Efficiency and cost savings begin with melting.
“Melting”, the process of obtaining molten metal from ingot, is the process of applying heat to the ingot. The melting process constitutes the first stage of serial production. Here, the metal, which reaches a sufficient temperature, is ready at this stage for the next process, that of “casting”. Although it is quite simple in terms of definition and cognition, the melting process is more complex and technology-based than one might think. Even in its most basic form, there are two ways to achieve melting. The first is “temperature”, which we all know, and the other is “pressure”.
In addition, we know that the cost situation of a foundry is largely affected by the efficiency of the melting section, so that we can offer our customers the best prices. Due to the constantly increasing price of aluminium processed in the melting workshop, metal loss is a major cost factor. Thanks to our efficiency efforts, we strive to reduce our melting costs, produce less scrap and achieve the highest quality standards in our products.
What is Aluminium Melting?
Melting is one of the most important steps of the production line, does not comprise merely the melting of the product. At the melting stage, composition adjustment, grafting, removal of impurities and degassing are also carried out. In other words, the product to be used is completed and ready for use in this stage with processes that will increase its durability and make its composition flawless. Given that the most common problem in the melting process is the changes in metal components and the inability to achieve the desired properties, the importance of the melting process can be better appreciated.
For these and similar reasons, the development of technology has a critical place in the melting process. Because the melting process varies according to the properties of the mineral and substance to be processed. As mentioned above, in order for some metals and minerals to be melted, ultra high temperatures are needed. In order to develop equipment and hardware that can provide this temperature, the technology has also needed to advance to a certain level. Thanks to advances in technology, the melting process is accelerated and made more perfect by changing the ambient pressure or ensuring high temperatures very quickly. Owing to the advantages provided by the technology, a much more homogeneous product is obtained, and therefore, much more flawless products can be delivered.
As KALKANCI, we are aware of how important melting is in the products we produce.
- Improved material fluidity results in better mould filling and fewer feeder defects.
- Many mechanical properties, such as higher elongation, are often a critical requirement for structural or engineered aluminium castings, and the best mechanic properties are associated with the excellence of the melting process.
- Increased melt cleaning causes us to encounter fewer problems with microporosity.
- A flawless melting process means less scrap and better processability.
Aluminium Melting furnaces
In view of these many details, we have five main melting furnaces in-house at KALKANCI, because we understand the importance of ensuring an effective and fast melting process. With the latest technology and innovative main melting furnaces, we can have a large amount of melting capacity according to demands and orders.
Our daily melting capacity at the KALKANCI Foundry is over 50 tonnes. We use five high-performance main furnaces in our foundry, where we can melt 5 different materials at the same time in order to provide fast deliveries to our customers and carry out an effective business process.
KALKANCI’s Melting furnaces
- 1 x 3.000 kg(1.500kg/h)
- 2 x 1.500 kg (500kg/h)
- 1 x 1.000kg(150kg/h)
- 1 x 1.000kg(150kg/h)