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Melting Process: Common Aluminum Melting Methods Explained
2026.05.07
What Are the Main Melting Methods?
At present, most aluminum processing plants produce billets for pressure processing by remelting solid aluminum ingots. There are generally four main melting methods Melting Process:
Batch melting
Semi-batch melting
Semi-continuous melting
Continuous melting
Batch Melting Method
The batch melting method means that the metal is discharged completely after the processes of charging, melting, slag removal, and refining. No metal remains in the furnace.
This method is mostly used to produce finished aluminum alloys with high quality requirements. It can better ensure the uniformity of the chemical composition of the ingot.
Semi-Batch Melting Method
The semi-batch melting method is basically the same as the batch melting method. The main difference lies in the amount of liquid metal retained in the furnace.
In semi-batch melting, after tapping, about 1/5 to 1/4 of the liquid metal remains in the furnace. The charge for the next heat is then added for melting.
The advantages of this method include:
The newly added charge can be immersed in liquid metal, reducing metal burning loss.
Some settled inclusions can remain at the furnace bottom during tapping.
Inclusions are less likely to mix into the liquid metal during casting.
Furnace temperature fluctuation is small, which helps extend furnace service life.
This method is suitable for melting pure aluminum.
Semi-Continuous Melting Method
The semi-continuous melting method is similar to the semi-batch melting method. After each tapping of about 1/3 to 1/4 of the molten metal, the charge for the next heat can be added.
The difference is that in semi-continuous melting, only a small amount of molten metal is tapped each time, while most of the melted liquid metal remains in the furnace. This allows tapping and charging to continue alternately.
This method is suitable for melting scrap in a double-chamber furnace. Since the added charge is immersed in liquid metal, it not only reduces burning loss but also increases melting speed.
Continuous Melting Method
The continuous melting method means that charge materials are added continuously, while tapping is carried out intermittently.
This method has poor flexibility and a limited application range. It is mainly suitable for melting pure aluminum and is also used for melting aluminum scrap, aluminum chips, and similar materials.
