KEVOS® MAKEOS · Materials
Melt Charge Blend (Two Materials to a Target Content, Batch Masses, Cost)
How much of each of my two charge materials do I melt to hit the target alloy content, what do I weigh out for the batch, and what does the charge cost per kilogram?
Blend of two charge materials (two scrap grades, a base metal and a master alloy) to reach a target content of an element by alligation (as the mixture blending tool), the masses of each for the batch with a melt loss allowance for the element, and the charge cost per kilogram as a weighted average (as the mixture value tool), checked against your cost limit.
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How this tool works
Inputs, units and where to find them
| Input | Unit | Typical source |
|---|---|---|
| Content of material A | % | Content of the element in material A. |
| Content of material B | % | Content of the element in material B. |
| Target content in the melt | % | Content wanted in the poured metal. |
| Melt loss of the element | % of content | Share of the element lost by oxidation in melting (the charge aims higher to make up for it). |
| Charge mass | kg | Total mass of the charge. |
| Price of A | $/kg | Price of material A. |
| Price of B | $/kg | Price of material B. |
| Highest charge cost | $/kg | Highest average charge cost you accept. |
Method and formulas
- Charge aim = target ÷ (1 − loss).
- Share of A = (c_B − aim) ÷ (c_B − c_A) by alligation; masses = share × batch (as the mixture blending tool).
- Cost per kilogram = Σ mass × price ÷ batch (as the mixture value tool).
- Example: charge 300 kg of A and 200 kg of B for 9%; the charge costs 2.4 $/kg.
Limitations
- Linear mixing of the element; other elements must be checked the same way.
- Single melt loss figure; actual loss varies with temperature and time.
- Example values are illustrations. Replace them with values for your actual task.
Typical uses
- Make up a furnace charge from two grades
- Dilute a master alloy to a target content
- Compare charge costs for a target chemistry
Who it is for
- Foundry metallurgists
- Furnace operators
- Buyers
What you get
- Charge content aimed for and shares of A and B
- Masses for the batch
- Charge cost per kilogram
Interpreting the result
- If the target is outside the two contents no blend of these two reaches it: add a third material.
References
- Machinery’s Handbook, 29th edition (Industrial Press, 2012), printed pp. 384. Topic reference; no source tables or recommended settings are reproduced.
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Open the Melt Charge Blend (Two Materials to a Target Content, Batch Masses, Cost) calculator
