie fined furnace is advantageous because inferior serap ‘may be used to make good stel; the basic process removes S&P from the metal. However the heats take longer time than in acid lined furnaces. = Moreover, basic refractories are costlier than acid refrac- The roof ofthe direct are furnace consists ofa stel roofing in silica bricks ate fixed in position, The direct are furnace may be charged either from the charg- ing door which also serves for removing stag from the (top of the) molten metal or from the Furnace roof which is made to lift of and swing clear of the Furnace. A few spare roofs can be made available at all times as the oof does not have a very long i Depending upon whether it sa two phase or three phase electric two or thre graphite electrodes are inserted through the holes in Hint the furnace, — Electrodes can be raised up or down, — For a 50 ton furnace, each electrode carties a current of the ‘order of 25000 amperes. Hlectrode guides placed on the furnace roof (not marked) are water lo dissipate damaging heat. )Allare furnaces rest in bearings on their two sides and bearings jh re mounted in trunnions; thus are furnaces canbe tilted backward, for charging, running off the slag and pouring the molten metal of the furnace (ie. refractory linings, ete.) is pre hefore placing the metal charge in the furna — Preheating is done by alternatively striking and breaking the are between the (vertical) electrodes and used clectrode pices kept on the hearth310 FOUNDRY — After preheating, the electrode pieces placed on the: CO are removed, (G®) ‘The furnace is charged either by swinging over the through the charging door. — For meliing cast irom (the furnace is aid lined and) proportion of the metal charge consists of cast iron. (return) scrap having sand adhered to it —For melting steel, the charge is usually steel ser ‘depending upon its Sulphur and Phosphorus content, or basic lined furnace is employed. — Besides remelting purposes, a direet are furnace ean used for making steel; the charge inthis case will consist irom and stecl scrap. Steel is made by using the same as described for open hearth furnace. (ii) Once the cold charge has been placed on the hearth furnace, electri arcis drawn between the electrodes andthe surface‘ metal charge by lowering the electrodes down till the current ju ‘gap between the electrode and the charge surface. (iv) The arc gap between the electrode and the change is automatic controls which raise or lower the electrode and maintain ted are gap (or are length) by maintaining constant are voltage. ler arc lengths produce more intense heat, however is alittle fear of contaminating molten metal with (the electrode material) 0) (i) (i) 1 i, € Electrode Root Steel shell ‘Spout titted post Pe -f wal 1 8 ll. 9. ig 1810, Diet are Furnace TING FURNACES AND PRACTICE, an ‘Three arcs burning simultancoudl produce a temperature ofthe ler of 11000°F, and readily melt ux, snd (embedded on the surface of ge) and the metal serap, = The slag formed due to melting of flu, sand ete, covers the ‘molten pool of meta 7 = Slag present on the top of the molten metal bath reduces its ‘oxidation, = rfines the metal, and — protects roof and side walls from the large amount of heat ‘radiated from the molten metal — The molten pool increases in the whole of the serap is melted, ‘Before pouring the liquid metal into the ladle, the furnace is with the passage of time tll od backward and the slags poured off from the charging door. ‘The furnace is then tilted forward (refer Fig. 13.10) and the olen metal is emptied into ladles. Hearth, side walls and roof of the furnace are repaired with the Jolp of suitable refractory materials after each heat. Advantages of Direct Are Furnace Unlike crucible furnaces, direct are furnaces undertake a def hie metal refining sequence. — Additions to the charge are made so as to form slags which hhave a refining action on the metal — Molten meta is refined toa proper analysis and is heated to a suitable pouring temperature. Electric furnaces lend themselves to close temperature and heat Analysis of melt can be kept to accurate limits. ‘A direet are furnace has a thermal efficiency as high as about “Alloying elements like Cy, Ni, and W’ can be recovered from the grap with litle losses. Tt ean make stecl directly from pig ion and steel sera. compared 1 an induction heating furnace: ‘Arc furnace is larger and its electrical equipment is cheaper to ‘An are furnace is preferred for its — quicker readiness for use,312 FOUNDRY — longer hearth if, — case of repair, — greater independence ofthe quality of the charge. Limitations 1. Heating costs are higher than for other (say crucible) ‘This however can be adjusted to some extent by using low cost turnings or borings as metal charge i) i) Uses In general, high quality carbon steels and alloy steels in made in electric direct are furnace, 13s, INDIRECT ELECTRIC ARC FURNACE (OR ROCKING FURNACE) Introduction ()._Anindirect electric are furnace has a capacity ranging kg up (02 tons, (ii) Itis preferred for producing smaller melts as compared to are furnace (ii). Unlike direct are furnace, an electric arc is struck bel fraphite electrodes and the metal charge does not form a part clecric circuit oO {ING FURNACES AND PRACTICE, Chersing door Pouring spout Mowten metal by a socking drive unit to rock the furna 313 ‘There are three openings, two for the two graphite electrodes the thd isthe charging door for feeding the metal charge into the ‘Built up withthe charging door is pouring spout Steet shel ‘Betractory Kp - Roller Fe L ig TL Ansoirc aeoce To rocking Furnace is mounted on the roller (Refer Fig. 13.11) which are e back and forth during : i hie (i) Anindret lecticare furnaces ofrckng pe becuse : ai back and forth during the melting process. The metal thus — While the fovznce roc, Hackl tal pees os (end contact wih ba etetry neg and pct wp beat for meng raiactoryUnings and sborb heat from them. tn dito, gS dhring rocking, metal charge consiuents got mixed up : thoroghiy. () Metal charge melts because of the heat radiations from — Rodi ering of furnace speeds up mcg srs the molten meth andthe bot refractory walls ofthe ornace and condaction fom och of epee rea mates to mln eh se ee ae sect ag fm ting red ‘ver the same : j = The ange of rocking of frnace is adjusted in sch manner (7 Anindret ar furnace ed for meting: Tha tiuid meta eel romain bow the pouring — Steel yration — Capper ands log ’ (v)Aninaivedt ar forace obtains loves temperatures and () First fal pgitonis charged inthe furnace 0) cffcieney as compared to a direct ar furnace (i) Construction (@)_Anmindirect arc furnace consists ofa barrel type shell steel plates, having refractory lining inside iw) Re Above pig iron, scrap is placed. With clectie power on, graphite electrodes are brought nearer he current jumps and an electric arcs set up between them, The heat generated in the arc is responsible for melting the314 FOUNDRY TECHNOLOGY. () As soon as some metal has melted, the furnace is set to rock and fro. Rocking helps better heat exchange between refractory lini ‘molten metal and solid metal (i) Rocking of furnace and adjustment of are gap between graphite electzodes is automatically controlled. (bil) When the melting is complete, the furnace stilted mechani (but not automatically) farther than for rocking, to permit liquid metal flow out the pouring spout (tap hol) into the ladle. Advantages (Metal charge does not form a part of electrical Gi) Rocking of furnace voids overheating and thus damaging of refractory li = Sirs and thus provides a melt of uniform composition, — speeds up melting (ii) Low cost serap metal can be used in an indirect are furnace (Ge) Operation and control ofthe furnace are simple. In an alternative design of a rocking furnace, instead of 38) resistance heating of a single electrode may provide necessary ‘melting (refer Fig. 13.12) ig 1312, Resistance Heating frac. The electrode has reduced diameter at its center greatest resistance tothe flow of current and henc> high heats which ae utilized for meting purposes. — The furnace operates noiseless. = The furnace involves high operational cost.