Foundry & Forging calculator
Melt Loss Calculator
Estimate the cost of melt loss from oxidation, slag, dross, furnace hold loss, ladle loss, returns, and alloy trim waste. Use it when quoting castings, reviewing heat performance, or deciding whether melt practice, furnace lining, charge mix, or ladle handling is costing too much metal.
What this calculator does
- Estimate the cost of melt loss from oxidation, slag, dross, furnace hold loss, ladle loss, returns, and alloy trim waste.
- Use it when quoting castings, reviewing heat performance, or deciding whether melt practice, furnace lining, charge mix, or ladle handling is costing too much metal.
- Costs metal lost during melting, holding, transfer, and pouring.
Formula used
- Total melt loss calculator = melt loss weight × metal cost per weight unit × recoverable loss included + fixed melt handling cost
- Melt loss cost per weight unit = total cost ÷ melt loss weight
Inputs explained
- Melt loss weight: Enter pounds or kilograms of metal lost between charge, melt, transfer, pour, and usable casting output.
- Metal cost per weight unit: Use current alloy, pig iron, scrap, return, aluminum, steel, bronze, or surcharge cost per pound or kilogram.
- Recoverable loss included: Enter the portion of melt loss charged to this part, heat, customer, alloy family, or production lot.
- Fixed melt handling cost: Add slag disposal, flux, sample testing, furnace cleanup, or labor cost tied to the loss.
How to use the result
- Use for melt-shop cost review and quoting.
- This calculator is an estimating tool. Results can change with alloy chemistry, furnace practice, ladle losses, mold design, gating and riser layout, core condition, pattern allowance, die temperature, press condition, inspection criteria, rework rules, energy rates, labor standards, and actual shop performance. Validate safety-critical, metallurgical, tooling, press-capacity, and customer-spec decisions with qualified engineering, metallurgy, OEM data, and the applicable control plan.
Common questions
- What information do I need before using the Melt Loss Calculator? Use melt loss weight, metal cost, allocation percentage, and any fixed handling cost.
- What does the result mean? It estimates total melt-loss cost and cost per weight unit or lot basis.
- When is the result only an estimate? This calculator is an estimating tool. Results can change with alloy chemistry, furnace practice, ladle losses, mold design, gating and riser layout, core condition, pattern allowance, die temperature, press condition, inspection criteria, rework rules, energy rates, labor standards, and actual shop performance. Validate safety-critical, metallurgical, tooling, press-capacity, and customer-spec decisions with qualified engineering, metallurgy, OEM data, and the applicable control plan.
- What decision can I make from the result? Use it to update quotes, compare furnace practice, justify melt-loss projects, or review alloy purchasing.
Last reviewed 2026-05-12.