This document summarizes the continuous casting process for producing copper magnesium (CuMg) wire rod, which requires tight alloy tolerances for strength and conductivity in electrical applications like high speed rail systems. It describes the Rautomead vertical casting process using a graphite crucible and heating system that maintains precise alloy composition control through oxygen reduction and specialized magnesium addition methods. This process has been proven to produce CuMg wire rod meeting high quality standards for train speeds over 400 km/h.
Rautomead technology for continuous casting of oxygen free copper, copper-mag...Rautomead Limited
Rautomead Technology for Continuous Casting of Oxygen-free Copper, Copper-magnesium and Copper Conductor Alloys
We offer copper continuous casting technology and a range of copper wire and cable continuous casting machines.
The copper rod continuous casting machines are specifically designed for the processing of electrolytically-refined grade 'A' copper feedstock to produce 8.0mm diameter wire rods. They may be configured to produce rod up to 22.0mm diameter if required. The machines are intended to be operated for long periods of uninterrupted production of continuous cast copper wire rod.
RS machines are configured as integrated melting, holding and casting units, featuring graphite crucibles, protected in an inert gas atmosphere with high intensity graphite resistance heating.
RDG machines feature large Induction furnace technology. Machines are either single furnace integrated melting and casting or dual furnace with cathode melter feeding a holding furnace, depending on production output.
continuous casting machines for copper wire & cable operating costs
Rautomead have paid great attention to minimising the cost of operating the machine. Furnaces are totally enclosed and built up using high performance insulations to achieve minimum economic heat loss. Casting dies are inexpensive and may be changed individually
RS 3000 CuMg machine with graphite crucible technology is ideally suited for production of high quality copper magnesium alloy wire rod.
The graphite crucible removes oxygen from cathode feedstock which minimises losses of the magnesium alloying element.
Technology available for high magnesium content (0.4 – 0.6% Mg) alloy rod for use in the manufacture of overhead contact wires and cables for high speed trains, also for low magnesium content (0.1 -0.2% Mg) alloy rod for use in the manufacture of small diameter automotive data communication cables.
Rautomead technology is being used by suppliers of CuMg catenary contact wires on European High Speed train lines.
The massive construction project in progress in China to build 15,000 – 20,000km of new high speed train track features CuMg contact wires made from rods produced on Rautomead technology installed at cable factories around China.
Effect of water flow rate casting speed alloying element and pull distance on...Rautomead Limited
Most parameters that control the solidification of castings, and consequently,
microstructure and mechanical properties, are: chemical composition, liquid metal treatment,
cooling rate and temperature gradient. In this work, characterization of the influence
of water flow rate, casting speed, alloying element and pull distance on tensile strength,
elongation percentage and microstructure of continuous cast copper alloys has been carried
out. A significant different in tensile strength, elongation percentage and grain structure
has been investigated and it was also found that these parameters could improve the physical
and mechanical properties of samples. As a particular example, water flow rate could
improve the elongation of samples from 10% to 25%.
RAUTOMEAD TECHNOLOGY FOR CONTINUOUS CASTING OF OXYGEN-FREE COPPER AND DILUTE...Rautomead Limited
Paper by Sir Michael Nairn, Chairman of Rautomead Limited, Dundee, U.K.
presented at the Global Continuous Casting Forum, during the Interwire 2015 Trade Exposition, being held in Atlanta, Georgia, USA
organised by WAI
27 – 30 April 2015
Rautomead Continuous Casting Technology for Railway and Automotive ApplicationsRautomead Limited
Rautomead offer a range of machines designed to cast Copper Magnesium and other conductor alloys for Railway Contact and Messenger Wires and Automotive wiring Harness.
Rautomead Limited are UK-based specialists in continuous casting of non-ferrous metals and construction of continuous casting equipment for copper, copper alloys, gold and silver, dental alloys and feed rod for Conform machines.
For a period of over 30 years Rautomead Limited has specialised in the design, manufacture and sale of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries around the world.
Rautomead promote Advanced Metals Technology Collaboration for research and development of new processing technology for non ferrous metals
www.rautomead.co.uk
sales@rautomead.co.uk
For over 30 years Rautomead Limited has specialised in the design and manufacture of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries worldwide.
Rautomead plants are being successfully applied to production of oxygen-free copper, a wide range of copper-based alloys, precious metals and zinc. Forms include wire rod, straight length bars, flats and hollow sections. According to material and section, the casting process selected may be vertical upwards, vertical downwards or horizontal. The machines may be used either as integrated melting, holding and casting machines, or may be arranged to be fed with pre-alloyed molten metal.
The Rautomead Continuous Casting System is based on electric resistance heating of its furnaces, with graphite containment crucibles, graphite heating elements and casting dies. This technology is particularly suited for production of high purity, high quality oxygen-free copper and copper alloy wire rods (copper silver, copper magnesium, copper tin).
The upward casting equipment may be used to manufacture rods of all diameters between 8.0mm and 30mm diameter and is suitable feedstock for wire drawing and continuous rotary extrusion processes. End use applications include: superfine wire, automotive wires, contact wire and trolley wires for high speed trains, data communication cables, CTC and transformer strips as well as enamelled wires.
Rautomead’s R&D facility at the factory in Dundee (casting equipment, technicians, design and operational experience) is available to companies who wish to commission experimental and research work to develop technology and tooling for the manufacture and processing of new alloys and materials. Rautomead’s partnership with the University of Dundee provides access to sophisticated laboratory equipment as well as support with analytical evaluation and academic contributions to the R&D effort.
www.rautomead.com
sales@rautomead.com
On first reading, it might seem strange that Rautomead, a leading company specialising in continuous casting technology, should publish a Practical Guide on wire drawing practice in the copper wire and cable industry.
Since 1994, Rautomead has supplied over fifty oxygen-free copper (Cu-OF) rod casting machines to companies all over the world, the majority of whose previous experience had been exclusively in using only tough pitch copper (Cu-ETP) rod. By its nature, the behaviour of Cu-OF in the initial
stages of rod breakdown from 8mm as-cast rod is a little different from Cu-ETP. Minor changes to die drafts in older rod breakdown machines are recommended to achieve greater area reductions than may have been used previously.
Rautomead is fortunate to have David Bluck as a member of the company’s technical staff.
David has many years previous experience of technical management in the wire drawing
industry and has been able to assist Rautomead customers both in the introduction of Cu-OF rod into
their existing wire drawing lines and more generally in optimising performance of their wire drawing operations.
This Practical Guide is designed to encapsulate the most common issues Rautomead has encountered in copper wire drawing, to classify the types of faults occurring and to offer practical guidelines as to how these should be overcome.
The information in this advisory paper is given in good faith and with the objective of providing practical assistance. It is intended to supplement the place of technical information which may be provided for their equipment by wire drawing equipment manufacturers.
Sir Michael Nairn
Chairman
Rautomead Limited
Rautomead Continuous Casting Technology for Brass RodRautomead Limited
Rautomead Limited are UK-based specialists in continuous casting of non-ferrous metals and construction of continuous casting equipment for copper, copper alloys, gold and silver, dental alloys and feed rod for Conform machines.
For a period of over 30 years Rautomead Limited has specialised in the design, manufacture and sale of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries around the world.
Rautomead promote Advanced Metals Technology Collaboration for research and development of new processing technology for non ferrous metals
www.rautomead.co.uk
sales@rautomead.co.uk
Rautomead technology for continuous casting of oxygen free copper, copper-mag...Rautomead Limited
Rautomead Technology for Continuous Casting of Oxygen-free Copper, Copper-magnesium and Copper Conductor Alloys
We offer copper continuous casting technology and a range of copper wire and cable continuous casting machines.
The copper rod continuous casting machines are specifically designed for the processing of electrolytically-refined grade 'A' copper feedstock to produce 8.0mm diameter wire rods. They may be configured to produce rod up to 22.0mm diameter if required. The machines are intended to be operated for long periods of uninterrupted production of continuous cast copper wire rod.
RS machines are configured as integrated melting, holding and casting units, featuring graphite crucibles, protected in an inert gas atmosphere with high intensity graphite resistance heating.
RDG machines feature large Induction furnace technology. Machines are either single furnace integrated melting and casting or dual furnace with cathode melter feeding a holding furnace, depending on production output.
continuous casting machines for copper wire & cable operating costs
Rautomead have paid great attention to minimising the cost of operating the machine. Furnaces are totally enclosed and built up using high performance insulations to achieve minimum economic heat loss. Casting dies are inexpensive and may be changed individually
RS 3000 CuMg machine with graphite crucible technology is ideally suited for production of high quality copper magnesium alloy wire rod.
The graphite crucible removes oxygen from cathode feedstock which minimises losses of the magnesium alloying element.
Technology available for high magnesium content (0.4 – 0.6% Mg) alloy rod for use in the manufacture of overhead contact wires and cables for high speed trains, also for low magnesium content (0.1 -0.2% Mg) alloy rod for use in the manufacture of small diameter automotive data communication cables.
Rautomead technology is being used by suppliers of CuMg catenary contact wires on European High Speed train lines.
The massive construction project in progress in China to build 15,000 – 20,000km of new high speed train track features CuMg contact wires made from rods produced on Rautomead technology installed at cable factories around China.
Effect of water flow rate casting speed alloying element and pull distance on...Rautomead Limited
Most parameters that control the solidification of castings, and consequently,
microstructure and mechanical properties, are: chemical composition, liquid metal treatment,
cooling rate and temperature gradient. In this work, characterization of the influence
of water flow rate, casting speed, alloying element and pull distance on tensile strength,
elongation percentage and microstructure of continuous cast copper alloys has been carried
out. A significant different in tensile strength, elongation percentage and grain structure
has been investigated and it was also found that these parameters could improve the physical
and mechanical properties of samples. As a particular example, water flow rate could
improve the elongation of samples from 10% to 25%.
RAUTOMEAD TECHNOLOGY FOR CONTINUOUS CASTING OF OXYGEN-FREE COPPER AND DILUTE...Rautomead Limited
Paper by Sir Michael Nairn, Chairman of Rautomead Limited, Dundee, U.K.
presented at the Global Continuous Casting Forum, during the Interwire 2015 Trade Exposition, being held in Atlanta, Georgia, USA
organised by WAI
27 – 30 April 2015
Rautomead Continuous Casting Technology for Railway and Automotive ApplicationsRautomead Limited
Rautomead offer a range of machines designed to cast Copper Magnesium and other conductor alloys for Railway Contact and Messenger Wires and Automotive wiring Harness.
Rautomead Limited are UK-based specialists in continuous casting of non-ferrous metals and construction of continuous casting equipment for copper, copper alloys, gold and silver, dental alloys and feed rod for Conform machines.
For a period of over 30 years Rautomead Limited has specialised in the design, manufacture and sale of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries around the world.
Rautomead promote Advanced Metals Technology Collaboration for research and development of new processing technology for non ferrous metals
www.rautomead.co.uk
sales@rautomead.co.uk
For over 30 years Rautomead Limited has specialised in the design and manufacture of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries worldwide.
Rautomead plants are being successfully applied to production of oxygen-free copper, a wide range of copper-based alloys, precious metals and zinc. Forms include wire rod, straight length bars, flats and hollow sections. According to material and section, the casting process selected may be vertical upwards, vertical downwards or horizontal. The machines may be used either as integrated melting, holding and casting machines, or may be arranged to be fed with pre-alloyed molten metal.
The Rautomead Continuous Casting System is based on electric resistance heating of its furnaces, with graphite containment crucibles, graphite heating elements and casting dies. This technology is particularly suited for production of high purity, high quality oxygen-free copper and copper alloy wire rods (copper silver, copper magnesium, copper tin).
The upward casting equipment may be used to manufacture rods of all diameters between 8.0mm and 30mm diameter and is suitable feedstock for wire drawing and continuous rotary extrusion processes. End use applications include: superfine wire, automotive wires, contact wire and trolley wires for high speed trains, data communication cables, CTC and transformer strips as well as enamelled wires.
Rautomead’s R&D facility at the factory in Dundee (casting equipment, technicians, design and operational experience) is available to companies who wish to commission experimental and research work to develop technology and tooling for the manufacture and processing of new alloys and materials. Rautomead’s partnership with the University of Dundee provides access to sophisticated laboratory equipment as well as support with analytical evaluation and academic contributions to the R&D effort.
www.rautomead.com
sales@rautomead.com
On first reading, it might seem strange that Rautomead, a leading company specialising in continuous casting technology, should publish a Practical Guide on wire drawing practice in the copper wire and cable industry.
Since 1994, Rautomead has supplied over fifty oxygen-free copper (Cu-OF) rod casting machines to companies all over the world, the majority of whose previous experience had been exclusively in using only tough pitch copper (Cu-ETP) rod. By its nature, the behaviour of Cu-OF in the initial
stages of rod breakdown from 8mm as-cast rod is a little different from Cu-ETP. Minor changes to die drafts in older rod breakdown machines are recommended to achieve greater area reductions than may have been used previously.
Rautomead is fortunate to have David Bluck as a member of the company’s technical staff.
David has many years previous experience of technical management in the wire drawing
industry and has been able to assist Rautomead customers both in the introduction of Cu-OF rod into
their existing wire drawing lines and more generally in optimising performance of their wire drawing operations.
This Practical Guide is designed to encapsulate the most common issues Rautomead has encountered in copper wire drawing, to classify the types of faults occurring and to offer practical guidelines as to how these should be overcome.
The information in this advisory paper is given in good faith and with the objective of providing practical assistance. It is intended to supplement the place of technical information which may be provided for their equipment by wire drawing equipment manufacturers.
Sir Michael Nairn
Chairman
Rautomead Limited
Rautomead Continuous Casting Technology for Brass RodRautomead Limited
Rautomead Limited are UK-based specialists in continuous casting of non-ferrous metals and construction of continuous casting equipment for copper, copper alloys, gold and silver, dental alloys and feed rod for Conform machines.
For a period of over 30 years Rautomead Limited has specialised in the design, manufacture and sale of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries around the world.
Rautomead promote Advanced Metals Technology Collaboration for research and development of new processing technology for non ferrous metals
www.rautomead.co.uk
sales@rautomead.co.uk
Our precious metals continuous casting machines have graphite crucible and resistance heating technology for high purity high quality continuous cast material. Machines may be used as batch casting machines or continuous casting, they may be feed with either liquid metal, alloyed grain or virgin metals depending on production quantity and cast section.
A wide range of machine sizes and specifications are available for precious metals processing, including gold and silver based alloys for:
jewellery, as sheet, rod and tube
electronics industry as lead frame alloys and contact materials
dental industry
minting industry, as bullion coinage strip
Bonding wire rod, 99.999 purity gold
Examples of finished final products which can be manufactured using these continuous casting machines for precious metals include:
Gold and silver coins
Medals
Gold bonding wire
Jewellery, silver picture frames, silver cutlery
Dental alloys
Electronic lead frame material
Sputtering targets for glass coating
Silver flutes
The physical principle of the electric arc furnace will be briefly explained. It will be made clear how latest context and technology bound developments triggered the breakthrough of the electric arc furnace as a future oriented technology. The increasing relevance of the electric arc furnace will be illustrated by some examples coming from a broad range of industrial sectors. Some indications will be given on the impact of the electric arc furnace on the electrical system.
Based on overall economic figures, indications will be given of the chance for further penetration of the electric arc furnace in industrial thermal processes.
This project are for understanding the working, advantages and disadvantages of plasma arc welding, the viewers can also use it for their needful purpose.
ELECTRIC ARC FURNACE AC (PART 2) The Raw Materials (steel, steelmaking, furna...Matteo Sporchia
A detailed report about the main raw materials used into the Electric Arc Furnace (EAF) based on the latest technologies of iron and steelmaking fields.
RAUTOMEAD TECHNOLOGY FOR UPWARDS CONTINUOUS CASTING OF COPPER ALLOYSRautomead Limited
RAUTOMEAD TECHNOLOGY FOR UPWARDS CONTINUOUS CASTING OF COPPER ALLOYS
Paper given by Brain Frame, MD Rautomead at teh IWCC technical Seminar, Santiago, Chile, March 2013
Our precious metals continuous casting machines have graphite crucible and resistance heating technology for high purity high quality continuous cast material. Machines may be used as batch casting machines or continuous casting, they may be feed with either liquid metal, alloyed grain or virgin metals depending on production quantity and cast section.
A wide range of machine sizes and specifications are available for precious metals processing, including gold and silver based alloys for:
jewellery, as sheet, rod and tube
electronics industry as lead frame alloys and contact materials
dental industry
minting industry, as bullion coinage strip
Bonding wire rod, 99.999 purity gold
Examples of finished final products which can be manufactured using these continuous casting machines for precious metals include:
Gold and silver coins
Medals
Gold bonding wire
Jewellery, silver picture frames, silver cutlery
Dental alloys
Electronic lead frame material
Sputtering targets for glass coating
Silver flutes
The physical principle of the electric arc furnace will be briefly explained. It will be made clear how latest context and technology bound developments triggered the breakthrough of the electric arc furnace as a future oriented technology. The increasing relevance of the electric arc furnace will be illustrated by some examples coming from a broad range of industrial sectors. Some indications will be given on the impact of the electric arc furnace on the electrical system.
Based on overall economic figures, indications will be given of the chance for further penetration of the electric arc furnace in industrial thermal processes.
This project are for understanding the working, advantages and disadvantages of plasma arc welding, the viewers can also use it for their needful purpose.
ELECTRIC ARC FURNACE AC (PART 2) The Raw Materials (steel, steelmaking, furna...Matteo Sporchia
A detailed report about the main raw materials used into the Electric Arc Furnace (EAF) based on the latest technologies of iron and steelmaking fields.
RAUTOMEAD TECHNOLOGY FOR UPWARDS CONTINUOUS CASTING OF COPPER ALLOYSRautomead Limited
RAUTOMEAD TECHNOLOGY FOR UPWARDS CONTINUOUS CASTING OF COPPER ALLOYS
Paper given by Brain Frame, MD Rautomead at teh IWCC technical Seminar, Santiago, Chile, March 2013
Rautomead Newsletter issue 01
continuouscasting.com
For over 30 years Rautomead Limited has specialised in the design and manufacture of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries worldwide.
Rautomead plants are being successfully applied to production of oxygen-free copper, a wide range of copper-based alloys, precious metals and zinc. Forms include wire rod, straight length bars, flats and hollow sections. According to material and section, the casting process selected may be vertical upwards, vertical downwards or horizontal. The machines may be used either as integrated melting, holding and casting machines, or may be arranged to be fed with pre-alloyed molten metal.
The Rautomead Continuous Casting System is based on electric resistance heating of its furnaces, with graphite containment crucibles, graphite heating elements and casting dies. This technology is particularly suited for production of high purity, high quality oxygen-free copper and copper alloy wire rods (copper silver, copper magnesium, copper tin).
The upward casting equipment may be used to manufacture rods of all diameters between 8.0mm and 30mm diameter and is suitable feedstock for wire drawing and continuous rotary extrusion processes. End use applications include: superfine wire, automotive wires, contact wire and trolley wires for high speed trains, data communication cables, CTC and transformer strips as well as enamelled wires.
Rautomead’s R&D facility at the factory in Dundee (casting equipment, technicians, design and operational experience) is available to companies who wish to commission experimental and research work to develop technology and tooling for the manufacture and processing of new alloys and materials. Rautomead’s partnership with the University of Dundee provides access to sophisticated laboratory equipment as well as support with analytical evaluation and academic contributions to the R&D effort
RAUTOMEAD TECHNOLOGY FOR CONTINUOUS CASTING OF OXYGEN-FREE COPPER, COPPER-MA...Rautomead Limited
Rautomead Chairman, Sir Michael Nairn, presented a paper at the ICDC seminar in Mumbai on 30 November 2014. Sir Michael talked about “Rautomead Technology for Continuous Casting of Oxygen Free Copper, Copper Magnesium & Other Copper Conductor Alloys” and reflected on the development and evolution of Rautomead continuous casting technology during its 35 year history.
A review of effect of welding and post weld heat treatment on microstructure ...eSAT Journals
Abstract
Today getting high thermal efficiency in thermal and nuclear power plant is a big challenge. Many new material are developed. SA 335 grade 91 steel is modified high chrome-moly martenstitic steel. This material is having excellent toughness and high temperature creep strength. During welding, this material is having tremendous change in its microstructure and hence mechanical property. Many research works were done in this area. This paper discusses weld ability of P91 material. Effect of different welding process, type of filler wire, its chemical composition and type of flux is discussed in this paper. PWHT is necessary after welding of P91 steel. PWHT temperature and its duration affects phase transformation and mechanical properties of weld metal, HAZ and parent metal. Major focus is given on hardness, creep resistance and notch toughness.
Keywords - P91, Welding, Microstructure, Toughness, Creep, Hardness, PWHT
1. Introduction
2. Theoretical basics of MSHC materials creating (basics rules, materials hardening methods, alloying rules)
3. Analysis of medium strength high conductivity copper alloys (phase diagrams, requirements, properties, fabrication and exploitation properties, main applications)
Cu-Ag
Cu-Mg
Cu-Sn
Cu-Fe
Cu-Zr
Cu-Ni-Si
other elements
4. Complex comparison analysis of medium strength high conductivity copper alloys vs. copper grade ETP.
5. Trends of medium strength high conductivity copper alloys development, new applications and cost-effectiveness.
6. Conclusions
Rautomead Newsletter issue 03
continuouscasting.com
For over 30 years Rautomead Limited has specialised in the design and manufacture of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries worldwide.
Rautomead plants are being successfully applied to production of oxygen-free copper, a wide range of copper-based alloys, precious metals and zinc. Forms include wire rod, straight length bars, flats and hollow sections. According to material and section, the casting process selected may be vertical upwards, vertical downwards or horizontal. The machines may be used either as integrated melting, holding and casting machines, or may be arranged to be fed with pre-alloyed molten metal.
The Rautomead Continuous Casting System is based on electric resistance heating of its furnaces, with graphite containment crucibles, graphite heating elements and casting dies. This technology is particularly suited for production of high purity, high quality oxygen-free copper and copper alloy wire rods (copper silver, copper magnesium, copper tin).
The upward casting equipment may be used to manufacture rods of all diameters between 8.0mm and 30mm diameter and is suitable feedstock for wire drawing and continuous rotary extrusion processes. End use applications include: superfine wire, automotive wires, contact wire and trolley wires for high speed trains, data communication cables, CTC and transformer strips as well as enamelled wires.
Rautomead’s R&D facility at the factory in Dundee (casting equipment, technicians, design and operational experience) is available to companies who wish to commission experimental and research work to develop technology and tooling for the manufacture and processing of new alloys and materials. Rautomead’s partnership with the University of Dundee provides access to sophisticated laboratory equipment as well as support with analytical evaluation and academic contributions to the R&D effort
Erosion and Cavitation Tests Applied to Coating Welded with Blends of Stainle...CSCJournals
The process GMAW with its your applications using two wires pointing in the market as an alternative to coating when high productivity is desired. Potential variants emerge from this process as GMAW cold wire and GMAW double wire. One of the biggest difficulty is the setting of its parameters, which in addition to duplicate compared to conventional GMAW, act in a dependent manner. A greater understanding of this technology applied to coatings on turbines in various positions is critical so that you can master the process and its variables, aiming to enhance the application in industry. It was proposed in this study an experimental evaluation to verify the influence of some variables on the profile of cord and wear resistance. For this it is proposed in this paper to make deposits with weld metal AWS 308LSi stainless steel and alloys of cobalt (Stellites 6 and 21) plates in carbon steel SAE 1020 in flat positions. In the characterization of wear in the lining was used the determination of the hardness and surface topography. It is concluded that cobalt alloys have superior resistance to erosive damage with emphasis on the Stellite 21 alloy in erosion and cavitation in Stellite 6. In an intermediate position with respect to wear are mixtures of austenitic stainless steel and cobalt alloys. Therefore, it is essential to study welding processes with multiple wires as proposed in this paper aiming the best combination of alloys for resistance to cavitation-erosion phenomena.
Micro-alloyed copper overhead line conductors - Wire & Cable Technology Inter...Leonardo ENERGY
http://www.bluetoad.com/publication/?i=217299&p=90
Overhead line conductors are traditionally a domain for aluminium, using either steel reinforced aluminium or aluminium alloys. Using copper for overhead lines might surprise some people because it is a substantially heavier material. Weight, however, is not the most crucial characteristic of the conductor. Its smaller section and hydrophobic coating reduces the wind and ice loads on the conductors, which makes the overhead line more resistant and resilient to weather conditions.
Also, the higher conductivity of copper reduces the losses and the life cycle cost of the overhead line.
Computational fluid dynamic simulations of solidification for enhancing speed...Rautomead Limited
In this research experiment computational fluid dynamic (CFD) models were constructed, within Ansys Fluent TM v.R1, to investigate phenomena occurring during the Vertically Upwards Continuous Casting (VUCC) of 8 mm diameter, oxygen free copper (OFCu) for alterations to the casting speed. The simulated influence of heat transported over a 0.1 mm air gap formed within the casting die was investigated and a value for the die wall heat transfer coefficient (hc) of (9.0 ± 0.2) 104 W/m2K, was extracted. Using this value for hc, simulations of the entire casting crucible and die were made for casting speed settings: pushback motion at 0.06 m/s, average; dwell motion (pause) at 0.05 m/s, average; and continuous motions at 0.022 m/s, 0.015 m/s and 0.008 m/s; and were validated against literature values for measured thermal distribution within the casting die. The fastest casting speed for 8 mmOFCu was investigated and a trend between simulated solidification front and measured grain growth direction was identified, highlighting,
the casting motions pushback and dwell yield improved casting conditions. Fluid flow rate was investigated within the casting crucible and showed a small influence on casting due to natural convection relative to flow within the die, 0.001 ± 0.0005 m/s compared with 0.1 ± 0.01 m/s for pushback casting, respectively.
Examination of anti-bacterial properties of Cu and Cu alloys and potential ap...Rautomead Limited
Report:-
Copper has been utilised throughout early human existence as a disinfectant used to clean
wounds and prevent infection. However, following the birth of antibiotics and
pharmaceutical drugs, the use of copper as an antimicrobial material severely declined.
Copper as an antimicrobial surface agent is now beginning to re-emerge in medical
institutions due to the rise of viruses and drug resistant bacteria, known as “superbugs”,
over the past century.
Yet, many institutions are hesitant on the reimplementation of copper as a surface agent.
This project aims to demonstrate the antimicrobial effectiveness of copper and its alloys
against an E. Coli O157:H7 strain as well as displaying the potential applications that an
antimicrobial copper surface agent can be applied to. Henceforth, the purpose of this
project is to formulate a systematic literature review, whereby the results from other
research papers will be compared and adopted into a novel concept of attempting to track
bacterial transmission through the use of a video-based monitoring system.
Examination of anti-bacterial properties of Cu and Cu alloys and potential ap...Rautomead Limited
Presentation:-
Copper has been utilised throughout early human existence as a disinfectant used to clean
wounds and prevent infection. However, following the birth of antibiotics and
pharmaceutical drugs, the use of copper as an antimicrobial material severely declined.
Copper as an antimicrobial surface agent is now beginning to re-emerge in medical
institutions due to the rise of viruses and drug resistant bacteria, known as “superbugs”,
over the past century.
Yet, many institutions are hesitant on the reimplementation of copper as a surface agent.
This project aims to demonstrate the antimicrobial effectiveness of copper and its alloys
against an E. Coli O157:H7 strain as well as displaying the potential applications that an
antimicrobial copper surface agent can be applied to. Henceforth, the purpose of this
project is to formulate a systematic literature review, whereby the results from other
research papers will be compared and adopted into a novel concept of attempting to track
bacterial transmission through the use of a video-based monitoring system.
Continuous Casting of Dilute Copper Alloys for Drawing to Wire in Specialist ...Rautomead Limited
Presentation given by Sir Micahel Nairn, Chairman Rautomead Limted, at Interwire 2019.
Abstract
Many modern industrial applications of copper-based conductor wires call not only for high electrical conductivity, but also for other matching physical properties, including high tensile strength, high softening temperatures, creep resistance, abrasion resistance and corrosion resistance, while maintaining also good ductility.
The paper shows examples of dilute copper alloys offering these properties and techniques and equipment which have been developed by Rautomead for reliable, continuous production to narrow chemical tolerances.
To enable the processing of new complex high performance alloys by improving ...Rautomead Limited
PHD Thesis for Ehsaan-Reza Bagherian
Summary
The analysis in this PhD thesis illustrated that the metallurgical and mechanical properties of components mainly produced by continuous casting are acceptable, and that this method could be a replacement production method for materials such as lead alloys and various copper alloy rod, e.g. CuMg and CuAg.. However, in the case of Deoxidized High Phosphorus (DHP) copper tubes, the performance of the as-cast material was significantly lower than that of from extrusion or planetary rolling process.
Characteristics of Hypoeutectic Cu-Zr Alloy Rods Manufactured by Vertical Upw...Rautomead Limited
The focus in this study is therefore on applying a vertical upwards continuous casting (VUCC) mass-production
method to the pilot-scale manufacturing of Cu-Zr alloy rods. The microstructure and physical characteristics of these
VUCC rods were subsequently investigated and compared with rods produced by CMC. In addition, the wire-drawing
capability of the VUCC rods was examined, and the adaptability of the VUCC method to the mass production of
hypoeutectic Cu-Zr alloys was fully investigated.
2.
EFFECT OF ANTIMONY ADDITION RELATIVE TO MICROSTRUCTURE AND MECHANICAL PROPERT...Rautomead Limited
It is well documented that the addition of antimony in pure lead increases tensile strength and reduced elongation. The goal of the present work is to identify the cause of these phenomena by investigation of the effects of the addition of Sb (1.25%) on the structure of pure continuously cast lead and lead alloy rods. The microstructure and morphology of both pure lead and lead 1.25% antimony were examined by digital optical microscope and scanning electron microscope respectively. Energy Dispersive X-ray Spectroscopy (EDX) was used to identify alloying elements. The results showed that the effect of additions of antimony on mechanical properties of lead-antimony alloys is mainly due to the solid solubility of the antimony element. Homogenized distribution of the antimony results in a decrease in the grain size of the pure lead. These smaller grains mean higher strength so long as there is a homogeneous grain structure
Investigation of the distribution of lead in three different combinations of ...Rautomead Limited
The main objective of this paper was to assess three leaded
brass samples (pending application with Copper Development
Association) using optical microscopy and mass
spectrometry to compare the distribution of lead. Based on
the mass spectrometry data, a great deal of variation was
not found within each of the samples based on five different
sample locations. Optical microscopy, scanning electron
microscopy and energy-dispersive X-ray spectroscopy
confirmed that the lead was homogenously distributed in
brass.
BWE Ltd, formerly Babcock Wire Equipment Ltd, has operated from its Ashford headquarters in the Southeast of England since 1969, when the company first produced cold welding machines. Conform™ machines have been manufactured since 1976 when they were initially used for extruding round wire. Continuous development aimed at extending the capabilities of the Conform process led to an
increasing number of applications including magnet wire, electrical conductors, refrigeration tube and ultimately, in 1984, the introduction of the Conklad™ process for aluminium clad steel wire and CATV and fibre optic cables.
billet, rod, or tube are continuous cast, defined
as the continuous solidification and withdrawal
of product from an open-ended shaping mold.
Methods include both vertical and horizontal
casting, depending on product size, shape, and
volume. Casting vertically has certain inherent
technical advantages. The symmetry of cooling
promotes a uniform and predictable solidification
growth pattern and uniform axial loading
on the freshly solidified shell as it is withdrawn
from the mold. In tube or hollow section casting,
the vertical process has particular merit.
The disadvantages of vertical casting are
mostly logistic: difficulty in handling long
lengths of section; cut-off can be more difficult
to engineer and control; and it is generally a
semicontinuous operation. Horizontal casting
requires lower capital investment, is compatible
with lower production rates, and is a continuous
operation.
This article briefly reviews the history and
methods of copper alloy continuous casting;
the information is drawn from the very detailed
and extensive coverage of the subject in Ref 1
and the numerous publications of equipment
supply companies such as Rautomead, SMS
Meer, and so on
Analysis and quantification of grain size in various dhp copper tubes manufac...Rautomead Limited
Abstract. Deoxidized High Phosphorus (DHP) Copper tubes are frequently used in numerous
industrial and household applications. To ensure the acceptability of DHP copper tubes prepared by
various industrial processes, the quality of the DHP copper tubes must be evaluated and one of the
best ways to do so is to examine the microstructure and metallography and quantify grain size. In
this paper the authors considered the average grain size of copper tube samples made traditionally
as well as by the planetary rolling and CastTube process. Because of the small thickness of the
CastTube samples, in certain circumstances traditional methods of grain counting were not
plausible and a new procedure for grain counting needed developed. This paper is about the
development and evaluation of grain sizes in continuously cast tube samples using both the
planimetric procedure (ASTM E112) and a new method, which will be herby, referred to as the
“total grain counting method”. This paper also concludes that there is a large difference in the grain
size of tubes with different manufacturing methods.
Rautomead Limited Newsletter Issue 12 continuouscasting.com
For over 30 years Rautomead Limited has specialised in the design and manufacture of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries worldwide.
Rautomead plants are being successfully applied to production of oxygen-free copper, a wide range of copper-based alloys, precious metals and zinc. Forms include wire rod, straight length bars, flats and hollow sections. According to material and section, the casting process selected may be vertical upwards, vertical downwards or horizontal. The machines may be used either as integrated melting, holding and casting machines, or may be arranged to be fed with pre-alloyed molten metal.
The Rautomead Continuous Casting System is based on electric resistance heating of its furnaces, with graphite containment crucibles, graphite heating elements and casting dies. This technology is particularly suited for production of high purity, high quality oxygen-free copper and copper alloy wire rods (copper silver, copper magnesium, copper tin).
The upward casting equipment may be used to manufacture rods of all diameters between 8.0mm and 30mm diameter and is suitable feedstock for wire drawing and continuous rotary extrusion processes. End use applications include: superfine wire, automotive wires, contact wire and trolley wires for high speed trains, data communication cables, CTC and transformer strips as well as enamelled wires.
Rautomead’s R&D facility at the factory in Dundee (casting equipment, technicians, design and operational experience) is available to companies who wish to commission experimental and research work to develop technology and tooling for the manufacture and processing of new alloys and materials. Rautomead’s partnership with the University of Dundee provides access to sophisticated laboratory equipment as well as support with analytical evaluation and academic contributions to the R&D effort
Rautomead Newsletter issue 11 pink
continuouscasting.com
For over 30 years Rautomead Limited has specialised in the design and manufacture of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries worldwide.
Rautomead plants are being successfully applied to production of oxygen-free copper, a wide range of copper-based alloys, precious metals and zinc. Forms include wire rod, straight length bars, flats and hollow sections. According to material and section, the casting process selected may be vertical upwards, vertical downwards or horizontal. The machines may be used either as integrated melting, holding and casting machines, or may be arranged to be fed with pre-alloyed molten metal.
The Rautomead Continuous Casting System is based on electric resistance heating of its furnaces, with graphite containment crucibles, graphite heating elements and casting dies. This technology is particularly suited for production of high purity, high quality oxygen-free copper and copper alloy wire rods (copper silver, copper magnesium, copper tin).
The upward casting equipment may be used to manufacture rods of all diameters between 8.0mm and 30mm diameter and is suitable feedstock for wire drawing and continuous rotary extrusion processes. End use applications include: superfine wire, automotive wires, contact wire and trolley wires for high speed trains, data communication cables, CTC and transformer strips as well as enamelled wires.
Rautomead’s R&D facility at the factory in Dundee (casting equipment, technicians, design and operational experience) is available to companies who wish to commission experimental and research work to develop technology and tooling for the manufacture and processing of new alloys and materials. Rautomead’s partnership with the University of Dundee provides access to sophisticated laboratory equipment as well as support with analytical evaluation and academic contributions to the R&D effort
Rautomead - The Manufacture of Brass Rod for Machining and Forging ApplicationsRautomead Limited
Rautomead Limited paper describing the process and equipment to manufacture around 150 tonnes per month, using either virgin metals or scrap brass feedstock.
Rautomead Limited are UK-based specialists in continuous casting of non-ferrous metals and construction of continuous casting equipment for copper, copper alloys, gold and silver, dental alloys and feed rod for Conform machines.
For a period of over 30 years Rautomead Limited has specialised in the design, manufacture and sale of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries around the world.
Rautomead promote Advanced Metals Technology Collaboration for research and development of new processing technology for non ferrous metals
Rautomead Limited are UK-based specialists in continuous casting of non-ferrous metals and construction of continuous casting equipment for copper, copper alloys, gold and silver, dental alloys and feed rod for Conform machines.
For a period of over 30 years Rautomead Limited has specialised in the design, manufacture and sale of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries around the world.
Rautomead promote Advanced Metals Technology Collaboration for research and development of new processing technology for non ferrous metals
www.rautomead.co.uk
sales@rautomead.co.uk
Transcript: Selling digital books in 2024: Insights from industry leaders - T...BookNet Canada
The publishing industry has been selling digital audiobooks and ebooks for over a decade and has found its groove. What’s changed? What has stayed the same? Where do we go from here? Join a group of leading sales peers from across the industry for a conversation about the lessons learned since the popularization of digital books, best practices, digital book supply chain management, and more.
Link to video recording: https://bnctechforum.ca/sessions/selling-digital-books-in-2024-insights-from-industry-leaders/
Presented by BookNet Canada on May 28, 2024, with support from the Department of Canadian Heritage.
Slack (or Teams) Automation for Bonterra Impact Management (fka Social Soluti...Jeffrey Haguewood
Sidekick Solutions uses Bonterra Impact Management (fka Social Solutions Apricot) and automation solutions to integrate data for business workflows.
We believe integration and automation are essential to user experience and the promise of efficient work through technology. Automation is the critical ingredient to realizing that full vision. We develop integration products and services for Bonterra Case Management software to support the deployment of automations for a variety of use cases.
This video focuses on the notifications, alerts, and approval requests using Slack for Bonterra Impact Management. The solutions covered in this webinar can also be deployed for Microsoft Teams.
Interested in deploying notification automations for Bonterra Impact Management? Contact us at sales@sidekicksolutionsllc.com to discuss next steps.
Securing your Kubernetes cluster_ a step-by-step guide to success !KatiaHIMEUR1
Today, after several years of existence, an extremely active community and an ultra-dynamic ecosystem, Kubernetes has established itself as the de facto standard in container orchestration. Thanks to a wide range of managed services, it has never been so easy to set up a ready-to-use Kubernetes cluster.
However, this ease of use means that the subject of security in Kubernetes is often left for later, or even neglected. This exposes companies to significant risks.
In this talk, I'll show you step-by-step how to secure your Kubernetes cluster for greater peace of mind and reliability.
GraphRAG is All You need? LLM & Knowledge GraphGuy Korland
Guy Korland, CEO and Co-founder of FalkorDB, will review two articles on the integration of language models with knowledge graphs.
1. Unifying Large Language Models and Knowledge Graphs: A Roadmap.
https://arxiv.org/abs/2306.08302
2. Microsoft Research's GraphRAG paper and a review paper on various uses of knowledge graphs:
https://www.microsoft.com/en-us/research/blog/graphrag-unlocking-llm-discovery-on-narrative-private-data/
UiPath Test Automation using UiPath Test Suite series, part 4DianaGray10
Welcome to UiPath Test Automation using UiPath Test Suite series part 4. In this session, we will cover Test Manager overview along with SAP heatmap.
The UiPath Test Manager overview with SAP heatmap webinar offers a concise yet comprehensive exploration of the role of a Test Manager within SAP environments, coupled with the utilization of heatmaps for effective testing strategies.
Participants will gain insights into the responsibilities, challenges, and best practices associated with test management in SAP projects. Additionally, the webinar delves into the significance of heatmaps as a visual aid for identifying testing priorities, areas of risk, and resource allocation within SAP landscapes. Through this session, attendees can expect to enhance their understanding of test management principles while learning practical approaches to optimize testing processes in SAP environments using heatmap visualization techniques
What will you get from this session?
1. Insights into SAP testing best practices
2. Heatmap utilization for testing
3. Optimization of testing processes
4. Demo
Topics covered:
Execution from the test manager
Orchestrator execution result
Defect reporting
SAP heatmap example with demo
Speaker:
Deepak Rai, Automation Practice Lead, Boundaryless Group and UiPath MVP
Generating a custom Ruby SDK for your web service or Rails API using Smithyg2nightmarescribd
Have you ever wanted a Ruby client API to communicate with your web service? Smithy is a protocol-agnostic language for defining services and SDKs. Smithy Ruby is an implementation of Smithy that generates a Ruby SDK using a Smithy model. In this talk, we will explore Smithy and Smithy Ruby to learn how to generate custom feature-rich SDKs that can communicate with any web service, such as a Rails JSON API.
Software Delivery At the Speed of AI: Inflectra Invests In AI-Powered QualityInflectra
In this insightful webinar, Inflectra explores how artificial intelligence (AI) is transforming software development and testing. Discover how AI-powered tools are revolutionizing every stage of the software development lifecycle (SDLC), from design and prototyping to testing, deployment, and monitoring.
Learn about:
• The Future of Testing: How AI is shifting testing towards verification, analysis, and higher-level skills, while reducing repetitive tasks.
• Test Automation: How AI-powered test case generation, optimization, and self-healing tests are making testing more efficient and effective.
• Visual Testing: Explore the emerging capabilities of AI in visual testing and how it's set to revolutionize UI verification.
• Inflectra's AI Solutions: See demonstrations of Inflectra's cutting-edge AI tools like the ChatGPT plugin and Azure Open AI platform, designed to streamline your testing process.
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The latest edition of the OT/ICS and IoT security Threat Landscape Report 2024 also covers:
State of global ICS asset and network exposure
Sectoral targets and attacks as well as the cost of ransom
Global APT activity, AI usage, actor and tactic profiles, and implications
Rise in volumes of AI-powered cyberattacks
Major cyber events in 2024
Malware and malicious payload trends
Cyberattack types and targets
Vulnerability exploit attempts on CVEs
Attacks on counties – USA
Expansion of bot farms – how, where, and why
In-depth analysis of the cyber threat landscape across North America, South America, Europe, APAC, and the Middle East
Why are attacks on smart factories rising?
Cyber risk predictions
Axis of attacks – Europe
Systemic attacks in the Middle East
Download the full report from here:
https://sectrio.com/resources/ot-threat-landscape-reports/sectrio-releases-ot-ics-and-iot-security-threat-landscape-report-2024/
State of ICS and IoT Cyber Threat Landscape Report 2024 preview
CONTINUOUS CASTING OF COPPER MAGNESIUM CONDUCTOR ALLOYS
1. CONTINUOUS CASTING OF COPPER MAGNESIUM CONDUCTOR
ALLOYS
Paper by Sir Michael Nairn, Chairman of Rautomead Limited, Dundee,
Scotland, U.K.
The paper was presented at the WAI Technical Conference at Interwire, at the
Georgia World Congress Center, Atlanta, Georgia, U.S.A., April 25, 2013.
2. CONTINUOUS CASTING OF COPPER MAGNESIUM CONDUCTOR ALLOYS
SUMMARY
CuMg wire rod must be produced consistently to a fine alloy tolerance to provide
an acceptable balance of tensile strength and electrical resistivity in the finished
wire. Given the reactive nature of Mg, this calls for highly specialised technology.
The totally enclosed Rautomead graphite furnace technology has been proved over
many years to be well suited to this application with important markets emerging in
high speed rail and the automotive industries.
BACKGROUND
HORIZONTAL PROCESS
Rautomead supplied its first two continuous casting machines for production of CuMg wire
rod in 1990. These were 8 strand horizontal machines built to produce a range of Cu-Mg
alloys from 0.2% to 0.5% Mg for high speed rail applications. Cathode and elemental Mg
were added direct to the graphite crucible in accurately measured proportions. Cast
diameter was 19mm and 28mm. Production speed was relatively low at around
30kg/strand/hour, but rod quality was sound and consistent, both in terms of alloy
composition and physical properties. These horizontal machines are still in use today.
UPWARDS VERTICAL PROCESS
The upwards vertical adaptation of the Rautomead continuous casting process was
developed in the early 1990s. It became apparent that upwards casting brought
advantages over the horizontal process in production of many copper-based alloys,
including CuMg, as well as tin-bronzes and a range of binary brasses. Crystalline
structure was notably improved with enhanced tensile properties (UTS and %
elongation) which benefited subsequent cold rolling or drawing. The vertical cast rod
presents greatly superior structural symmetry compared with horizontally cast rod. The
latter tends to lean forward owing to the uneven effects of gravity around the
circumference of the solidifying metal. In the upwards vertical mode, the characteristic
mix of central equiaxed grains and fine chill grains on the outer diameter remain, but
the larger columnar grains were of a steeper angle towards the direction of cast,
typically 50 – 70 deg. rather than 40 – 45 deg. in horizontal casting. Higher rates in
casting (cooling) also led to the grains being more refined and more evenly distributed.
fig 1. grain structure in as cast CuMg
3. Casting speeds of around 100 kg/hour are achievable in production of 28mm diameter
rod in CuMg – a three-fold increase from horizontal casting. Time taken to change
casting dies was reduced and made significantly safer than in the horizontal process.
Rautomead’s first upwards vertical casting machine for CuMg production was supplied
in 1997, since when this has become something of an industry-standard specification in
contact wire applications for high speed rail. Eight machines of this type have been
supplied to customers in China over the past three years.
MARKET APPLICATIONS
International demand for copper conductors with high tensile strength and high electrical
conductivity stems from many industries. Two major applications are in high speed rail
and in the automotive industry.
HIGH SPEED RAIL
Overhead single strand contact wire conductors are used to transmit electrical current
to drive the train via a pantograph mounted on the roof. To avoid arcing, to minimise
abrasive wear and to maintain an uninterrupted supply of power, the pantograph
should be in constant contact with the stationery wire. The catenary system requires to
have minimum vibration and motion to ensure smooth operation at high train speeds
and in strong wind conditions. It must be corrosion resistant and be able to withstand
hot ambient temperature conditions. As design train speeds have increased, demands
placed on performance of the catenary have risen significantly. For safety reasons,
maximum train speed should not exceed 70% of the wave propagation velocity. Two
means of achieving that objective are to heighten the tension in the contact wire and to
adopt lightweight materials. In recent years, copper-magnesium alloys have been
widely adopted as the electrical conductors in catenary systems to meet these
requirements.
fig.2 grooved trolley wire in CuMg0.5
AUTOMOTIVE
Increasing complexity in automotive design has led to a sophistication in wiring
harnesses not in contemplation twenty years ago. The weight of copper used in the
construction of a car now ranges from around 15kg in a low cost model to over 28kg in
a luxury saloon.
4. AUTOMOTIVE (cont’d)
This tendency towards greater weight and greater cost of materials has coincided with
a time when automotive manufacturers are under pressure to reduce manufacturing
costs, to reduce vehicle weight and to reduce fuel consumption. Hence, pressure is
being exerted to achieve smaller copper section sizes used in control and signal
cables, whilst not jeopardising performance or reliability. Copper-magnesium (CuMg)
alloys meet many of these requirements as a direct replacement for tough-pitch copper
(CuETP), enabling significantly reduced wire gauges to be used.
OTHER APPLICATIONS
Other important applications for CuMg alloys occur in manufacture of connectors and
semi-conductor pins, where the combination of high tensile strength, low resistivity, good
solderability and plateability make this material an attractive option.
STANDARDS
CuMg rod is specified in accordance with ASTM B250, designated as C18661. This
covers the range of Cu alloys with Mg content from 0.1 to 0.7%.
COMPARISON OF MATERIALS
Table 1 below compares the tensile strength and electrical resistivity properties of various
available materials.
Material
CuETP
CuAg0.1
CuSn0.3
CuCd0.7
CuCd1.0
CuMg0.2
CuMg0.5
tensile strength
N/mm2
360
375
420
430
445
430
490
elongation
(min) %*
3
3
3
2
2
3
5
electrical resistivity
10-08 Ohm.m
1.777
1.777
2.155
2.005
2.155
2.778
2.778
*percentage elongation after fracture. nom. x section 100mm2
table 1
Despite its good combination of physical properties, CuCd is no longer accepted in most
applications as a conductor alloy on account of the toxicity hazard and risks of respiratory
disease associated with Cd, both in initial manufacturing and in later recycling.
Traditionally, CuETP was a standard material used for trolley wire and is still used in train
and tramway applications up to a running speed of around 160 km/hour. Above that
speed, a higher tensile strength material is required to match the higher tension required
in the trolley wire.
Alternatives to CuCd include CuAg, CuSn and CuMg. CuAg possesses higher tensile
properties than CuETP and is suitable for train speeds up to around 250 km/hour. For
higher train speeds in excess of 250 km/hour, CuSn and CuMg are the preferred alloys.
High speed trains in Europe at regular operating speeds up to 320 km/hour are now
running under trolley wire made in these alloys. Grooved contact wire in Europe must
conform to the relevant European standard (EN 50149:2012).
5. Repeated attempts have been made to introduce aluminium for trolley wire applications,
but this forms a hard non-conductive surface oxide layer, leading to arcing and erosion.
The reduced conductivity of aluminium also predicates a 60% increase in cross-sectional
area to achieve the same conductivity as copper. Aluminium is thus not generally
favoured.
As shown in table 2, relationships between design train speeds and the tension applied to
contact wire are indicative of the technical requirements in the material.
material
CuETP
CuAg0.1
CuSn0.3
CuMg0.5
grooved conta max design tra contact wire ten
wire section
speed
sq.mm
km/hour
kN
100
160
10-15
120
250
15
150
360
27
120
400
27
table 2
CASTING PROCESSES
CuETP and CuAg wire rod are most conveniently produced on a Properzi™, Southwire™
or Contirod™ line. By contrast, CuMg cannot be produced efficiently by those processes
on account of the volatility of magnesium and the demanding requirement to maintain a
tight tolerance of magnesium content over long lengths in the alloyed material. Production
of CuMg alloy wire rod requires different technology and is a speciality of Rautomead™.
RAUTOMEAD STANDARD CuMg CASTING LINE
Rautomead offers a standard line of upwards vertical continuous casting equipment for
production of a nominal 3,000 tonnes per year of CuMg wire rod. This line comprises an
RS 3000/5 CuMg upwards vertical combined melting and casting machine, configured to
produce five strands of trolley wire rod up to 30mm diameter and five heavy duty rod
coilers. Wire rod for the single strand contact wire is cast at 28-30mm diameter. Wire rod
for the stranded cable used for support wire and droppers is typically cast at 20mm
diameter. Feedstock for the line is Grade A quality cathode with elemental magnesium
additions. No separate melting furnace is used. Typical alloy compositions are CuMg0.1
to CuMg 0.6.
fig. 3 Rautomead RS 3000/5-CuMg Casting Machine
6. The Rautomead upwards vertical process is especially well-suited to CuMg rod
production. Tensile strength and resistivity in the finished product are very sensitive to
alloy composition. The totally enclosed nature of the process permits the user to control
the level of magnesium within a tolerance better than +/- 0.05%.
PROPRIETARY TECHNOLOGY
Rautomead continuous casting technology is based on electric resistance heating, using a
graphite crucible furnace and graphite heating elements protected in an inert gas
atmosphere. By contrast, the majority of competing systems were originally designed for
production of oxygen-free copper using electric channel-induction induction heating with
rammed ceramic lined furnaces to melt, hold and cast the copper.
THE RAUTOMEAD SYSTEM
In the Rautomead system, the graphite crucible forms a twin-chamber still metal bath with
no induced electro-magnetic stirring in the charge. Energy to melt the materials is applied
by radiation and convection through the walls of the graphite crucible. The crucible itself
forms part of the stored energy in the process. This is conducive to achieving steady
casting temperature (normally within +/- 3deg. C), despite a relatively small molten metal
bath (approx. 2,500 kg Cu). The process is largely automatic, with all key operating
parameters monitored and alarmed.
fig. 4 Rautomead RS 3000/5-Cu-Mg Casting Machine Layout
7. GRAPHITE CRUCIBLES
The Furnace crucible for CuMg applications is machined from a vibration-moulded solid
block to form a homogenous containment vessel, with two inter-connecting chambers.
Copper cathodes are automatically and progressively lowered into the melting
chamber. The molten metal flows with gravitational force through ports in the base of
the crucible to the separate casting chamber. Sacrificial linings are used to protect
exposed surfaces from oxidation. The naturally reducing effect of the graphite material
assists in ensuring the full de-oxidation of copper and avoids contact with and
contamination of the melt by refractory particles.
fig.5 graphite crucible
GRAPHITE HEATING SYSTEM
The good electrical conductivity of graphite enables this material to be used as heating
elements in a low voltage resistance furnace heating system. Secondary power is fed
to water-cooled graphite busbars and to a chain of accurately rated heating elements
which surround the crucible. Energy is fed to the metal in the crucible by radiation and
convection and all at low voltage (typically 40 V). The arrangement is not only thermally
efficient, but also very safe in operation. CuMg is prone to slag formation in processing,
particularly in narrow induction channels or when exposed to atmosphere. These
serious processing difficulties which can lead to significant non-productive time are
avoided in the Rautomead.
8. fig. 6 graphite heating elements
PHYSICAL PROPERTIES OF GRAPHITE
Graphite is elemental carbon. Mechanical properties of graphite are similar to those of
ceramic materials, while thermal conductivity and electrical resistivity correspond to
those of metals. See table 3 below. It is this unique combination of refractory and
metallic properties which makes graphite so well suited for use in electro-thermal
processes at elevated temperatures.
Bulk density
Open porosity
Young’s modulus
Flexural strength
Resistivity
Thermal conductivity
Coefficient of thermal expansion
graphite crucible
1.83
9
10.8
21.5
7.7
165
2.7
g/cm3
%
kN/mm2
N/mm2
Ωμm
Wm-1 K-1
10-6 K-1
table 3
The change in electrical resistivity of carbon during the graphitization process is very
marked. The material is transformed from being an insulator to a conductor. Thermal
conductivity of graphite is at its maximum at about room temperature. Strength and
Young’s modulus both increase with temperature and peak at ca. 2500deg C., where
values are 50-100% higher than at room temperature.
Above 1400deg C, the specific strength (strength/density) of graphite is greater than
that of metals and most other refractory materials. Graphite used at higher
temperatures is often exposed to sudden temperature changes or large temperature
gradients, both introducing mechanical stresses. Table 4 shows the thermal stress
resistance of graphite compared with some other refractory materials.
W/m
50,000
1,000
50
1
Graphite
Titanium carbide
Magnesia
Alumina
table 4
9. OXYGEN REDUCTION
The graphite furnace naturally reduces oxygen to extremely low levels (normally less
than 5ppm). Normal grade A cathode may be expected to have an oxygen content of
60-80ppm. In the case of the Rautomead integrated melting and casting system for
CuMg production, there are five stages where the oxygen is reduced:
• graphite pellet metal cover over melting chamber
• graphite sacrificial lining of upper part of melting chamber
• graphite walls of crucible
• graphite sacrificial lining of casting chamber
• graphite flake cover over casting chamber
The graphite crucible in the model RS 3000CuMg machine has a capacity of approx.
2,500kg Cu. With an hourly output of 500 kg, the copper has a dwell time of approx.
five hours, which has been shown to be well in excess of the time required to complete
the oxygen reduction.
60
50
Oxygen
ppm
40
30
20
10
2 ppm
X
0
1
2
Time - Hours
(Retention time in Graphite Lined System)
3
fig. 7 oxygen reduction in graphite lined system
Mg ALLOY ADDITION
A key aspect of the process is the method used to incorporating Mg as the alloying
material. As shown in table 5, contrasts between the physical properties of copper and
magnesium are significant. Magnesium, while imposing no health hazard, is a light and
highly reactive element.
Density at room
temp
Density at melting
temp
Melting temp
Boiling temp
gm/cc
Cu
8.96
Mg
1.738
gm/cc
8.02
1.584
deg C
deg C
1085
2567
650
1090
table 5
10. Three possible methods are used to introduce the magnesium. All include individual
weighing of cathodes as these are fed automatically to the furnace. All of the feeding
methods below have been successful in production of CuMg alloy wire rods to a
consistent chemical specification within Mg +/- 0.05%.
Master Alloy
Master alloys with 10-50% Mg content are commercially available. Additions are made
simultaneously with cathode feeding, to ensure the master alloy is effectively plunged
into the melting chamber of the crucible.
Elemental Mg powder
Measured amounts of Mg powder wrapped to Cu foil is added in a similar way as
feeding master alloy.
Cored Rod
The latest technique, through a joint development between Rautomead and Affival® of
Solesmes, France is by controlled automatic feeding of a cored copper rod with
magnesium powder as the core. The rate of feed is electronically adjusted to cathode
weight data and the cored rod plunged beneath the surface of the melt. The technique
is an the evaluation stage at present, but shows promises tighter alloy tolerances,
reduced Mg losses and reduced slag formation on the surface of the melt.
Rautomead Limited
P O Box 100
Dundee DD1 9QY
UK
t. + 44 1382 622341
f. + 44 1382 622941
e. sales@rautomead.com
www.rautomead.com