Manufacturing process crucible furnace

Cortes,M.I; Sacristan,A.D; Sanchez,L.T; Sanchez, J.M; Orjuela,C.C; Rodriguez, N.D;

Avila, C; Villalba,N.A; Torres,D; Serrano,B; Leal, F; Caicedo, S; Quiñonez, F; España,
H; Urueña, S; Arciniegas,H*

Fabricacion de piezas II
Universidad de Ibagué.

Abstract- This proyect has like an objetive design and manufacture of the tilting and
the burner for a crucible furnace to melt aluminium. In the firts part, the bench was
designed, this will support the discharge system`s and it`s generator is base d on the
power transmission`s by gears.

Subsequently, the fuel was chose (propane), continuedly the flame temperatura and the
power that this should be to reach, was calculated.

The join of the whole bench system`s will realice whit welding “SMAW”. Fort the welds
have made we will have to do the respectives strength calculation`s for verify these will
can to support.

The furnace weight also we hace to evaluate the posibles defects through no
destructives test`s : ultrasound and penetrating dyes.

Keywords : burner, tiling , bench, discharge system

because that, the propane is the best

INTRODUCTION
After years of service, a lot of
components made from non-ferrous
material have to be discarded, because
that is so important to re-melting and re-
casting the material. For this reason an
eficient crucible furnace is very useful,
because the available local means of
recycling process is slow and wasted a
lot of heat[ CITATION Bel96 \l 3082 ]
Crucible furnace can be fired by
different kinds of fuels, such as diesel,
coke or biodiesel; but this fuels have
limiting as Price and heat capacity,
choice, it is environmentally friendly,
economic and it have a good heat
capacity[ CITATION Ola15 \l 3082 ]
A furnace consist of: a complex sistema
interconected betwen it. First, the
furnace need a refractory materials for
lining it to return heat at high
temperaturas, after, a Steel Shell to
contein everything, and the burners; a
very important elements for the
smelting it need to reach temperaturas
of more tan 1000ºC, also it need a
chimney to remove the exhaust gases
from the combustión chamber[ CITATION
Abu14 \l 3082 ]

EXPERIMENTAL TECHNIQUES
For the crucible furnuce was made, first,
it`s must doing one matrix of selection
to decíde which was the fuel most
appropiate, after ir was must design all
the system from the base to transmition
system for gears in one axis to ensure
the torque of furnice.
In the time to begin to welding the
structure is essential to identify the
material on the which is work in the
electrode calculated to this application.
Also it`s important identify the weinght
that must support and throungh load
determinate if the welds can support this
work condition.
Finally, it must evaluate the final results
through undestructile test such as
penetrants inks and
ultrasound[ CITATION Flo141 \l 3082 ].
Were used equipment and supples.
Shielded metal are welding (SMAW) is
a welding process in wich the base
metals are heated to fusión or melting
temperatura by an electronic arc;
temperatura of the arc in SMAW can
over 5000ºC[ CITATION Jho93 \l 3082 ]
In SMAW, electrical current flows
across an air gap between the covered
electrode and base metal. Welding
machines, also called power sources,
produce two types of current, direct
current(dc) and alternating current(ac),
in this cause, is direct current with a
negatively charged, it is used whit
electrodes that do not produce deep
penetration.
The function of a power supply is to
take the high-voltage, low-current
supplied power and charge i tinto the
low-voltage, high current power needed
for welding.[ CITATION Har14 \l 3082 ]
Also, the equipment had a motor
generator for use to créate dc power,
this motor is very important for the
work[ CITATION Var12 \l 3082 ]
For the construction, the material deman
is very big, because the need of
structural Steel for the bench, rowlocks,
shafts, gears and a Steel sheel to the
surface of the crucible furnace whit a
cover and a sufficient suppy of propane.
For the test it used nondestructive
testing; Nondestructive testing (NDT) is
the process of inspecting, testing, or
evaluating materials, components or
assemblies for discontinuities, or
differences in characteristics without
destroying the serviceability of the part
or system. In other words, when the
inspection or test is completed the part
can still be used.[ CITATION AWS10 \l
3082 ]
It used two kinds of testing: liquid
penetrant testing, is that when a very
low viscosity liquid is applied to the
surface of a part, it will penetrate into
fissures and voids open to the surface .
[ CITATION Ste04 \l 3082 ]
The other one is the ultrasonic testing,
uses the same principle as is used in
naval SONAR .  Ultra-high frequency
sound is introduced into the part being
inspected and if the sound hits a
material with a different acoustic
impedance (density and acoustic
velocity), some of the sound will reflect
back to the sending unit and can be
presented on a visual display.[ CITATION
ASN09 \l 3082 ]
 were not generated. This is because
usually the cracks are formed when the
material is in service and not on new
materials.

ANALYSIS OF RESULTS

At the beginning of the practice, the

material used to te bench was unknown,
for that reason was necessary make a
metalography whit a little sample of the
Steel, this is the study of the
microstructure of all types of metallic
alloys and is very useful when the
material is unknown like this case.

After a comparison of hardness and

microstructure, the conclusion was, that
structural steel is medium carbon steel,
probably AISI 1045[ CITATION
TER \l 3082 ], and the steel for the
shell and the cover is ASTM
A36[ CITATION SUM \l 3082 ],
Knowing the material is easier selecting
the electrode, E-6013 for this case

The welds have to be taken into account

to calculate resistance and apply non-
destructive testing for defects, that for
do not in the service condition.

After to do the ultrasonic non-

destructive test we could see the
presence of porosity also we identified
slag inclusions from the radiographs
taken with the EPOCH XT.

Significantly the bench is not

supporting the furnace weight`s, cracks

CONCLUSION equipment to be much more

It was posible to créate a tilting
crucible furnace, wich provides security
to the operator.
Whit proper selection of materials that
make up the crucible furnace, allow the
manageable and esthetic.
Calculations relevant to the design
elements are made, so we proceeded to
the selection of hig quality materials.
The construction process showed the
need for technical skills to prepare the
walls and the base of the crucible
furnace, support structures and correct
assembly of parts.

Tests made in the laboratory for

validating the design parameters
submitted to note that the bench
supports the weight of the crucible
furnace.

All information collected through

research was of great importance for
undestanding the operation,
construction, methods and design
parameters of the different elements that
compose a crucible furnace.
RECOMMENDATIONS
The high weight of the crucible furnace
must to be a problem in the future,
because that, it is recommended the use
of less dense materials for future
prototypes, with the final purpose to
make it more versatile, easy to the
transport and operation.
It could adapt a more flow blower, for a
faster temperatura rise and save energy
because the process will be faster.

Adjust on the burner a dispersion

system of diesel for a more powerful
combustion, not required much propane
and the process will be more economic.

Proporcionate some kind of filter

system in the mouthpiece of the crucible
furnace, for clean the foundry of slag
and impurities.
 REFERENCES

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