How to Melt Aluminum

Melting aluminum requires careful handling and proper equipment due to its high melting point and the dangers associated with molten metal. Here’s a general guide on how to melt aluminum safely.

Equipment and Materials

  1. Aluminum scrap (clean and free of contaminants)
  2. Crucible (made of graphite or other high-temperature materials)
  3. Furnace or foundry (propane or electric)
  4. Protective gear (gloves, face shield, apron, and heat-resistant clothing)
  5. Tongs (to handle the crucible)
  6. Flux (to remove impurities)
  7. Mold (for casting the melted aluminum)

Steps to Melt Aluminum

  1. Safety First:
    • Wear appropriate protective gear.
    • Ensure you are working in a well-ventilated area, ideally outdoors.
  1. Prepare the Furnace:
    • If using a propane furnace, connect the propane tank and ignite the furnace.
    • If using an electric furnace, set it to the required temperature (660°C or 1220°F for aluminum).
  1. Place Aluminum in the Crucible:
    • Put the aluminum scraps into the crucible. Ensure the crucible is clean and free of any moisture to avoid dangerous steam explosions.
  1. Heat the Crucible:
    • Place the crucible in the furnace.
    • Monitor the temperature and wait for the aluminum to melt. This can take some time, depending on the furnace and the amount of aluminum.
  1. Add Flux:
    • Once the aluminum starts melting, add flux to help remove impurities. Stir gently with a heat-resistant tool.
  1. Remove Slag:
    • As the aluminum melts completely, a layer of slag (impurities) will form on top. Use a skimming tool to remove the slag.
  1. Pour the Molten Aluminum:
    • Carefully use tongs to lift the crucible from the furnace.
    • Pour the molten aluminum into the mold. Do this slowly and steadily to avoid splashing.
  1. Cool and Solidify:
    • Allow the aluminum to cool and solidify in the mold.
    • Once fully cooled, remove the solid aluminum casting from the mold.


  • Always be cautious when handling molten metal to avoid burns and injuries.
  • Ensure your work area is free from flammable materials.
  • Never use a wet mold or crucible as moisture can cause dangerous explosions when in contact with molten aluminum.

Disposal and Cleanup

  • Dispose of slag and any unused aluminum safely.
  • Clean the crucible and tools thoroughly after use to prevent contamination for future melts.

By following these steps and safety precautions, you can melt aluminum effectively and safely for various projects.


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