Heat Treatment

Induction furnace technology and

far as production of different alloys is
concerned, in particular for melting ductile
iron.

melting, pouring, automation Induction furnace

In 1966 German author Karl-Heinz
Brokmeier wrote: “Induction melting is in
a state of rapid development.”
Throughout the 60s and 70s a dramatic
The principle of induction corresponds to 67 per cent of total casting Indian foundry are cupola furnace using growth of mains frequency induction
melting is that a high production. The remaining are steel casting coke as fuel and induction furnace using furnace was seen across the world. Later
12 per cent, SG iron and non-ferrous 10 per electricity. On the basis of primary energy in the 80s with introduction of medium
voltage electrical source
cent each. They provides castings to various consumption, if induction furnace and frequency induction furnace, the ball-game
from a primary coil induces
sectors, automotive is major, almost one cupola are compared, the weight turns changed totally. This was starting of a
a low voltage, high current third of total casting production. Sectorial completely in favour of cupola. boom of induction furnace in foundries.
in the metal or secondary break-up of castings consumer is shown But the advantages of a crucible furnace (Contd. on pg 6)
coil. Induction heating in Figure 2. over cupola furnace include flexibility as
is simply a method of
transferring heat energy Figure 1 Production of castings in million metric tons (India)
Source: Foundry Informatics Centre
11
We are in the age of change; enormous
changes take place in industry and business.
Those who see change as opportunity 9
survive the global competition and those
see it as a problem will perish. Foundry is 8
a challenging business. In today’s foundry,
productivity enhancement and improving 6
energy efficiency are two key aspects of
success for the Indian foundry industry.
5
Productivity could be seen as tons of
casting produced per foundry or simply
tons of castings produced per man-hour, 3
either ways we are way below the world’s
average; in fact our productivity is one- 2
fourth when compared with German
foundries. 0
The Indian foundry industry has grown 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13
leaps ahead in the past decade or two, but
Grey CI 2.840 3.180 4.116 4.870 5.332 4.532 5.050 6.180 6.798 6.254
global competition has grown at equally SG Iron 0.363 0.442 0.618 0.762 0.802 0.785 0.800 0.984 1.090 0.981
rapid pace. The production from our Malleable 0.039 0.040 - 0.062 0.065 0.061 0.060 0.069 0.066 0.060
foundries almost touched 10 million tons Steel 0.465 0.581 0.805 0.914 0.964 0.916 0.880 1.070 1.140 1.158
last year. Production in the past decade is Non-ferrous 0.331 0.380 0.516 0.578 0.608 0.547 0.653 0.750 0.900 0.891
shown in Figure 1. Total 4.038 4.623 6.055 7.186 7.771 6.841 7.443 9.053 9.994 9.344
Casting industry
It can be seen from graph that total Melting
production grew from 4.038 million metric Melting is the heart of the foundry
tons (mt) in 2003-04 to 9.344 million mt in industry. A melting furnace derives its
2013-14, this corresponds to a compound Bühler AG
heat from solid fuels (coke), natural gas,
annual growth rate (CAGR) of 8.75 per Die Casting – Empowering Success. Do you want to boost productivity?
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Furnaces vary in design, geometry, capacity
China has also grown at CAGR of 8.88 Ecoline: A model series in four different sizes. Designed for a long life.
productivity (melting rates), materials-
per cent during the same period, whereas With options available to meet your speci�c needs. Your bene�ts: Powerful
of-construction, and mode of operation
the world’s casting production grew from injection unit, ideal range of sizes, robust technology, standardised models.
(batch or continuous). Numbers of options
73.554 million mt in 2003-04 to 100.834 are available for melting furnace.
million mt in 2013-14. This corresponds to Apart from the furnaces mentioned in
a CAGR of 3.20 per cent only. Table 1, there are numerous innovative
The high growth in India and China, melting technologies under research and
when compared to the world, is because development. Some of these are: Electron
during this period casting industry beam melting, immersion heater, infrared
witnessed shifting of casting production heater, microwave melting, plasma heating
from Europe to Asia. Europe witnessed a and solar furnace.
negative growth with CAGR of -0.37 per In case of ferrous castings, predominant
cent during this period. The new Ecoline with multistep technology.
share is of cast iron, for melting cast iron
The Indian foundry industry majorly two most common furnaces used in
produces grey iron castings which

Figure 2 Sector-wise Consumption of Castings

Auto
9%
2% Sanitary
3%
Pipes and fittings
3% 32%
Agriculture
4%
Industrial machines

5% Railways

Pump and compressor

5% Power
Buhler (India) Pvt. Ltd. 12D, 13B, 13C & 13D KIADB Industrial Area Attibele 562107 Bangalore India.
T +91 80 6777 0000 F +91 80 2289 0001 buhler.bangalore@buhlergroup.com www.buhlergroup.com/die-casting
Valves
6%
9% Electrical equipment

7% Diesel engines
8% Innovations for a better world.
7% Machine tool
Source: IIF, 2012

FOUNDRY REVIEW
5
● AUGUST 2014
 Heat Treatment
Table 1 gives categorization of furnace for melting and fuels
Fuel Form of fuel
Coal Powdered bituminous
Anthracite lumps
Coke Sized lumps
Oil
Gas
Electricity Direct arc
Indirect arc
Resistance
Induction
The principle of induction melting is
that a high voltage electrical source from
a primary coil induces a low voltage, high
current in the metal or secondary coil.
Induction heating is simply a method of
transferring heat energy.
Two laws that govern induction heating
are: Electromagnetic induction and the joule
effect. The electromagnetic force creates
intensive stirring in molten metal leading
to uniform temperature and homogeneity
in composition. These conditions are also
conducive for melting low weight material
such as chips or sheets or turnings as well
as carburizing and alloying elements. The
furnace consists of four types of parts:
(a) Mechanic: Furnace body, lining
material, hydraulic and tilting frame
(b) Electric: Transformer, convertor,
capacitor bank, high current connection
and coil
(c) Control systems: Weighting system
and process control and
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(a) Inverter voltage is high and circuit
losses are less (energy saving 15%
Metal melted Furnace compared to SCR type)
Cast iron Air furnace (b) Its power factor is always greater
Cupola than 0.95 (energy saving 3-5% compared
Cast iron Cupola to SCR type)
Non-ferrous Crucible furnace (c) IGBT is faster than SCR, heat within
Iron and steel Open-hearth the furnace exit losses can account for 3
Non-ferrous Crucible furnace per cent of the whole process
Iron and steel Open-hearth (d) High-order harmonic from rectifier
Steel One-, two-, and three- adjust the voltage when the SCR generated
Cast iron phase electric arc voltage spikes, IGBT does not produce
furnace high-order harmonics
Non-ferrous Rocking arc furnace (e) SCR supplies power with voltage
Cast iron
and power regulators whereas IGBT
Non-ferrous Crucible furnace supplies with frequency and power
All metals Tilting and lift-induction regulator
furnace Typical specific energy consumption for
melting cast iron in India foundry using
induction furnace is 625 kWh per mt. In
(d) Auxiliary equipment: Cooling
a typical induction furnace the energy
system, charging system and exhaust
loss in equipment is between 100 to 130
system
kWh per mt, depending upon the size of
Electrical energy required for heating
the furnace.
one tone of iron to 1500 °C is 396 kWh. In
The furnace efficiency is around
furnace numerous losses takes place which
65 to 75 per cent. Currently, furnace
increases the specific energy consumption
manufacturers are working towards new
to above 500 kWh corresponding to
development in energy efficient coils, new
efficiency of 80 per cent. The losses are:
refractory material, reduction of converter
thermal furnace losses, furnace coil losses,
losses and reduction in transformer losses
capacitor bank losses, convertor losses
to reduce overall energy loss to less than
and losses on main side transformer. The
half of present losses, thus improving the
losses are represented in Figure 3.
efficiency of induction furnace to 80 to
Induction furnace 85 per cent.
Medium frequency induction furnace Efficient operation of coreless
could be categorised based on convertor induction furnace depends primarily on
type, there are two types predominant implementation of good/best operating
in market: Silicon Controlled Rectifier practices. The steps involved in operation
type (SCR) and Insulated Gate Bipolar of induction furnace are shown in Figure 4.
Transistor type (IGBT).
Pouring and automation
IGBT type is more energy efficient than
In 2002, India’s output from around
SCR type (by over ~25%) because:
4,700 foundries was about 3.3 million
mt and now almost a decade later,
e 4 Steps of operation of induction furnace
Figure
Charge
preparation
Charging
Source: ABP Induction - High energy efficient melt-shop design and operation
in 2011 marginally less number of
foundries produced nearly 10 million
mt. This increase in productivity is nearly
entirely because of increasing trends
of mechanization and automation in
foundries.
The manpower spent to produce one
ton of saleable casting varies between 60
to 300 hours in India, whereas Japan and
Germany produce with 20 to 45 hours,
depending on product size and profile.
Around 75 per cent of foundries in
India are estimated to operate manually
and from the remaining 25 per cent
substantial majority is semi-automatic
technology and around 150 foundries
use high pressure moulding line and latest
global technologies.
We could categorize molten metal
pouring in three main categories: manual
pouring, semi-automated using transfer
ladle (either crane system or mono-rail
system) and fully automated pouring
system.
Automation in pouring system is being
offered by number of manufacturers,
such as pressure pour, opti-pour, auto-
pour and multi-pour. The automatic
pouring provides flexibility in melting
area, excellent temperature control, level
AUGUST 2014 ●
Figure 3 Sankey diagram of energy
loss in coreless induction furnace
Total supplied
Total supplied
suppli ed
100%
Transmission
losses 3-5%
Radiation losses
without lid 6-8%
Coil losses
17-23%
Mostly
absorbed
Lining- by cooling
conducted water
heat losses
3-10%
Useful energy
62-75%
Source: BCIRA Efficient Melting in coreless induction furnace
sensing device and system controller. Level
sensing is done using camera, point laser
or line laser. System control is through
PLC control. Basic working of automatic
pouring system is shown in Figure 5.
Automation does not only mean just
installing a high pressure moulding line,
it also means installation of wide variety
of controllers and sensors, such as sand
level sensor and temperature controller
for core making, low cost automatic
inoculation addition mechanism, use of
vibro-feeder for charging raw material
in-to furnace crucible, oil level sensor
for air compressor, and many more. The
change in metal pouring practice has a
major role in improving the operating
results of foundry mainly because of
reduction in rejection in castings caused
by metals related defects and improving
productivity.
There used to be a time when
automation was considered expensive,
even now many tag automation with
Melting
Make the
melt ready
Emptying the
furnace
huge investments. But this is only because
of small production scale, as scale starts
to increase, automation helps in reducing
per unit cost of production. In India we
have advantage of huge population
(thus easy labour) and most of foundry
people decide on using available cheap
man-power against investing in costly
automation.
But cost of labour i0s on rise and the
day is not far when the labour cost will
be so high that foundry will have to think
in favour of automation. Automation
demand in Indian foundries is increasing
and it will continue to increase. Medium
and large foundry should move from
semi-automatic pouring system to fully
automated metal pouring system whereas
micro and small enterprises should move
from manual pouring to low cost semi-
automatic metal pouring system.
Skilled manpower
The biggest challenge to foundries is
shortage of skilled manpower. Foundry
historically has an image of 3Ds viz-a-
viz, dirty, dark and dangerous, hence
this has not helped to attract younger
workforce.
India is among the world’s top three
FOUNDRY REVIEW
6
 Heat Treatment

Figure 5 Automatic pouring control systems China sees the foundry industry Mike Swartzlander, a leading foundry
as important constituent for national strategist from US, stated in one of his
Pouring system
economic development. Similar initiatives articles: “The most massive infrastructure
must come from the Indian government spend in history seems certain to unfold
towards foundry. Revitalization of the over the next 20 years. Estimates are as
Stopper mechanism Molten metal sensor industry relies on advanced innovation high as $40 trillion to be spent on energy,
in foundry. water and transportation infrastructure –
all huge castings market. Of course, India
Need for encouraging should be at the centre stage for much of
policies this infrastructure spends and foundries
Innovation at initial stage requires should benefit from this.”
support from government and government Moreover, with the new government
Mould
should bring in encouraging policies and in India, infrastructure development is
schemes suitable to the Indian context for expected to intensify.
foundries to grow faster and bigger. This means good days are ahead for the
The automobile sector demand has the foundry industry.
largest share of the pie. Currently, from
Servo drive PLC Controller
Indian foundries, however, its percentage
Source: William Pflung, Inductotherm – Automatic Pouring System
is expected to shrink as other industries
evolve. Even globally, the automobile
largest casting producers but it should on process re-engineering, fortification, sector demand accounts for one-third of
be noted that there is only one National technology up-gradation and creating total castings demand. It is anticipated that
Institute of Foundry and Forge Technology safe and work-friendly environment by construction, infrastructure, earthmovers, E Nand Gopal
in Ranchi. Most engineers employed are adopting lean manufacturing practices pumps and agriculture will pick up Research Associate,
The Energy and Resources
not formally trained and exposed to best or Kaizen activities in all functional areas faster. Institute, New Delhi
practices of foundry. in foundry.
Some foundry clusters have taken
initiative to bring up metallurgy/foundry
courses in colleges/universities. Kolhapur
and Coimbatore are two pioneer examples
in this field.
With increase in automation in foundry,
the requirement of manpower will come
down, but the necessity would be of
highly skilled set of manpower. Unskilled
manpower does hold any position in an
automated foundry.
Every cluster must have foundry-related
courses in selected colleges to train
manpower. Also, they should tie up with
foundry for job guarantee, so more and
more youth would be motivated to take
�������� ��� ��� �����
up the course. For example, in Coimbatore
every year around 25-30 students join
the 3-year course on foundry in selected
colleges. The entire course is funded
by select foundries and the job is also
guaranteed.
After completion of the course they
have option to join a job or continue
����� �� ��
and finish engineering by studying 3
more years. Schemes such as the above-
mentioned are necessary in other clusters
also to motivate youth to work in foundry,
at the same time foundries get skilled
manpower.
The courses should include management
aspects, state-of-the-art casting simulation
study and case studies on present-day
requirement of foundries. These will
deal with showcasing that foundry is
not using age-old technology, but there
is modernization in foundries which will
increase the interest of students for the
course.

Major challenges �����������������������������������������������������������������������������������������������������������

The major challenges in front of the
����������������������������������������������������������������������������������������������������������
foundry industry are improving energy
efficiency, reduction of wastage, improving ������������������������������������������������������������������������
productivity, safety and pollution. These
challenges could be faced by keeping ����������������������������������������������������������������������������������������������������������
foundry clean and favourable to work �����������������������������������������������������������������������������������
by applying pollution control norms and
eradicating indirect labour through low- ����������������������������������������������������������������������������������������������������
cost automation. ������������������������������
For example, minimizing mould core
and casting travelling distance, fixing cycle ���������������������������������������������������������������������������������������������������������������
time to reduce idle time and introduction
of auto core shooters and core cells. Also,
the concept of green foundry is taking all
possible energy efficiency concepts for
design stage while setting up a new foundry.
Germany has seven times less foundry
than India, but their productivity is four
times that of our foundry. Enhancement in
productivity can be achieved by focusing

FOUNDRY REVIEW
7
● AUGUST 2014