Half-crucible dry hearth melter

A method of melting a metal charge, the method comprising:

• providing a metal furnace for melting a metal charge, the metal furnace comprising:
• a chamber having a top section and a bottom section, the chamber comprising:
• a half crucible;
• a refractory cover superposed on at least one portion of the half crucible;
• a liner disposed along the top surface of the half crucible;
• a heating element wherein at least one portion of the heating element is exposed and at least one portion of the heating element is embedded within the half crucible;
• a discharge outlet at the front end of the chamber;
• a filter operably coupled to the top and bottom sections of the chamber, positioned between a charge within the chamber and the discharge outlet;
• and
• a viewing cover disposed above the filter and operably coupled to the top section of the chamber;
• an insulation material affixed to the top and bottom sections of the chamber;
• a cover overlaid over an outer surface of the insulation material;
• a temperature sensor extending from within the chamber through the refractory cover, insulation layer, and cover;
• and
• one or more support legs mechanically coupled to the half crucible;
• placing a metal charge on a top surface of the half crucible within the chamber;
• electrically charging the heating element to melt the metal charge;
• and
• directing molten metal through the discharge outlet.