Calculation of charge burden to foundry furnaces by computing the proportions of particular charge materials is a most complicated task as a variety of technological aspects have to be considered. For practical and economic reasons, this problem is typically solved using computer-based optimisation methods, the main criterion being the optimal amount of charge materials related to the lowest costs of the burden. The problem is further complicated when the chemical composition of the charge materials is not accurately defined. So far the calculations of the charge burden were performed in order to work out the detailed melt procedure, which was to be modified and corrected by the trial and error method in subsequent melt processes.
An algorithm has been developed for use in calculating the charge burden depending on the target chemical composition of the casting alloy. Of particular importance is the application of the algorithm when the process conditions are changeable.