Design and Development of a Pilot Aluminum Smelting Crucible Furnace for Educational Foundry Applications.

The growing emphasis on practical competencies in foundry technology and metal casting has created a need for cost-effective and reliable training equipment in engineering and technical institutions. Nevertheless, the availability of functional aluminum melting furnaces (AMFs) in many educational workshops remains limited because of the high cost of commercial equipment, restricted access to industrial furnaces, and inadequate practical training infrastructure. This study presents the design, fabrication, and performance assessment of a pilot aluminum-smelting crucible furnace developed for educational foundry applications. The furnace was constructed from locally obtainable materials, including mild steel, refractory bricks, ceramic fiber insulation, a crucible pot, and a liquefied petroleum gas (LPG) burner assembly. The design incorporated key engineering requirements related to heat transfer, combustion performance, structural integrity, operational safety, and user-friendliness. The fabricated furnace measured 900 mm in height and 550 mm in diameter and was designed to accommodate an aluminum charge of 5 kg per batch. Its performance was evaluated based on operating temperature, aluminum melting duration, fuel consumption, temperature distribution, and thermal efficiency. The furnace achieved a maximum temperature of approximately 1200°C, demonstrating adequate thermal capacity for aluminum melting. A 5 kg aluminum charge was completely melted within 30–45 minutes, giving an average melting time of 37.5 minutes. The furnace also demonstrated consistent combustion, satisfactory heat retention, and a thermal efficiency of approximately 65–75%, with comparatively low fuel consumption. The pilot crucible furnace developed in this study provides a practical and economical solution for foundry education, laboratory-based demonstrations, and small-scale aluminum casting activities. Further improvement could involve the incorporation of automated temperature regulation, digital monitoring and data acquisition systems, and alternative energy sources to improve thermal performance, operational safety, and effectiveness as an instructional tool.