Overflow transfer furnace and control system for reduced oxide production in a casting furnace

1. A method of transferring molten aluminum from a melting furnace to a casting furnace, the steps comprising:

(a) providing a transfer furnace having a plurality of chambers with at least one connection between the chambers, the connection being structured to provide for the transfer of molten metal between the chambers while allowing the melt level in one of said chambers to be higher than in another of said chambers;

(b) supplying molten aluminum to the transfer furnace; and

(c) overflowing the transfer furnace such that the molten aluminum flows through a trough and downspout into a casting furnace.

2. The method of claim 1 wherein the molten aluminum is supplied to an upstream chamber of the transfer furnace and subsequently pumped into a downstream chamber of the transfer furnace such that the pumping causes the overflow of molten aluminum from the downstream chamber into the casting furnace, wherein said pump is structured to provide a melt level in said upstream chamber that is different than the melt level of said downstream chamber.

3. The method of claim 1 wherein the flow of molten aluminum into the casting furnace occurs substantially without contacting the atmosphere.

4. The method of claim 1 further comprising the step of recirculating molten aluminum in the transfer furnace.