Foundry Engineering-II

Lab Report no.2

Submitted to:
Sir. Atif Makkhdoom
Submitted by:
17MME-S1-303
USMAN LIAQAT
Dept. of Metallurgy and Materials Engineering
5th Semester
University of the Punjab
Experiment #2
“Melting of aluminum from available scrap and casting an ingot”
Theory
“Aluminum is very cheap metal because it is 3rd abundant element on the earth. It is casted in the
form of a ingot to use as a raw material in further mechanical processes for its production.”
“Good melting practice referres to the defect free casting, if we melt the metal in good way by
making sure about all the necessities of melting then our casting will be defect free. Melting of
alumina is always good melting practice. Alumina melt at 660°C which is not a very high
temperature it can be achieved easily and less difficulties come at low temperatures. Flux is
added in alumina during melting the purpose of adding flux is to reduce the melting temperature
and not to allow the gases to pass in the liquid metal, for entrapped gases in aluminum a
degasing tablet is used which removes the gases from aluminum by making bubbles which
comes out on the surface the tablet is forced to put at the bottom of the crucible during melting.
Aluminum makes alumina Al2O3 very rapidly so this should not be entrapp in the casting. After
casting it can be checked by cutting a section to see whether there are bubbles on the surface or
not. A good casting is bubble free and smooth.”
Apparatus required
 “Crucible”
 “Tong”
 “Pit furnace”
 “Casting mold”
 “Thermocouple”
Materials requires
 “Aluminum scrap”
 “Flux”
 “Degasing tablet”
Experimental procedure
“Scrap of aluminum was taken and placed in the crucible inside pit furnace and allowed to heat,
the temperature was measured with the help of thermocouple during melting. Flux and degasing
tablet are also added in aluminum during melting. The aluminum was melted a little above its
melting temperture. After melting the aluminum it is poured into a mold. The aluminum is
obtained after cooling in the form of ingot.”
S
Steps for Casting
 Mold Making
 Prepration of Cavity
 Removal of pattern
 Pouring of metal
 Cooling of metal
 Removal of Product
 Machining

Figure 1 Cavity making by pattern

Figure 2 Escaping of Gas

 Figure 3 Casting agting sysytem

Figure 4 final product

Result
The final product of casting obtain by removing gating system.