In real-world production, zinc and its alloys are primarily melted using a crucible furnace, though 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. However, it's important to note that zinc alloys can react with iron at typical melting temperatures. To prevent contamination of the alloy by iron, cast iron crucibles should be avoided. Instead, tools should either be coated with an appropriate refractory material or designed to create a protective layer that resists iron interaction. This includes applying a layer that prevents oxidation, graphite burn-off, and ensures a stable phase change during the melting process.
Zinc alloys typically consist of a zinc-rich phase and another phase that may contain different elements. Due to their varying densities, these elements tend to separate during melting. To ensure a uniform composition before casting, effective stirring of the molten metal is essential. Coreless induction furnaces often come with built-in stirring mechanisms, while those in coreless induction systems may require some manual stirring. In contrast, reverberatory furnaces usually require full-scale stirring of the molten material before pouring. Additionally, proper tools such as ladles, large spoons, bell jars, sampling spoons, slag scoops, and other essential equipment must be prepared to facilitate smooth and efficient melting and casting operations.
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