Magnesium Alloy Ingot Casting Machine

The line is intended for qualified magnesium and magnesium-alloy scrap, internal returns or prepared charge materials. Scrap must be sorted and assessed for alloy identity, contamination, moisture, oil, coatings and foreign-metal content before a melting process is selected.

Start with required saleable tons per hour or per year, operating hours, line availability, metal yield and ingot weight. The casting conveyor must then be matched to melting rate, holding capacity, mold count, solidification time and downstream handling.

Yes. A single furnace may suit lower output or batch operation. Multiple melting furnaces can feed a common holding and casting system when higher continuity is required, provided transfer timing, holding volume and alloy-change procedures are engineered together.

The holding furnace buffers the casting line from variations in melting cycles. It maintains a controlled pouring condition and gives the quantitative pump a stable supply while the next charge is melted or refined.

A protected pump-and-pipe system can reduce open handling, turbulence and heat loss when correctly designed. It also supports a more enclosed layout between the melting and holding furnaces. Pump materials, immersion depth and maintenance access must match the alloy and operating cycle.

The pump delivers a controlled quantity for each mold in coordination with conveyor position and line speed. Repeatability depends on melt level, pump condition, timing, pipe design, metal temperature and PLC calibration; final tolerances should be defined in the acceptance plan.

The existing reference lists 7.5 kg and 12 kg standard ingots. Other weights, shapes and customer logos can be developed from an approved mold drawing, required handling method and cooling time.

The reference line uses electric mold preheating with 20 kW listed power. Final heater capacity depends on mold mass, starting temperature, target preheat condition, conveyor speed, insulation and ambient conditions.

Molten magnesium can oxidize rapidly and may burn when exposed to air. A designed cover-gas and enclosure system helps stabilize the melt surface during holding, transfer and pouring. Gas selection and operating procedures require qualified safety review.

No single gas should be assumed for every project. The existing machine data includes a legacy dilute SF6/N2 reference, while lower-emission alternatives may be available. The selected technology must suit the alloy, equipment, local regulations, emissions controls and supplier-supported operating procedure.

Control begins with clean sorted charge, protected melting and suitable stirring. Stable transfer and quantitative pouring should minimize turbulence and secondary oxidation. Dross-removal practice, sampling and acceptance criteria must be established for the specific alloy.

The original line describes low-speed mechanical stirring or inert-gas-assisted stirring. The method and intensity must promote homogenization without excessive turbulence, oxide entrainment or accelerated wear of the crucible and internal components.

Mold quantity depends on line speed, filling interval, ingot mass, solidification and cooling time, conveyor length, release temperature and available floor space. The reference range is 50–120 molds.

The PLC coordinates mold preheating, conveyor motion, quantitative pouring, protective-gas functions, cooling and alarms. Interlocks should stop the relevant process on loss of critical gas, cooling, drive or temperature conditions.

The project should define melt protection, gas monitoring, local extraction, fire response, spill containment, cooling alarms, emergency stops, material handling and operator procedures. Requirements vary by jurisdiction and must be reviewed by qualified local safety professionals.

Provide alloy grades, scrap description, required hourly and annual output, furnace batch size, ingot weight and drawing, operating hours, preferred fuel or electric heating, available gases, voltage, cooling water, extraction conditions, building layout and local compliance requirements.