In real-world production, zinc and its alloys are primarily melted using a crucible furnace, although other options such as coke furnaces, gas furnaces, resistance furnaces, and induction furnaces are also commonly used. Because zinc alloys have a relatively low melting point, the wear on the furnace lining or crucible is significantly reduced. Moreover, zinc alloys tend to react with iron at typical melting temperatures. To prevent contamination from iron, it's crucial to avoid using cast iron crucibles. Instead, tools should be coated with an appropriate refractory material or designed to form an iron-resistant layer on the crucible’s surface, which helps protect against oxidation, graphite burning, and phase changes.
Zinc alloys typically consist of a zinc-rich phase and another alloying element-rich phase. Due to differences in their densities, these elements can separate during melting, leading to uneven composition. Therefore, effective stirring of the melt is essential before casting. Coreless induction furnaces often come equipped with automatic stirring systems, while those without such features require manual stirring. Similarly, in reverberatory furnaces, the molten metal must be thoroughly stirred before pouring to ensure homogeneity.
During the melting process, it's important to have various tools on hand, such as ladles, large spoons, bell jars, sampling spoons, slag removal tools, and more. These tools help manage the melt efficiently and maintain quality throughout the process. Proper preparation and handling are key to achieving high-quality zinc alloy castings.
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