In today's demanding manufacturing environment, foundries require equipment that is efficient, affordable and reliable. Long known for its innovations in the melting industry, Prestige Thermal Equipment has addressed this need with seventeen pre-engineered coreless induction systems, which are offered in either a single or dual output configuration.

Melting metals with Solid State Vulcan induction heating is usually accomplished by heating the metal in a crucible made from a non-conductive refractory material. The charge of metal within the crucible is melted down to liquid form.

This process is commonly used to produce high quality steels and nonferrous alloys for casting operations. The liquified metal is poured into a cavity having the desired shape. The metal solidifies with a minimum of shrinkage, after which the mold is removed to reveal a finished, machinable product.

Modern induction heating provides reliable, repeatable, non-contact and energy-efficient heat in a minimal amount of time. Induction produces circular eddy currents within the molten mass, creating a stirring action which results in a very uniform product. Induction heating provides fast, controllable temperature ramp, allowing for consistent quality results.

Both ferrous and non-ferrous alloys can be melted in induction furnaces. The flexibility and cleanliness of induction melting cannot be duplicated by conventional steel mill and foundry methods.

Prestige Thermal Equipment offers coreless induction systems for the following applications:

• Small Ferrous with capacities between 1 Kg. and 1500 Kg. and connected loads of 10 KW's to 1000 KW's,
• Nonferrous for the melting of aluminum alloys, brasses, bronzes, copper and zinc in a crucible or rammed type lining,
• Large Ferrous with capacities between 2000 Kg. and 20000 Kg. and connected loads of 1250 KW's to 10,000 KW's,
• Precious Metals for the refining or smelting of platinum, silver and gold,
• Investment Casting high frequency, high power density furnaces designed to minimize metal exposure and maximize efficiency,
• Holding Furnaces for the superheating of metal from a primary melting furnace or cupola,
• Dual Frequency Power Units and Furnaces to enable the production of ferrous and nonferrous alloys in the same furnace.
• Vacuum Power Units and Furnaces designed for the production of recreational and aerospace products.

The metal charge is placed inside a well-insulated crucible, made from a con-conductive refractory material such as graphite. The insulation helps reduce the amount of heat lost due to radiation. The crucible is placed inside the induction coil and power is supplied. The charge can be melted and then maintained in the liquid state, depending on the application requirements.

Metal to be melted (must be conductive)
Induction coil
Crucible (non-conductive)
Insulation around crucible
Heat source: Fast, precise heating works best.

• Casting (see above)
• To remove low temperature metals used in machining of complex parts, such as aircraft engine turbine blades
• To join two metal components, such as lead battery terminals

Benefits to the customer

• Metal flexibility is now available, allowing a multiple grade choice in a foundry or between various foundry units.
• Extended shifts and multiple shift working were made possible.
• Higher profits due to higher yields.
• Controllability of temperature.
• The grade of metal required is easily and repeatably achieved.
• Decrease in raw material cost.
• Improved product quality.
• Ideal solution for alloying requirements.
• Reduced metal loss.
• Ideal solution for light metal scrap recycling units.
• Rugged design enables to withstand most severe foundry conditions.
• Easy maintenance.
• Microprocessor based control systems along with Man Machine Interface (MMI)
• Desired levels of automation.
• Better homogeneity of molten metal and temperature uniformity.