Furnace Casing

About Furnace Casing

 What is FurnaceCasting?

Furnace Casting refers to the melting of metals ina furnace and pouring the molten metal into molds to form a desiredshape (castings). This process is widely used in foundries for producing partsin steel, iron, aluminum, copper alloys, etc.

 Core Concept

1. Metal is melted in a furnace (induction, electric arc, cupola, etc.).
2. Molten metal is poured into a pre-made mold (sand, ceramic, metal die).
3. The casting is allowed to solidify.
4. The mold is removed to extract the cast component.
5. Casting is cleaned, machined, or heat-treated as needed.

 Types of FurnaceUsed for Casting

 Materials CommonlyCast

• Ferrous:
• Grey Cast Iron
• SG Iron (Ductile Iron)
• Mild Steel / Alloy Steel / Stainless Steel
• Non-Ferrous:
• Aluminum alloys
• Copper / Bronze
• Zinc
• Magnesium

 Casting ProcessFlow (Typical)

1. Pattern Making
2. Mold Preparation (green sand, shell mold, investment)
3. Melting in Furnace
4. Pouring molten metal
5. Cooling and Solidification
6. Shakeout and Mold Removal
7. Fettling and Finishing
8. Inspection and Testing

 TechnicalSpecifications (Typical Range)

 Relevant Design& Quality Standards

• ASTM A48 / A536 “ For iron castings
• IS 210 / IS 1865 “ Indian standards for CI and SG Iron
• EN 1561 / 1563 “ European standards
• ASME / ANSI “ For pressure-retaining castings
• ISO 8062 “ Dimensional tolerances for castings
• NDT: UT, RT, MPI, DPI for defect detection

 Advantages

• Complex shapes in a single pour
• Cost-effective for large production
• Wide range of sizes and materials
• Good mechanical properties with alloys
• Suitable for both ferrous and non-ferrous metals

 Limitations

• Shrinkage and porosity issues
• Requires pattern and mold setup
• Surface finish may require post-processing
• Limited precision vs machining

 Applications

• Automotive “ Engine blocks, manifolds, gear housings
• Power Plants “ Turbine components, burner nozzles
• Pumps & Valves “ Casings, impellers, covers
• Heavy Equipment “ Frames, counterweights
• Agriculture Equipment
• Mining & Earthmoving
• Railway & Defense