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Metal Casting Technologies : March 2007
www.metals.rala.com.au 36 TECHNICAL FEATURE sledgehammer was employed. During stripping of ingot scoring can happen. The slag can break and particles get trapped between the ingot and mould. Also the fins formed on ingot due to slag skin breaking can cause problems. This can cause damage to mould tube when the ingot is removed. The electrode should be straight to permit entry into the mould without touching the mould wall. Too large a fill ratio may lead to arcing between the electrode and the mould, which may lead to puncturing of the mould. Water is under forced circulation and the water jet will rush inside the mould. This can cause a big accident as molten slag will be splashed out causing damage to people near the ESR unit. Water should not get trapped below the metal. This can cause steam explosion. The person dealing with ESR should always wear protective clothing and must wear a good face shield. The glare from the slag bath is not good for eyes hence proper eye goggles should be used. Metal can leak in a continuous process and one should be careful. Fume extraction is important in ESR unit. The prefused slag which is made in an induction furnace releases fumes and proper fume extractor should be fitted. The water temperature rise in the mould should be checked always. After the process is over the power is switched off. The slag colour changes from yellow to orange. The metal inside has solidified and is still red/orange in colour. Water should be running through the mould even after the process is over as the slag and metal is hot inside and at a high temperature. Overheating of inner mould tube can occur if water supply in the mould is stopped causing reduced life of the mould. ● Molten metal can be dangerous and unsafe practices can cause injuries. Great care should be taken when dealing with metal casting processes. Author Amit M Joshi B.Engg. Mechanical, M.I.Prod.E, A.I.E Dept. of Metallurgical Engineering and Materials Science, Indian Institute of Technology - Bombay, India. Email: firstname.lastname@example.org, email@example.com Figure 14.