Collect and inspect raw aluminum scrap, ingots, or bauxite ore.
Sort the scrap materials to ensure they are free of impurities such as oils, paints, or other contaminants.
Crush or shred large pieces of scrap to ensure consistent feeding into the furnace.
Charging the Furnace
Charge the prepared aluminum material into the furnace. Furnaces can be induction, reverberatory, or rotary, depending on the scale and requirements.
Add fluxing agents if necessary to help remove impurities and prevent oxidation during the melting process.
Casting
Heat the furnace to the required melting temperature, typically around 660°C (1220°F) for aluminum.
Monitor the temperature to ensure that the aluminum melts uniformly without overheating.
Heating and Extrusion
Heating: The foundry logs are heated in a furnace to a temperature where the aluminum becomes plastic.
Extrusion: The heated log is placed in a hydraulic press. A die with the desired shape is placed at the other end of the press. The press forces the aluminum through the die, creating the desired profile.
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