morganite crucible - inproheatinproheat.com/sites/files/documents/care_and_use_nologo.pdfcopyright -...
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Copyright - Morganite Crucible Inc 2000 1
Morganite Crucible
Care and Use of Crucibles
Website: www.morganitecrucibleinc.com e mail: [email protected]: 203-239-1624 Fax: 203-239-5829
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Copyright - Morganite Crucible Inc 2000 2
Purpose
To promote better care and use of crucibles and extend crucible lifeTo explain what can cause short crucible lifeBasic rules of use
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HandlingAvoid abrasion of the glaze - this will lead to oxidation in serviceAvoid impact damageDo not roll the crucible - glaze damage will result
Damage to glaze followedby oxidation in use
Incorrect & correct handling
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Incorrect & correct storage
Stacked inside one another
Storage
Store crucibles in a warm dry place (above 20°C)Stand crucibles on pallets, never directly on the floorNever nest crucibles one inside the otherWhen stacking crucibles, separate with hardboard or similar material
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Base Block
The use of a crucible base block is essential in providing uniform heating of the crucible baseThe base block should provide complete support over the whole crucible baseFor optimum efficiency - the base block must be the correct height- The base block and crucible must be installed
centrally
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Correct Installation of Base Block
Correct height of stand/alignment of burnerCorrect stand support
for Morganite crucible
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Use of Incorrect Base Block
Thermal stress will result if a low conductivity material is usedInadequate support will be provided if the base block is too narrow leading to distortion of the crucible baseBurner flame impingement on the crucible wall will result if the base block is too short
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Use of Incorrect Base BlockGlaze deterioration from flame impingement
Distortion due to support on fire-bricks
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Correct Setting In Bale-Out Furnaces
Allow 1/3”(8mm) expansion gap between top cover bricks and crucible top edge to allow for expansionPlace layer of ceramic fiber over top of lining and crucible to insulate metal top platesAllow 1/3”(8mm) expansion gap between top ring flange and crucible where applicableKeep all the labels from the crucible, in case of a claim these will be required
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Copyright - Morganite Crucible Inc 2000 10
Correct Setting in a Bale Out Furnace
Setting of crucible
in a bale out furnace
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Incorrect Setting In Bale-Out Furnaces
Insufficient expansion gap will result in lateral cracking below the top cover bricksThe upper wall of the crucible will be insulated if ceramic fiber is pushed down between cover bricks and crucible thus preventing the glaze from functioningVertical cracking will result from a tight fitting flanged top ring
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Oxidised top edgesection due to insulating effect of ceramic fibre
Top edge vertical cracking due to tight fitting top ring
Incorrect Setting in Bale Out Furnaces
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Copyright - Morganite Crucible Inc 2000 13
Correct Setting In Tilting Furnaces
Ensure stand is central and levelSpread a thin layer of refractory cement evenly over the standLower crucible onto standAllow 1/3” (6-10mm) expansion gap between crucible and grip bricks (use combustible spacer)Allow 38mm gap below spout to avoid hanging up on the spout as a result of settlementKeep all the labels from the crucible, in case of a claim these will be required
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Setting of cruciblein a tilting furnace
Correct Setting of Crucible In Tilting Furnace
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Incorrect Setting In Tilting Furnace
Grip bricks set to tight! Vertical cracks due to crucible expansion
Insufficient gap below spout ! Crucible hangs on refractory – 1.5” (38mm)
gap recommended below spout
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Top edge vertical cracking due to tightfitting grip-brick
Crack showing gripbrick too tight
Incorrect Setting In Tilting Furnace
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ChargingCharge and melt as soon as the crucible has reached red heat all overNever introduce moist charge materialCharge light scrap first to form a cushion for heavier materialUse tongs to charge ingots or large pieces to avoid crucible damagePlace ingots vertically to avoid bridging or wedging across the crucibleDo not pack metal tightly, allow room for metal to expand
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Charging
Place ingots with tongs
Place ingots verticallyDo not over fill
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Correct crucible charging
Charging Practice
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Tightly packed charge causes ‘U-shape’ crackingBridged ingots cause inverted ‘Y-shape’ cracksIngot impacts produce cone-shape holesRe-heating frozen charge leads to bursting cracks due to metal expansion
Mechanical Damage
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‘U’ orshield shape crack
‘Y’ shape crack inverted
Mechanical Damage
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Cone shaped fracture
Mechanical Damage
Do not reheat frozen metal
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Correct & incorrect fitting oftongs
Correct & safe use of liftingtongs
Mechanical Damage
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Dross/Slag Build-Up
High expansion rate of dross causes internal pressure (approximately ten times expansion rate of crucible material)Dross has low thermal conductivity which insulates the metal thus necessitating higher furnace temperatureLeads to higher energy costsDross absorbs flux which accelerates chemical attack on the crucible
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Dross accumulation in crucible leading to expansion cracking
Dross and Slag Build Up
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Chemical AttackAluminum
Aluminum Applications! Excessive use of flux! Incorrect flux! Reactions are temperature dependentLeads to! External holes! Random cracking! Melting of the glaze and body material
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Random Cracking
External Holes
Melting of Body and Glaze
Chemical AttackAluminum
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Chemical AttackCopper Alloys
Internal corrosion by fluxes! Flux added prior to charge and not mixed ! Over fluxing and excessive time at temperature
External corrosion by fluxes! Caused by over filling, and flux running down
outside wall
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Flux and slag corrosion of lowerinside wall of crucible Mouse holing due to flux attack
Chemical AttackCopper Alloys
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How To Limit Chemical AttackUse minimum quantity of flux in keeping with metal qualityUse correct flux for specific operation/temperatureUse metallic sodium in preference to alkaline fluxes where applicableCarry out treatment in transfer vessel, not holding crucible where possibleEnsure crucible is kept free from dross by regular scraping and cleaning
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Oxidation
Results in reduced strength and thermal conductivity, loss of material integrity
Caused By:! Glaze damage prior to use! Excessive use of ceramic fiber around top wall of
crucible! Use of excess oxygen in fuel fired furnaces! Flame impingement - glaze stripped by flame directly
contacting crucible
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Cracking near top edge from bad setting followed by oxidation
Dry un-matured glaze/cracking/oxidationdue to poor furnace conditions
Oxidation
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Thermal Shock
Thermal stress cracking due to rapid or localized heating ! Improperly positioned crucible! Direct burner impingement! Badly adjusted burner – short flame
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Thermal stress crack across base
Thermal Shock
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Summary
If a crucible experiences shorter than normal lifeCall your Morganite Sales Representative and they will advise if a claim is requiredIf it is follow the procedure detailed on the web site remembering to take pictures and retain labels so a claim can be filed properly