By Manager Ding | Sales Manager, Juding Thermal Energy Technology
Background
In early 2022, I received an inquiry from a die-casting plant in Vietnam. The plant manager, Mr. Nguyen, had a problem that many die-casters know too well: inconsistent aluminum quality was causing high scrap rates, and their existing furnace could not keep up with production demand.
The plant runs two 1,600-ton die-casting machines producing automotive components for export. Their customers demanded high-quality parts with minimal porosity and consistent mechanical properties. But the existing melting setup was letting them down.
Mr. Nguyen explained: “We need better aluminum quality. Our scrap rate is too high, and we’re losing orders because of it. We also need more capacity—our machines are often waiting for metal.”
That conversation marked the beginning of a project that would address both quality and capacity in one solution.
The Challenge
The Vietnamese plant faced two critical issues:
1. Aluminum Quality Problems
The existing furnace was delivering aluminum with inconsistent temperature and high impurity levels. This resulted in:
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High porosity in finished parts
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Inconsistent mechanical properties
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High scrap rates (over 8%)
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Customer complaints and risk of losing export contracts
2. Insufficient Melting Capacity
With two 1,600-ton machines running, the plant needed a reliable supply of molten aluminum. The old furnace could not keep up, causing:
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Production delays
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Machine idle time
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Inability to take on larger orders
Mr. Nguyen needed a furnace that could deliver both quality and capacity.
The Solution: QDW Series Tilting Furnace
After reviewing their production data and quality requirements, I recommended the QDW Series Tilting Furnace with the following configuration:
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Capacity: 2,000 kg/h (matched to their two 1,600-ton machines)
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Temperature Control: ±5℃ accuracy
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Holding Temperature: 700-750℃
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Burn Loss: <0.8%-1.3%
But the key to solving their quality problem was the optional degassing brick in the holding chamber. This feature removes hydrogen and impurities from the molten aluminum before it reaches the die-casting machine—directly addressing the porosity issue.
Why This Configuration?
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Degassing Brick: Reduces hydrogen content, minimizing porosity and improving surface finish.
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±5℃ Accuracy: Ensures consistent temperature, which is critical for mechanical properties.
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Tilting Design: Allows for complete drainage and easy cleaning, reducing contamination between batches.
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2,000 kg/h Capacity: Matches the demand of two 1,600-ton machines, eliminating waiting time.
Project Timeline: From Inquiry to Successful Sintering
January 2022 – Initial Inquiry
Mr. Nguyen contacted us through our website. We had an initial video call to discuss his quality issues and production requirements.
February 2022 – Proposal and Order Confirmation
After reviewing their data and discussing options, we submitted a detailed proposal. The plant confirmed the order, including the degassing brick option.
March 2022 – Delivery and Installation
The QDW furnace was shipped to Vietnam and installed by our technical team. Despite the challenges of international logistics during this period, we completed installation on schedule.
March 2022 – Commissioning and Sintering
The commissioning process was critical. For a furnace to perform at its best, the refractory lining must be properly sintered—a process that removes moisture and creates a strong, durable lining.
Our technical team followed a strict sintering schedule:
| Stage | Temperature Range | Duration | Purpose |
|---|---|---|---|
| 1 | 100-200℃ | 8 hours | Remove free moisture |
| 2 | 200-500℃ | 12 hours | Remove chemically bound water |
| 3 | 500-800℃ | 8 hours | Complete sintering of refractory |
| 4 | 800-900℃ | 4 hours | Final curing and stabilization |
After sintering, we conducted test melts to verify:
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Temperature accuracy: ±5℃ ✅
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Melting capacity: 2,000 kg/h ✅
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Degassing performance: Hydrogen content reduced to acceptable levels ✅
March 2022 – Final Acceptance
The plant formally accepted the equipment after successful trial production. Mr. Nguyen was pleased with the results.
Results After Implementation
Three months after installation, I followed up with Mr. Nguyen. Here’s what he reported:
Aluminum Quality:
“The degassing brick made a huge difference. Our porosity rate dropped dramatically. Scrap rate went from over 8% to under 3%. Our customers are happy, and we’ve received new orders.”
Production Capacity:
“We no longer have machines waiting for aluminum. The QDW delivers exactly what we need. Our overall efficiency is up by at least 25%.”
Temperature Consistency:
“The ±5℃ accuracy is impressive. Our parts have consistent mechanical properties now. We’ve had zero quality complaints since installation.”
Maintenance:
“The tilting design makes cleaning easy. We can drain almost all the aluminum, which reduces contamination between batches. Maintenance is simple and fast.”
Key Takeaways
This case demonstrates how the right furnace configuration can solve both quality and capacity challenges:
| Challenge | QDW Solution | Result |
|---|---|---|
| High porosity and scrap rate | Degassing brick in holding chamber | Scrap rate reduced from 8% to under 3% |
| Inconsistent temperature | ±5℃ control accuracy | Consistent mechanical properties |
| Insufficient capacity | 2,000 kg/h capacity | Matched two 1,600-ton machines |
| Contamination between batches | Tilting design for complete drainage | Easy cleaning, less contamination |
| Production delays | Reliable, continuous delivery | Efficiency increased by 25% |
Why Sintering Matters
For any furnace, proper sintering is essential for long-term performance. A poorly sintered lining can lead to:
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Cracks and premature wear
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Reduced thermal efficiency
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Contamination of the molten aluminum
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Shorter furnace life
Our technical team follows a strict sintering protocol and stays on-site until the process is complete. This ensures that every QDW furnace performs at its best from day one.
Is Your Plant Facing Similar Challenges?
If you’re struggling with aluminum quality, production capacity, or both, the QDW Series Tilting Furnace could be the solution. I’m happy to discuss your specific requirements and help you find the right configuration.
Contact me directly:
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Sales Manager: Manager Ding
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Phone/WeChat: 15962220217
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Address: No. 30, Anfu Road, Northern Industrial Zone, Dongbang Town, Changshu City, Jiangsu Province, China
Scan the QR code to add me on WeChat for a free consultation and customized solution.
