melttechnology

Melttechnology refers to the set of processes and technologies that manage and exploit materials in the molten state to produce, refine, or reshape products. It covers melting, alloying, purification, and subsequent shaping as well as methods to control solidification and microstructure after cooling. The term is used in industry and academia to describe both traditional foundry practices and newer methods that rely on liquid-state processing.

Core methods include melting in furnaces such as induction, electric-arc, or plasma systems; refining and degassing; alloying in the molten state; and shaping through pouring, casting, or direct energy deposition. Advanced variants include laser-assisted or electron-beam melting, rapid solidification control, and continuous casting. In polymers and glasses, melttechnology encompasses thermal shaping and re-flow techniques to achieve desired geometries and properties.

Measurement and control rely on temperature monitoring with pyrometers and thermocouples; atmosphere and fluxes are managed to reduce oxidation and contamination; models simulate heat transfer, fluid dynamics, and solidification to predict porosity, segregation, and grain size.

Applications include metal casting and alloy development, aerospace and automotive components, electronics packaging, and glass manufacture, along with recycling of scrap metals. In recycling contexts, molten processing enables material recovery with improved purity and the potential for energy-efficient refining when integrated with downstream treatments.

Challenges and outlook center on energy intensity, oxidation, contamination, slag management, and worker safety; environmental concerns; and the need for improved in-situ sensing and digital twins. Ongoing research aims to enhance efficiency, material properties, and circularity in molten-state processing.

See also: metallurgy, casting, solidification, additive manufacturing.