Are you struggling with inconsistent melts or high energy costs? You’re not alone—many metalworkers face the same issue.
A melting furnace is a high-temperature industrial device used to liquefy metals like iron, steel, aluminum, and copper efficiently and consistently, making it essential for metal casting and forging.
Let’s take a closer look at how melting furnaces work, what types are available, and how the right one can optimize your production process.
How does a melting furnace work?
Confused about how raw metal turns into molten liquid ready for casting? Understanding the process is the first step to better results.
A melting furnace heats metal beyond its melting point using electric induction or combustion, turning solid metal into liquid for further processing like casting, molding, or alloying.
Melting furnaces operate on different heating technologies—primarily induction heating and fuel combustion. Induction furnaces use electromagnetic fields to generate heat directly within the metal, offering precise temperature control and high energy efficiency. Combustion furnaces, on the other hand, burn fuels such as natural gas or oil to produce heat.
Inside the furnace chamber, the metal is placed in a crucible or a refractory-lined shell. As the temperature rises, the metal absorbs heat until it reaches its melting point and transitions into liquid form. This process must be closely monitored to avoid oxidation, contamination, or overheating.
Modern industrial melting furnaces, like those offered by Kehua, include automation features, temperature monitoring systems, and energy-efficient designs that allow for continuous operation. Whether you’re working with aluminum for lightweight parts or cast iron for durability, the right furnace ensures consistent melt quality and reduces waste—critical factors for cost-effective production and client satisfaction.
What types of melting furnaces are there?
Choosing the wrong furnace can lead to higher energy bills and equipment downtime. Let’s avoid that mistake.
Common types include induction furnaces, electric arc furnaces, and cupola furnaces, each suited for different metals and production needs.
Induction furnaces are popular for their cleanliness, speed, and energy efficiency, making them ideal for high-quality steel, copper, and aluminum melting. They are particularly useful in foundries and precision casting environments because they produce minimal emissions and allow tight temperature control.
Electric arc furnaces (EAFs) are widely used in steel production. They melt scrap metal using an electric arc between graphite electrodes and are known for handling large volumes, although they consume significant electricity.
Cupola furnaces, often found in traditional foundries, use coke as a fuel source and are mainly employed for cast iron. While they’re cost-effective upfront, they generate more emissions and require more manual operation.
At Kehua, we provide a wide range of furnace types including steel shell, aluminum shell, and hydraulic lifting induction furnaces, each designed for specific applications. The right choice depends on the type of metal, desired melting capacity, and energy goals.
How can a melting furnace improve productivity and cost control?
Are inefficiencies eating into your profits? The right furnace might be the upgrade your factory needs.
A modern melting furnace reduces energy consumption, speeds up melting cycles, and minimizes downtime, resulting in lower costs and higher output.
Productivity and energy efficiency are two pillars of profitability in metalworking. Traditional melting methods often suffer from heat loss, inconsistent temperatures, and frequent maintenance—factors that reduce throughput and increase costs.
Advanced melting furnaces, especially induction-based models, deliver faster heating, precise control, and lower operational costs. For example, Kehua’s IGBT induction furnaces use solid-state technology to minimize power loss and achieve uniform melts in shorter cycles. This allows for more frequent production batches and reduced scrap rates.
In addition, integrating automated loading and temperature control systems helps streamline workflow, reduce manual labor, and ensure safer working conditions. For procurement managers like David Lin, this means fewer unplanned shutdowns, lower repair costs, and a better bottom line.
Ultimately, investing in the right melting furnace is not just about buying equipment—it’s about securing consistent quality, meeting delivery deadlines, and staying ahead in a competitive market.
Melting furnaces are the backbone of efficient metal processing, offering control, speed, and energy savings that translate directly into higher profits and better-quality output.
