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My son and I have had this discussion a few times. He is a precision CNC machinist we agree that the level of perfection should be based on the function of the part, I cast and machine so my parts are never to the perfection level that he is used to. He has worked on things like the optics...

I ship 42 lb boxes of aluminum ingots from melted engines in the USPS medium boxes. I ship about 4 tons per year. I tape all corners both directions with FIBER REINFORCED tape. They look like Fort Knox but even then once in a while I have one that doesn't survive shipping . They will...

Here is a few pics of the furnace firing 1 with the furnace after the metal is melted, the other 2 are cold fire running about 60%, if i closed it this would have smoked due to not enough air. Art B

The residential Natural gas system is limited at about 600,000 BTUH ( 4.25 GPH diesel) that the meter will actually pass. In order to get that flow you need to have a very short piping run. Most NG utilities wont put a higher pressure system in residential. On my furnace as I run the Propane...

I use waste oil for my scrap processing furnace, The 2 burners have a small (60,000 BTUH) adjustable propane burner built into the combustion air for the waste oil, the propane flame surrounds the nozzle for stable cold furnace ignition and shuts off when the furnace temp gets to the 750F...

For me I tend to repond only to topics that my input may be of help, Those areas are combustion (Burners) and electrical controls systems (Arduino or other PLC) I am a intermediate manual machinist with a son that runs a cnc shop. The interesting thing is that the largest influence in my...

you might try earth grounding the buss, it appears that the buss is floating, Art b

Are all the ground points tied together at only one end. if you have multiple ground points you can have current running through wiring in the opposite direction of the intended signal this can generate package drops in SPI Bluejets is rite about the ignition systems. My next venture with...

Steam chick. Your boiler explanation is good. our melting furnaces are actually combustion chambers as we tend to fire the furnace completely full of flame. Co ignition temp is about 1100F, most boiler combustion chambers are refractory lined and will maintain a temp above Co's ignition...

I'll chime in here in a couple areas, The compressed air's only purpose is atomization, fuel flow is based on the pressure between the fuel line and the area right in front of the nozzle the siphon effect is a by-product of the atomization process. I run my burners with 6 to 8 psi on the oil...

As i expalained in another thread, the flame temps most often quoted are a perfect mix of air and fuel with 0% excess air. In reality any of our burners will have some excess air, this excess air reduces the delivered flame temp. Weed burners normally draw as much as 200% excess air as thy...

The servos are connected to the oil needle valves and vary the firing rate on the oil. it takes full fire to get the melt done in a reasonable time frame 140 lbs in about 25 minutes once the furnace gets to 1000f. but then i need to back the burners off to keep the furnace from over heating...

I have time to tie them but don't seem to find the time to put them in the water. Art b

Pat I was wondering if Green Twin was you, I had lost track during the time I was down with the heart Valve replacement. I have processed 18 tons of engines parts since I started This last furnace build is based on a 200 gallon fuel tank, it is probably as big as i will go it is the 3rd...

My large furnace uses 2 waste oil burners firing about 5 to 6 GPH on high fire, I use it to process aluminum engine parts into to ingots and sell them. Each pour is between 140 and 200 lbs. from cold start to 1500F takes about one hour. the flame temps your are mentioning are the temp at...

toymaker totally agreed, what I have experienced was temp controls that when disconnected sent a 32 degree reading, Myself, i like to see the programs such that if the reading is out of range it shuts down and alarms. Most boilers have manual reset high limits etc. that are redundant to...

I'm some what of a Lurker but my background before I retired was boiler controls and combustion. From experience always have a redundant mechanical back up on boiler system primary controls. I have seen electronic systems fail from either a shorted connection or a open connection depending...

I agree with what has been shared so far, entrained gases are normally pinholes under magnification through out the casting ,normally remelting ingots releases the entrained gases. My processing furnace is direct fired with the scrap in the flame, this does entrain gases, the degassing recipe...

I have had a number of small mag fires in my processing furnace mostly "Audi" rocker arm covers. If it is during the initial melt I pull them out and dry sand them. if it is after I have a melt pool formed I pull out what I can and submerge the rest into the melt pool, It quickly forms an...

I had another thought on the casting problem, if you were using aluminum without enough silicon -about 8%- the surface tension is high enough that it doesn't flow well through a thin casting. I only process automotive castings or wheels so that the aluminum that i sell is consistent at about 9...