KEVOS® MAKEOS · Materials
Energy and Time to Melt Metal
How much energy and time does it take to melt and superheat this charge of metal?
Energy to heat a metal charge to its melting point, melt it and superheat the liquid to the pouring temperature, and the melting time and energy cost at a furnace power and efficiency.
Open the calculatorRuns in your browser. No account needed.
How this tool works
Inputs, units and where to find them
| Input | Unit | Typical source |
|---|---|---|
| Charge mass | kg | Mass of metal charged. |
| Starting temperature | °C | Temperature of the charge when loaded. |
| Melting point | °C | Melting point (or liquidus) of the alloy. |
| Pouring temperature | °C | Temperature to which the liquid is superheated before pouring. |
| Specific heat of solid | kJ/(kg·K) | Average specific heat of the solid over the range (aluminium about 0.9, steel about 0.65, copper about 0.39 kJ/kg·K). |
| Latent heat of fusion | kJ/kg | Latent heat of fusion (aluminium 397, iron about 270, copper about 205 kJ/kg). |
| Specific heat of liquid | kJ/(kg·K) | Specific heat of the liquid metal. |
| Furnace power | kW | Furnace rated power. |
| Furnace efficiency | % | Share of furnace energy that reaches the metal (induction about 55–75%, fuel-fired lower). |
| Energy price | AUD/kWh | Energy price per kWh (or equivalent fuel cost). |
Method and formulas
- Q = m [cs (Tm − T₀) + L + cl (Tp − Tm)].
- Energy drawn = Q ÷ efficiency; time = energy drawn ÷ power.
- Cost = energy drawn × price.
- Example: 500 kg of aluminium to 720 °C needs 144.97 kWh in the metal, about 0.96648 h at 250 kW.
Limitations
- Average property values; alloys melt over a range and properties vary with temperature.
- Holding losses while waiting to pour are not included.
- Example values are illustrations. Replace them with values for your actual task.
Typical uses
- Estimate furnace time and energy per melt
- Compare melting costs of alloys
- Size a furnace for a production rate
Who it is for
- Foundry engineers
- Process engineers
- Estimators
What you get
- Energy to heat, melt and superheat
- Melting time
- Energy drawn and cost per melt
Interpreting the result
- Keep superheat to what the casting needs; each degree costs energy and increases gas pick-up and oxidation.
References
- Machinery’s Handbook, 29th edition (Industrial Press, 2012), printed pp. 371–374, 1404–1420. Topic reference; no source tables or recommended settings are reproduced.
WORKOS tools are screening and decision-support utilities. Verify important financial, engineering, safety, legal or operational decisions using appropriate professional standards and your organisation’s approved data.
