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COPPER MELTING AND ADDITIVES
The general problem of melting of copper and copper based alloys are having below technological problems :
Oxidation of metallic impurities;
In copper alloysa, either scrap form or any inter metallic form contains readily oxidizing elements such as Zinc, Tin, Lead, Aluminium,Iron , Magnesium, Silicon, Cobalt,Arsenic,.
In metal melting process all other metallic impurities of many of above elements may be eliminated . Oxidation on melting as oxides more or less would be in a dross format to flow due to specific gravity. However this dross may entrap considerable amount of genuine metal along with the unwanted impurities causes high metal losses.
Non Metallic inclusions some oxide are formed as a result of melx oxidation other solids inclusions i.e. oxides, carbides are made available from refractory metals and scrapa since the densities of non metallic inclusions are quite lower than the molten copper. The inclusions float up and are absorbed by during the Flux treatment but some still remains in the molten copper.
Copper is an element which is readily oxidise in the molten stage during the melting with oxidizing Flux or passing of Oxygen.The oxygen penetrates in to the molten copper from the atmosphere or as a result of oxidizing flux. The solubility of Oxygen in the molten copper is ready to increase rapidly with temperature under the any Oxidizing atmosphere.When Copper is in more alloy form ( Zinc,Tin etc ) it would be subject to less oxygen.
All our aim during th process is to deoxidizing the metal that would decrease the oxygen content. Hence Oxidizing Flux also captures the oxides, inclusions and other impurities during the process.
QUANTITY OF FLUX 1 % OF THE METAL
After melting in oxidizing atmosphere we need to deoxidize the molten copper with “De Oxidising Tubes “ The tubes are designed to take the oxygen by dipping in the molten metal.
DE OXDISING TUBES ( DO1 for 25kgl, DO2 for 50Kg, Do3 for 100kg, melt )
These are solid substances which generate gas bubbles when heated in the molten metal. These bubbles contines Hydrogen as well as other gases.
DE GASSING TABLETS ( 1 PIECE for 300 Kg Metal,Reaction last 8710 Minutes)
When we need to achieve higher purity in Copper i.e. 99.999 % for increased electrical conductivity we used “CB” tubes. er gases.
“CB” TUBES For very high conductivty ( CB1 for 100 Kg, CB2 for200kg,Cb3 for 400kg Melt )