Metal Melting Best Practices
Learn industry-approved metal melting best practices covering safety, furnace operation, quality control, and energy efficiency. Ideal for foundry, manufacturing, and metallurgical professionals.
- Online – Microsoft Teams
- 19 – 20 March 2026
- 2 CPD Points
- Price : R 8 499.00
LEARNING OUTCOMES
After successfully completing this course, you will be able to:
Gaining insight into phase transformations
Different types of liquid steel temperature measurement
Discussing causes of metal splash and furnace eruptions
Discussing different types of metal testing
Discussing the impact of poor temperature control
Handling impurities to optimize efficiency in melting
Reviewing the principles of metallurgy (Ferrous and Non-Ferrous)
- Analyzing the equilibrium phase diagram
- Gaining insight into phase transformations
- Liquids
- Solidus
- Solidification
- Discussing precipitation and non-metallic inclusions
Chemical and material Testing
- Theoretical and visual demonstrations on chemical testing
- Discussing different types of metal testing
- Tensile testing
- Impact testing
- Creep testing
- Elaborating on material fatigue
- Understanding corrosion (causes and impact)
Furnace Charging Procedures
- Charge furnace and charge bucket make-up
- Melt mix best practices
- Material grading and its impact
- Optimizing charge calculations
- Elaborating on melting composition
Temperature measurement and control techniques
- Different types of liquid steel temperature measurement
- Disposable lances
- Continuous dip measurement
- Optical measurement systems
- Thermocouple methods
- Continuous temperature measurement of molten steel
- Thermocouple accuracy checking and calibration
- Controlling pouring temperature
- Discussing the impact of poor temperature control
Furnace and furnace operations
- Identifying different types of furnaces and operation best practices
- Selecting and applying the best furnace for melting certain metals
- Understanding different mechanisms applicable for furnace linings and coil protection
- Furnace lining inspection and maintenance
- Uncovering the theory behind refractory
Purposes and methods of alloying
- Understanding different alloying elements
- Evaluating the impact of alloying elements in different metals
- Discussing the purpose of alloying
- Strength enhancement
- Corrosion resistance
- Cost reduction
- Lowering melting points
- Surface and heat treatment processes
- Linking alloying to corrosion kinetics for different materials
Addressing melting safety related issues
- Risks and hazards associated with melting
- Wet charge materials, sealed scrap, bridging
- Discussing the significance of quality control in melting processes
- Emphasizing on the role played by Personal Protective Equipment (PPE)
- Understanding why scrap metal has to be inspected and treated
- Discussing causes of metal splash and furnace eruptions
- Reducing possibilities of molten metal explosions
Optimising melting efficiency
- Raw and recycled materials efficiency optimisation
- Understanding the role played by impurities to the melting process
- Handling impurities to optimize efficiency in melting
- Discussing cause of melt loss and methods applicable to control metal loss
- Elaborating on fluxing and melt treatment for efficiency optimisation purposes
- Melt sampling procedures
- Energy consumption and efficiency optimisation
- Elaborating on how advancements in technology enhances efficiency
Optimising melting efficiency
- Raw and recycled materials efficiency optimisation
- Understanding the role played by impurities to the melting process
- Handling impurities to optimize efficiency in melting
- Discussing cause of melt loss and methods applicable to control metal loss
- Elaborating on fluxing and melt treatment for efficiency optimisation purposes
- Melt sampling procedures
- Energy consumption and efficiency optimisation
- Elaborating on how advancements in technology enhances efficiency
Pouring techniques
- Reviewing the traditional art of pouring
- Understanding the role played by ladles and ladle lining
- Evaluating the system of filters
- Uncovering the modern pouring techniques
- Controlling the pouring temperature and pouring speed
- Slag and or dross control during metal pouring
- Applying pouring methods which save on energy consumption