Melting Of Aluminum And Aluminum Alloys

MELTING is the initial step in the fabricating of all aluminum and aluminum-alloy products. Its function may be considered as threefold: to improve the metal quality, to adjust the composition, and to change the form to that required for subsequent fabrication. Because the melting operation is generally somewhat removed from the final product fabrication, its importance is frequently overlooked. Melting equipment and melting procedures can reflect materially on fabricating procedures as well as on quality and cost of final product. The selection of equipment and the establishment and control of melting procedures, therefore, should be given careful consideration. It is the purpose of this paper to present the various factors that should be considered in establishing melting procedures and in selecting melting equipment. Certain of these are the result of the inherent characteristics of aluminum and can be treated rather specifically. Others depend on the particular production requirements and hence will have to be considered more generally. This paper is intended to cover only the melting of solids, as differentiated from fines, such as borings, turnings, and sawdust. The melting of fines, in many respects, is a subject that should be treated by itself, and practices for melting fines are by no means as standardized as are those for melting solids. The melting of fines is today the subject of considerable developmental interest; hence practices discussed today may soon be replaced by new or improved ones. CHARACTERISTICS OF THE METAL THAT AFFECT MELTING Aluminum and aluminum alloys possess several inherent characteristics that affect the melting problem. Of the physical properties, density, heat content, thermal conductivity, emissivity, and melting temperatures are important because of their effect on equipment design. A list of such properties for commercially pure aluminum is given in Table r, compared with similar properties for iron and copper. The low density of aluminum as well as of the aluminum alloys is of material advantage in the design of melting equipment, in that such equipment can be considerably lighter than similar equipment for handling the heavier metals. The density, however, particularly of the molten metal, is not greatly different from that of the oxides and other nonmetallic materials that develop or become part of the melt during the melting process. Separation of such nonmetallics is not as rapid a process as with some of the other metals, and consideration of this must be made in establishing melting procedures. Sufficient holding time to permit such materials to separate out and, in some cases, fluxing treatments to aid the separation, are required. Since some of these nonmetallics settle to the bottom of the melt, provision should also be