A die casting furnace that will not hold setpoint temperature is a serious problem. It affects casting quality, cycle time, and scrap rate. In my 25 years, I have traced this issue in foundries across China, Southeast Asia, India, the UK, Eur...

A furnace that will not reach setpoint temperature is not necessarily broken. It is telling you that heat is being lost faster than it is being added. The cause is usually one of six things: a damaged lining, leaky door seals, a misadjusted burner, low...

Fix inconsistent aluminium melt quality. Causes: temperature, alloying, contamination, fluxing, degassing. 25 years of foundry experience. Inconsistent melt quality is one of the most frustrating problems in a foundry. One day the castings a...

Fix an aluminium furnace that overheats frequently. Check thermocouple, controller, gas valve, air-fuel ratio, and safety limits. 25 years of foundry experience. A furnace that overheats frequently is not just wasting energy. It is damaging your refra...

Troubleshoot why your aluminium furnace is using more gas than usual. Check burner, gas pressure, lining, and operation. 25 years of foundry experience. A sudden jump in gas consumption is almost never the gas meter’s fault. It is a signal t...

Step-by-step guide to fixing a gas furnace burner that won't ignite. Check gas supply, igniter, flame sensor, and safety interlocks. 25 years experience. A gas furnace burner that won’t ignite is usually caused by one of five things: no gas supply...

How to diagnose and repair refractory cracking in aluminum melting furnaces. Causes, inspection, repair methods, and prevention. 25 years of foundry experience。 Note: I use British spelling “aluminium” throughout, but “aluminum” appears where North Am...

Step-by-step troubleshooting for an aluminium melting furnace that won't heat properly. Common causes: burner, thermocouple, heating elements, gas supply. 25 years experience. Note: I use British spelling "aluminium" throughout, as most of m...

Troubleshoot why your aluminium furnace keeps shutting down. Common causes: burner, thermocouple, gas supply, safety interlocks. 25 years of foundry experience. Note: I use British spelling "aluminium" throughout, as most of my readers are in the UK, ...