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SOCIAL MEDIA DISCUSSION Aluminum Dosing Furnace Buildup

On the AFS Foundry and Diecaster Network on LinkedIn, a member asked, “What are some reasons for buildup inside an aluminum dosing furnace? Air leaks, moisture or other factors? Any ideas to minimize glow bar consump- tion?” Below are excerpts of some of the discussion points:

“If you have air leaks, they will increase oxygen exposure in the fur- nace and the oxide fi lm on the metal. If moist air is pressurizing the dossing furnace, it increases the oxidation of the metal and the hydrogen content. If there is an immersion thermocouple in the bath, a thick oxide layer on the top of the bath can create an insulat- ing cover of oxide build-up on the thermocouples which will lead to an inaccurate temperature measurement and can make the glow-bars overheat which could cause reduced

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grow-bar life and further increase the oxidation rate.”—Gordon P.

“Glow bars need to be matched ac- cording to their Amp number stamped on the box and sometimes on the bar itself. This is based on 15 glow bar furnace but that’s the idea. With build up, there are several factors, such as the furnace temperature. The higher the temperature the faster oxide will grow. Excess air burners will kill an aluminum furnace lining. The type of fl ux you are using could be off- gassing and causing your refractory

binder to fail.”—David W.

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Editor’s Note: MODERN CASTING does not endorse the views expressed in the discussion.


Collaboration Isn’t Just for Customers

Our editorials and blogs often preach the need for casting customers to reach out to their metalcasting sup- pliers to establish a partnership in which both parties can benefi t from design and engineering collaboration. Some of the onus for collaboration must fall on the casting supplier.

In the last couple of months, I’ve spoken with end-users from three different industries on casting projects made possible and/or profi table thanks to collaboration with their casting supplier. The customers’ approach to the projects is commendable, from the initial creative spark to the patient development work conducted between the supplier and customer.

On the fl ip side, the metalcasters involved in each project were up to the challenge of trying out something new. In my conversations with the end-users, it was evident the col- laboration was mutually benefi cial. As much as we talk about casting end-users needing to be open to input from the metalcasting supplier, when they do approach you for collabora- tion, will you as metalcasters be ready, willing and able?

— S. Wetzel, Digital Managing Editor

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December 2012 MODERN CASTING | 3

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