Westomat® Aluminum Dosing Furnace
Featuring ProDos® 3 Technology
The Westomat® is a non-crucible dosing furnace for a fully automatic metal feed into a die-casting machine or die-casting mold. The Westomat is suitable for any size casting requirement, with models ranging from 450 to 3100 kg (990 to 6800 lbs) capacity.
The Westomat offers the highest process reliability when casting thin-walled structural components. By heating the closed elongated riser tube up to the casting chamber, even fewer oxides are formed during dosing. Ideal for precision casting too. The pure metal is removed from beneath the bath surface and dosed without turbulence into the filling chamber of the die-casting machine. The contact with any oxidizing atmosphere is minimized; metal reactions and oxide inclusions are practically non-existent. For that reason the closed, electrically heated dosing furnace uses only around one third of the energy used by bale-out furnaces.
Using a Westomat®, energy costs are cut down 66% compared with automated ladle systems with holding furnaces.
Dozens of Options
The most diverse of options are available with Westomat®. Elongated riser tube for structural components and precision die-casting, pneumatic filling system, electric heating chute, porous plugs, biscuit correction, rim cleaning jet for the riser tube or options for energy management: We design custom furnaces to meet the needs of the customer.
The closed Westomat® furnace system with only 0.06% metal loss is unmatched by any ladle system. The entry of oxides in the casting process is eliminated by the design of the system.
Melt perfectly tempered.
The Westomat® maintains melt temperature exactly within ± 3.6° F of the desired temperature. It is not necessary to overheat the melt because no temperature loss occurs on the way down into the casting chamber, therefore making compensation unnecessary too.
- Lower energy consumption — energy costs are cut down 66%, using only approximately 1/3 of the energy required by conventional holding furnace / auto-ladle systems
- High melt quality and exceptionally low metal loss, approx. 0.06%, as molten metal is added and removed from below the bath surface, eliminating the formation of oxides.
- Compact size and holding chamber capacities to fit any die casing line
- Automated dosing optimization for rapid cycle times
- High useable proportion of the total capacity means longer intervals between filling
- Uninterrupted dosing cycle — even when refilling
- All operation are continuously and automatically monitored and adjusted to ensure high dosing accuracy
Built for Performance
How It Works
The metal discharge cycle begins with a positive pressure produced inside the furnace chamber. This increases the molten metal level inside the riser tube to just short of overflowing (Top- Stop-Position®). At the time of dosing, the pressure inside the furnace increases so that melt is discharged immediately. When the predetermined quantity is reached, the dosing process is terminated by reducing the pressure. The metal level again returns to the Top-Stop-Position® and the Westomat® is ready for the next dosing. Production interruptions of the die-casting machine or variability in cycle time do not cause any additional time delays – your benefit: increased productivity.
Controlled Fill Level
Bath level is continually monitored for consistent bath volume. A signal lamp shows the current fill level at all times. The metal is both fed and discharged below the surface of the bath via a large funnel. The filling process does not affect production as the dosing unit remains ready for dosing even as it is being refilled.
The inner furnace chamber roof features durable SiC heating elements that have stood the test of time in die-casting practice. The temperature is controlled via a heating element installed in the melting bath, and the use of top-quality control electronics guarantees minimal temperature deviation in holding mode. If the melt is not sufficiently hot when poured in, the higher power setting is automatically activated and the metal is heated until reaching the desired temperature value without overheating.
The scissors table lifts Westomat to required pouring position for the die-casting machine. The desired position is set via a hydraulic cylinder, either with a manual hydraulic pump or optionally via a powered unit. Tilting the Westomat® completely empties the furnace body – thus making both cleaning of the furnace and alloy changes easy. Additional options for movability and three-dimensional positioning are available.
- Extended, heated riser tube for precision casting and the casting of thin-walled structural elements. Thanks to the closed fill tube which extends right up to the casting chamber, even less oxides are produced during dosing.
- PneuCo®, the electro-pneumatic metal level detecting method. A small volume of air is blown through a nozzle just below the upper edge of the dosing tube. As soon as the rising molten metal reaches this hole, the control interrupts the pressure build-up. The lack of mechanical components means a further improvement in production security.
- Biscuit Correction: Due to the feedback data signal from die-casting machine to Westomat®, the out-of-tolerance rate of the biscuit is permanently self-optimized. This results in improved dosing accuracy and significantly reduces the scrap rate.
- Riser tube: Rim cleaning jet: A short pressure surge prevents the formation of solidified molten metal threads at the transition between riser tube and casting channel. Manual cleaning becomes obsolete and the dosing accuracy remains constant.
- High-performance insulation – leads to a further 10% reduction of energy consumption. The investment pays for itself – often after just one year.
- Cast iron fill funnel without refractory lining: Thanks to reduced wear-and-tear, longer operating lives are achieved compared with lined fill funnels.
- Launder heating: Optimal melting temperature right up to the point of transfer at low bath temperatures or for long casting channels.
- Subframe in various designs: manual, motorized, hydraulically movable or with rotating assembly for the three-dimensional positioning of the Westomat®.
- Pneumatic feed appliance: The closed ladle system meets the highest demands in terms of health & safety and in terms of maintaining melt quality.
|Holding capacity||450 kg
|Useable capacity||300 kg
|Temperature stability||± 3.6° F|
|Refractory material||5 year warranty on lining|
|Dosing accuracy||+/- 1.5 % (with out-of-tolerance rate < 1 %) with optional biscuit correction +/- 2 % (with out-of-tolerance rate < 1 %)|
|Metal yield||Up to 99.94 %|
|Metal quality||Up to density index of < 2 with optional porous plug technology|
|Availability||Up to 99% uptime|
*All data are guide values, for confirmed performance parameters of the specific operating conditions and feed materials must be used as a basis for calculations.