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on the freshly solidified shell as it is withdrawn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
This document provides an overview of continuous casting of copper-based alloys and precious metals. It discusses the history and evolution of continuous casting machines and processes. It describes different types of continuous casting including vertical, vertical upward, and horizontal casting. It also discusses crucibles, furnaces, casting dies, cooling systems, and safety aspects of continuous casting operations. Finally, it reviews the continuous casting of specific metal alloys like copper, brasses, bronzes, nickel-silver, and precious metals.
EFFECT OF CASTING PARAMETERS ON MACROSTRUCTURE OF STEELSurya Teja Botu
The document summarizes a student project conducted at Vizag Steel Plant investigating the effect of casting parameters on the macrostructure of steel. It was presented by five students and guided by P.V. Bhujanga Rao of Vizag Steel Plant. The project examined how melt temperature and casting speed influence steel structure and defect formation during continuous casting, and modeled temperature and melt flow in the caster sump. It provides background on Vizag Steel Plant and describes its raw material sources, production units including coke ovens, sinter plant, blast furnaces, and rolling mills.
Steel Making and Rolling (Metalworking): Process & Applications, Rod and Bar...Ajjay Kumar Gupta
The steel industry has taken note of the continued growth in steel imports and a number of projects have been planned and are under implementation.In rolling mills, intermediate steel products are given their final shape and dimension in a series of shaping and finishing operations. Rolling of steel is one of the most important manufacturing processes for steel. It is usually the first step in the processing of steel after it is made and cast either in Ingot or continuous cast product in a steel melting shop.
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Business guidance for steel rolling industry, Business Plan for a Startup Business, Business plan for steel rolling mill, Business start-up, Fusion welding processes, Great Opportunity for Startup, Hot rolled steel properties, Hot rolling mill process, Hot Rolling Mill, Hot Rolling mill, Hot Strip Mill, How is Steel Produced, How to Start a Steel Production Business, How to start a successful steel rolling business, How to start steel mill industry, How to Start Steel rolling Industry in India, How to start steel rolling mill, Indian Steel Industry, Industrial steel rolling mill, Modern steel making technology, Most Profitable Steel Business Ideas, New small scale ideas in Steel rolling industry, Opportunity Steel Rolling Mill, Plate Mill, Process & Applications, Process of steelmaking, Profitable small and cottage scale industries, Progress and Prospect of Rolling Technology, Project for startups, Rod and Bar Rolling, Rod and bar rolling, Rolling Metalworking, Rolling Mill for Steel Bars, Rolling process, Setting up and opening your steel rolling Business, Small scale Commercial steel rolling business, Small Scale Steel rolling Projects, Small Start-up Business Project, Start a Rolling Mill Industry, Start steel rolling mill in India, Starting a Steel Business, Starting a Steel rolling Business, Starting Steel Mini Mill, Start-up Business Plan for steel rolling, Startup Project for steel rolling business, Steel and hot rolling Business, Steel Based Profitable Projects, Steel Based Small Scale Industries Projects, Steel business plan, Steel hot rolling process, Steel Industry in India, Steel making and rolling, Steel making Projects, Steel making technology, Steel Making, Steel manufacturing process, Steel mill process, Steel mill, Steel production process, Steel rerolling mill feasibility start up, Steel rolling Industry in India, Steel rolling machine factory, Steel rolling mill industry demand, Steel rolling mill industry overview, Steel rolling mill industry, Steel rolling mill market forecast, Steel rolling mill market growth, Steel rolling mill market, Steel rolling mill size, Steel rolling mill starts production, Steel rolling mill, Steel Rolling Technology, Steelmaking, Steelmaking Processes, Types of rolling mills
This document provides information about Shani Kumar Singh's 15-day industrial training report at the Blast Furnace 1 & 2 plant of Jindal Steel and Power Limited in Raigarh, India from March 25th to April 8th, 2017. It includes an acknowledgment, introduction on Jindal Steel and Power Limited, facilities at the Raigarh plant, an introduction and process of the blast furnace, and descriptions of major equipment like the stock house, blast furnace, stoves, slag granulation plant, gas cleaning plant, pulverized coal injection, and pig casting machine.
1) Analysis of casting data over three months found higher incidence of slivers on some specific casting dates, possibly due to process variability in the plant.
2) Slivers were more common in lower slab widths and at higher ramping positions due to higher surface velocity of steel in the mould in those conditions.
3) Running the electromagnetic brake (EMBR) reduced sliver occurrence compared to when it was off, while higher argon flow induced more turbulence and resulted in more slivers.
This document summarizes steel melt processing and refinement techniques. It discusses primary steelmaking processes like electric arc furnaces and basic oxygen furnaces. It also covers secondary refining using various furnaces and vessels. Some key secondary processes mentioned are argon oxygen decarburization (AOD), vacuum induction melting, and ladle metallurgy techniques. The document provides detailed information on the equipment, processes, reactions, and purposes involved in steel melt processing and refinement.
This document discusses induction melting technologies and processes. It begins with an outline and overview of induction furnaces for melting, holding, and pouring metals, including induction crucible furnaces and induction channel furnaces. It then discusses specific applications like melting ferrous and non-ferrous metals, holding and pouring metals, and melting high-performance metals. The document also covers melting in cold crucibles, and skull melting and pouring of oxides and glass. Diagrams and images are provided to illustrate typical designs and applications of different induction furnace types.
We are the professional manufacturer of wire rod rolling mill, we also provide complete design for your rolling mill workshop, not only turnkey project but also tailor-made service, and we provide all the parts for roughing rolling mill, intermediate rolling mill process, including pinch roll, all kinds of shears, laying head, all of these crucial parts work extremely precisely and reliably.
Hani is a well-experienced enterprise; we have more than 20 year experiences in manufacturing rolling mill machinery, our core technology team is very experienced and they are all well-known in this industry in China, with high technology and best service, after decades of researching and developing in this industry, we gain really high reputation, and customer satisfaction.
This document provides an overview of continuous casting of copper-based alloys and precious metals. It discusses the history and evolution of continuous casting machines and processes. It describes different types of continuous casting including vertical, vertical upward, and horizontal casting. It also discusses crucibles, furnaces, casting dies, cooling systems, and safety aspects of continuous casting operations. Finally, it reviews the continuous casting of specific metal alloys like copper, brasses, bronzes, nickel-silver, and precious metals.
EFFECT OF CASTING PARAMETERS ON MACROSTRUCTURE OF STEELSurya Teja Botu
The document summarizes a student project conducted at Vizag Steel Plant investigating the effect of casting parameters on the macrostructure of steel. It was presented by five students and guided by P.V. Bhujanga Rao of Vizag Steel Plant. The project examined how melt temperature and casting speed influence steel structure and defect formation during continuous casting, and modeled temperature and melt flow in the caster sump. It provides background on Vizag Steel Plant and describes its raw material sources, production units including coke ovens, sinter plant, blast furnaces, and rolling mills.
Steel Making and Rolling (Metalworking): Process & Applications, Rod and Bar...Ajjay Kumar Gupta
The steel industry has taken note of the continued growth in steel imports and a number of projects have been planned and are under implementation.In rolling mills, intermediate steel products are given their final shape and dimension in a series of shaping and finishing operations. Rolling of steel is one of the most important manufacturing processes for steel. It is usually the first step in the processing of steel after it is made and cast either in Ingot or continuous cast product in a steel melting shop.
See more
http://goo.gl/lUUh86
http://goo.gl/fSIHG7
http://goo.gl/4os7IE
http://www.entrepreneurindia.co/
Tags
Business guidance for steel rolling industry, Business Plan for a Startup Business, Business plan for steel rolling mill, Business start-up, Fusion welding processes, Great Opportunity for Startup, Hot rolled steel properties, Hot rolling mill process, Hot Rolling Mill, Hot Rolling mill, Hot Strip Mill, How is Steel Produced, How to Start a Steel Production Business, How to start a successful steel rolling business, How to start steel mill industry, How to Start Steel rolling Industry in India, How to start steel rolling mill, Indian Steel Industry, Industrial steel rolling mill, Modern steel making technology, Most Profitable Steel Business Ideas, New small scale ideas in Steel rolling industry, Opportunity Steel Rolling Mill, Plate Mill, Process & Applications, Process of steelmaking, Profitable small and cottage scale industries, Progress and Prospect of Rolling Technology, Project for startups, Rod and Bar Rolling, Rod and bar rolling, Rolling Metalworking, Rolling Mill for Steel Bars, Rolling process, Setting up and opening your steel rolling Business, Small scale Commercial steel rolling business, Small Scale Steel rolling Projects, Small Start-up Business Project, Start a Rolling Mill Industry, Start steel rolling mill in India, Starting a Steel Business, Starting a Steel rolling Business, Starting Steel Mini Mill, Start-up Business Plan for steel rolling, Startup Project for steel rolling business, Steel and hot rolling Business, Steel Based Profitable Projects, Steel Based Small Scale Industries Projects, Steel business plan, Steel hot rolling process, Steel Industry in India, Steel making and rolling, Steel making Projects, Steel making technology, Steel Making, Steel manufacturing process, Steel mill process, Steel mill, Steel production process, Steel rerolling mill feasibility start up, Steel rolling Industry in India, Steel rolling machine factory, Steel rolling mill industry demand, Steel rolling mill industry overview, Steel rolling mill industry, Steel rolling mill market forecast, Steel rolling mill market growth, Steel rolling mill market, Steel rolling mill size, Steel rolling mill starts production, Steel rolling mill, Steel Rolling Technology, Steelmaking, Steelmaking Processes, Types of rolling mills
This document provides information about Shani Kumar Singh's 15-day industrial training report at the Blast Furnace 1 & 2 plant of Jindal Steel and Power Limited in Raigarh, India from March 25th to April 8th, 2017. It includes an acknowledgment, introduction on Jindal Steel and Power Limited, facilities at the Raigarh plant, an introduction and process of the blast furnace, and descriptions of major equipment like the stock house, blast furnace, stoves, slag granulation plant, gas cleaning plant, pulverized coal injection, and pig casting machine.
1) Analysis of casting data over three months found higher incidence of slivers on some specific casting dates, possibly due to process variability in the plant.
2) Slivers were more common in lower slab widths and at higher ramping positions due to higher surface velocity of steel in the mould in those conditions.
3) Running the electromagnetic brake (EMBR) reduced sliver occurrence compared to when it was off, while higher argon flow induced more turbulence and resulted in more slivers.
This document summarizes steel melt processing and refinement techniques. It discusses primary steelmaking processes like electric arc furnaces and basic oxygen furnaces. It also covers secondary refining using various furnaces and vessels. Some key secondary processes mentioned are argon oxygen decarburization (AOD), vacuum induction melting, and ladle metallurgy techniques. The document provides detailed information on the equipment, processes, reactions, and purposes involved in steel melt processing and refinement.
This document discusses induction melting technologies and processes. It begins with an outline and overview of induction furnaces for melting, holding, and pouring metals, including induction crucible furnaces and induction channel furnaces. It then discusses specific applications like melting ferrous and non-ferrous metals, holding and pouring metals, and melting high-performance metals. The document also covers melting in cold crucibles, and skull melting and pouring of oxides and glass. Diagrams and images are provided to illustrate typical designs and applications of different induction furnace types.
We are the professional manufacturer of wire rod rolling mill, we also provide complete design for your rolling mill workshop, not only turnkey project but also tailor-made service, and we provide all the parts for roughing rolling mill, intermediate rolling mill process, including pinch roll, all kinds of shears, laying head, all of these crucial parts work extremely precisely and reliably.
Hani is a well-experienced enterprise; we have more than 20 year experiences in manufacturing rolling mill machinery, our core technology team is very experienced and they are all well-known in this industry in China, with high technology and best service, after decades of researching and developing in this industry, we gain really high reputation, and customer satisfaction.
This document discusses the process of continuous casting of steel. It begins with an introduction and overview of the process. It then describes the three main types of continuous casting machines - vertical mould, vertical mould with bending, and curved mould. It provides details on the equipment, materials, process steps, defects, and modern developments of continuous casting. Some advantages are improved yield, quality, productivity and cost efficiency compared to ingot casting. Disadvantages include the need for a large facility and efficient cooling.
BSP Project (Based on Continuous Casting) [Final]Subham Shit
MARS-2 is a machining, assembly, and re-engineering department of Bhilai Steel Plant. It has light and heavy machining bays and an assembly bay. MARS-2 specializes in machining high-value parts, repairing and reclaiming worn parts, and assembling machinery. Some key assemblies MARS-2 performs include five roll sets, ten roll sets, and pinch roll assemblies for the continuous casting shop. MARS-2 aims to support most departments of BSP. It is well-equipped with machines like lathes, mills, grinders, and has an annual machining capacity of 2,200 tons and assembly capacity of 6,000 tons.
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
This document provides a summary of the vocational training completed by Rishav Ghosh at the Bokaro Steel Plant (BSL) operated by Steel Authority of India Limited (SAIL). It includes an acknowledgement, abstract about BSL, and sections covering the organizational profile of SAIL and key parts of the integrated steel plant including the raw material handling plant, coke oven, sinter plant, blast furnace, steel melting shop, continuous casting, and rolling mills. The training covered various processes and gave Ghosh practical knowledge of the blast furnace and steel melting shop operations.
The document provides information about Indo Farm Equipment Limited, an ISO certified company located in Himachal Pradesh, India that manufactures tractors, cranes, engines, and generators. It discusses the company's founding, facilities, research and development activities, and organizational structure. It also describes the foundry plant's objectives, core making process, types of cores used, and the activities completed during a 10-day training session in the core shop, including making different types of cores by hand and machine.
This document discusses welding defects and their causes. It outlines the four zones in a welded joint and how they appear on an iron-carbon phase diagram. The zones are the fusion zone, weld interface zone, heat affected zone, and base metal. Solidification can be epitaxial or non-epitaxial depending on whether filler metal is used. Common welding defects include cracks, porosity, inclusions, incomplete fusion, imperfect shape, and residual stresses. Various defect types like longitudinal cracks and underbead cracks are described in more detail.
The document discusses different types of metals and alloys used in engineering. It describes ferrous metals like steel and cast iron, which are alloys of iron and carbon. It also discusses nonferrous metals like aluminum and copper, as well as superalloys. Key production processes for metals are described, including ironmaking in a blast furnace and steelmaking using basic oxygen or electric arc furnaces. Phase diagrams are introduced to show the different phases that can exist in metal alloys at various temperatures and compositions.
This document provides information about the wire rod mill and bar mill at a steel plant, including:
- The wire rod mill has a capacity of 550,000 tons per year and can produce wire rod sizes from 5.5 to 22 mm. It is equipped with a 150 ton per hour walking beam reheat furnace.
- The bar mill has a capacity of 900,000 tons per year and can produce bar sizes from 8 to 50 mm. It is equipped with a 160 ton per hour walking beam reheat furnace.
- Both mills have multi-stand blocks for rolling, laying heads to form coils, and cooling beds. The document includes layout diagrams and details of the key equipment for each mill
The document discusses continuous casting of steel and defects that can occur during the continuous casting process. It provides details on:
- Continuous casting involves delivering liquid metal into a water-cooled copper mold where the cast section is formed and then continuously withdrawn for further solidification. More than 50% of current steel production is continuously cast.
- Defects originate from factors like mold oscillation, mold flux, segregation, and phase transformations. Common defects include cracks, blowholes, inclusions, segregation, and pipes.
- Cracks are caused by mechanical and thermal stresses during casting and processing. Blowholes are caused by insufficient deoxidation or humidity. Inclusions arise from physical-chemical effects
This document summarizes Piyush Verma's presentation on the Fe-Fe3C phase diagram for plain carbon steel. It introduces the key phases in iron like ferrite, austenite, cementite and pearlite. It explains how carbon enters the iron crystal lattice and affects its properties. The phase diagram shows the different phases present at various temperatures and carbon concentrations. It also describes the mechanisms of phase transformations like reconstructive and displacive transformations during heating and cooling of steel.
This document discusses welding metallurgy and basic metallurgical concepts relevant to welding. It covers topics like crystalline structures of metals, phase transformations, alloying effects, microstructures like ferrite, pearlite, and martensite, and the influence of cooling rate on microstructure. It also discusses the heat affected zone and issues that can arise from changes in composition and cooling rate near the weld interface.
Bulk metal forming processes change the shape of metal parts through plastic deformation. Hot working above the metal's recrystallization temperature allows for significant shape changes with less force. Cold working below this temperature increases strength but requires more force. Common bulk metal forming processes include forging, rolling, and extrusion, which can produce parts near their final net shape with little waste.
Continuous casting is a process used to cast metal into a continuous length. Molten metal is poured into a mold and solidifies into a casting as it travels downward. New molten metal is continuously supplied to the mold to keep the process going and produce a casting of indefinite length. The process requires precise control of parameters like molten metal flow to ensure smooth, continuous casting.
CONTINUOUS CASTING OF COPPER MAGNESIUM CONDUCTOR ALLOYSRautomead Limited
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.
1) The document discusses various defects that can occur during steel ingot solidification such as pipe, columnar structure, blow holes, and segregation.
2) It provides remedies for preventing these defects, such as using a hot top feeder head to avoid pipe formation and soaking ingots to minimize segregation.
3) The document also covers the mechanisms of ingot solidification, describing how killed, rimmed, and semi-killed steels solidify into chill, columnar, and equiaxed zones within the ingot.
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.
This document provides an overview of continuous casting of aluminium, specifically focusing on strip casting and wire bar casting technologies. It describes the basic principles of continuous casting, including key features like using rotating drums or belts to form a mould for molten aluminium. It discusses different types of casters like twin drum casters, single drum casters, and those using belts or blocks. It also addresses properties of continuously cast products and their behavior in further processing like rolling. The document aims to give readers an understanding of the possibilities and limitations of continuous casting aluminium.
This document discusses welding metallurgy and the structure of fusion welds. It describes the different zones that make up a typical fusion welded joint, including the fusion zone, weld interface, heat affected zone, and base material. It explains how the microstructure varies across these zones due to melting and solidification processes during welding. Factors like welding parameters, heat input, and joint geometry are described as influencing weld pool shape and grain structure. The concept of thermal severity number is introduced as a way to assess cracking susceptibility based on total plate thickness.
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
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.
This document discusses the process of continuous casting of steel. It begins with an introduction and overview of the process. It then describes the three main types of continuous casting machines - vertical mould, vertical mould with bending, and curved mould. It provides details on the equipment, materials, process steps, defects, and modern developments of continuous casting. Some advantages are improved yield, quality, productivity and cost efficiency compared to ingot casting. Disadvantages include the need for a large facility and efficient cooling.
BSP Project (Based on Continuous Casting) [Final]Subham Shit
MARS-2 is a machining, assembly, and re-engineering department of Bhilai Steel Plant. It has light and heavy machining bays and an assembly bay. MARS-2 specializes in machining high-value parts, repairing and reclaiming worn parts, and assembling machinery. Some key assemblies MARS-2 performs include five roll sets, ten roll sets, and pinch roll assemblies for the continuous casting shop. MARS-2 aims to support most departments of BSP. It is well-equipped with machines like lathes, mills, grinders, and has an annual machining capacity of 2,200 tons and assembly capacity of 6,000 tons.
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
This document provides a summary of the vocational training completed by Rishav Ghosh at the Bokaro Steel Plant (BSL) operated by Steel Authority of India Limited (SAIL). It includes an acknowledgement, abstract about BSL, and sections covering the organizational profile of SAIL and key parts of the integrated steel plant including the raw material handling plant, coke oven, sinter plant, blast furnace, steel melting shop, continuous casting, and rolling mills. The training covered various processes and gave Ghosh practical knowledge of the blast furnace and steel melting shop operations.
The document provides information about Indo Farm Equipment Limited, an ISO certified company located in Himachal Pradesh, India that manufactures tractors, cranes, engines, and generators. It discusses the company's founding, facilities, research and development activities, and organizational structure. It also describes the foundry plant's objectives, core making process, types of cores used, and the activities completed during a 10-day training session in the core shop, including making different types of cores by hand and machine.
This document discusses welding defects and their causes. It outlines the four zones in a welded joint and how they appear on an iron-carbon phase diagram. The zones are the fusion zone, weld interface zone, heat affected zone, and base metal. Solidification can be epitaxial or non-epitaxial depending on whether filler metal is used. Common welding defects include cracks, porosity, inclusions, incomplete fusion, imperfect shape, and residual stresses. Various defect types like longitudinal cracks and underbead cracks are described in more detail.
The document discusses different types of metals and alloys used in engineering. It describes ferrous metals like steel and cast iron, which are alloys of iron and carbon. It also discusses nonferrous metals like aluminum and copper, as well as superalloys. Key production processes for metals are described, including ironmaking in a blast furnace and steelmaking using basic oxygen or electric arc furnaces. Phase diagrams are introduced to show the different phases that can exist in metal alloys at various temperatures and compositions.
This document provides information about the wire rod mill and bar mill at a steel plant, including:
- The wire rod mill has a capacity of 550,000 tons per year and can produce wire rod sizes from 5.5 to 22 mm. It is equipped with a 150 ton per hour walking beam reheat furnace.
- The bar mill has a capacity of 900,000 tons per year and can produce bar sizes from 8 to 50 mm. It is equipped with a 160 ton per hour walking beam reheat furnace.
- Both mills have multi-stand blocks for rolling, laying heads to form coils, and cooling beds. The document includes layout diagrams and details of the key equipment for each mill
The document discusses continuous casting of steel and defects that can occur during the continuous casting process. It provides details on:
- Continuous casting involves delivering liquid metal into a water-cooled copper mold where the cast section is formed and then continuously withdrawn for further solidification. More than 50% of current steel production is continuously cast.
- Defects originate from factors like mold oscillation, mold flux, segregation, and phase transformations. Common defects include cracks, blowholes, inclusions, segregation, and pipes.
- Cracks are caused by mechanical and thermal stresses during casting and processing. Blowholes are caused by insufficient deoxidation or humidity. Inclusions arise from physical-chemical effects
This document summarizes Piyush Verma's presentation on the Fe-Fe3C phase diagram for plain carbon steel. It introduces the key phases in iron like ferrite, austenite, cementite and pearlite. It explains how carbon enters the iron crystal lattice and affects its properties. The phase diagram shows the different phases present at various temperatures and carbon concentrations. It also describes the mechanisms of phase transformations like reconstructive and displacive transformations during heating and cooling of steel.
This document discusses welding metallurgy and basic metallurgical concepts relevant to welding. It covers topics like crystalline structures of metals, phase transformations, alloying effects, microstructures like ferrite, pearlite, and martensite, and the influence of cooling rate on microstructure. It also discusses the heat affected zone and issues that can arise from changes in composition and cooling rate near the weld interface.
Bulk metal forming processes change the shape of metal parts through plastic deformation. Hot working above the metal's recrystallization temperature allows for significant shape changes with less force. Cold working below this temperature increases strength but requires more force. Common bulk metal forming processes include forging, rolling, and extrusion, which can produce parts near their final net shape with little waste.
Continuous casting is a process used to cast metal into a continuous length. Molten metal is poured into a mold and solidifies into a casting as it travels downward. New molten metal is continuously supplied to the mold to keep the process going and produce a casting of indefinite length. The process requires precise control of parameters like molten metal flow to ensure smooth, continuous casting.
CONTINUOUS CASTING OF COPPER MAGNESIUM CONDUCTOR ALLOYSRautomead Limited
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.
1) The document discusses various defects that can occur during steel ingot solidification such as pipe, columnar structure, blow holes, and segregation.
2) It provides remedies for preventing these defects, such as using a hot top feeder head to avoid pipe formation and soaking ingots to minimize segregation.
3) The document also covers the mechanisms of ingot solidification, describing how killed, rimmed, and semi-killed steels solidify into chill, columnar, and equiaxed zones within the ingot.
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.
This document provides an overview of continuous casting of aluminium, specifically focusing on strip casting and wire bar casting technologies. It describes the basic principles of continuous casting, including key features like using rotating drums or belts to form a mould for molten aluminium. It discusses different types of casters like twin drum casters, single drum casters, and those using belts or blocks. It also addresses properties of continuously cast products and their behavior in further processing like rolling. The document aims to give readers an understanding of the possibilities and limitations of continuous casting aluminium.
This document discusses welding metallurgy and the structure of fusion welds. It describes the different zones that make up a typical fusion welded joint, including the fusion zone, weld interface, heat affected zone, and base material. It explains how the microstructure varies across these zones due to melting and solidification processes during welding. Factors like welding parameters, heat input, and joint geometry are described as influencing weld pool shape and grain structure. The concept of thermal severity number is introduced as a way to assess cracking susceptibility based on total plate thickness.
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
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.
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.
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.
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
SINOM GROUP CO., LTD. is one of the largest manufacturer of copper mould tube in China. Based on customers requirement, we design, manufacture and install the square copper mould tube, round copper mould tube, beam blank, rectangular copper mould tube, diamond type, non-standard type etc.
This document discusses troubleshooting copper wire networks. A bad cable is one that falls outside specifications, such as exceeding maximum length. Common copper wire problems include mismatched termination standards between devices, split pairs during termination, and transmit/receive reversals. The TIA/EIA created termination standards T568A and T568B to reduce problems and ensure consistency.
CompTIA exam study guide presentations by instructor Brian Ferrill, PACE-IT (Progressive, Accelerated Certifications for Employment in Information Technology)
"Funded by the Department of Labor, Employment and Training Administration, Grant #TC-23745-12-60-A-53"
Learn more about the PACE-IT Online program: www.edcc.edu/pace-it
This lecture describes the function and design of all parts of the running and gating systems used in the production of castings. The students will be able to tackle the design of a simple running system in a systematic manner. Basic knowledge of foundry processes and basic mathematics is assumed.
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
Continuous casting is a steelmaking process where liquid steel is solidified into a semi-finished billet, bloom, or slab. In this process, liquid steel flows from a ladle into a water-cooled copper mold. As the steel exits the mold, it begins to solidify on the surface while the core remains liquid. The semi-solid steel strand is then cooled further through water sprays to fully solidify it into the desired cross-section. The continuous casting process allows for higher productivity and quality than traditional ingot casting.
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%.
ArcelorMittal Dofasco provides strict scrap specifications to ensure high quality steel production. Material not meeting specifications will be rejected, and suppliers could face penalties. The document then provides detailed specifications for various scrap types including chemical composition limits and size requirements.
Comprehensive and up to date presentation on the importance of ferrous scrap in the world steel market. Includes the role that Turkey plays in this market and the future of scrap in derivatives.
The document discusses casting as a manufacturing process. It provides details on the casting process, including the basic steps of placing a pattern in sand to create a mold, filling the mold with molten metal, and allowing the metal to cool. It also discusses casting terminology like patterns, flasks, cores, and risers. Different types of patterns are described, along with factors that affect pattern material selection.
The document discusses various smelting processes used to extract metals from ores. Smelting involves melting the metal out of its ore using reducing substances. There are two main types of smelting: reduction smelting uses carbon to reduce the ore, while matte smelting does not use a reducing agent. Blast furnaces and reverberatory furnaces are commonly used smelting devices. Flash smelting is a high-temperature process that uses the energy in sulfur and iron to melt copper ore without external heating.
Continuous casting was conceived in the 1860s and has since led to major improvements in efficiency, productivity, and cost reductions for metal production. The process involves cleaning and equalizing molten metal in a ladle before pouring it into a tundish where impurities are removed, then the metal travels through water cooled copper molds to begin solidifying as it moves downward along supported rollers. The key advantages are 100% casting yield due to no waste metal, an automatic and consistent process, and reproducible mechanical properties.
This document provides information on dental casting procedures. It discusses the history of casting, steps in the casting process such as wax pattern fabrication and sprue attachment, types of investments and burnout procedures. The key points are: casting has been used since ancient times to produce jewelry and was introduced to dentistry by Taggart in 1907; the process involves fabricating a wax pattern, investing it, then burning out the wax and casting dental alloys into the mold.
This lecture helps to understand the basic principles of die forging and the characteristic features of special aluminium die forging processes. It aims at learning about the basic design of dies in order to obtain optimum part qualities and tool life. General understanding of metallurgy and deformation processes is assumed.
This document provides an overview of the history and processes of continuous casting of metals such as steel, aluminum, and other alloys. It discusses some of the earliest developments in continuous casting in the 1840s and the commercialization of casting processes in the 1930s. The key types of continuous casting processes described include direct-chill casting, twin-roll casting, and casting of steel. Factors that influence casting such as mold depth and speed of solidification are also summarized.
ITRI Ltd is the world's foremost authority on tin and its applications. They conduct research to expand the use of tin and improve technological processes involving tin. Their research areas include tinplate packaging, tin coatings, solder technology, and chemical and environmental applications. Tinplate is produced by coating thin mild steel sheet with tin. The steel sheet is made through a process involving basic oxygen steelmaking and continuous casting into slabs. The slabs then undergo rolling, annealing, pickling, and coating with tin through either hot dipping or electrolysis to produce the final tinplate.
Introduction to Mechanical Engineering Sciences --- KTUDr. Rejeesh C R
This document provides an overview of manufacturing engineering and materials. It begins with definitions of manufacturing and a brief history, including early manufacturing methods dating back 5000-4000 BC using materials like gold, copper, and iron. The industrial revolution marked a transition to mechanized production. A wide variety of metallic and non-metallic materials are now used in manufacturing. The document then discusses different classes of materials like metals, alloys, ceramics, polymers, and composites, providing examples and properties of common materials in each class.
1) Harry Brearley discovered in 1913 that adding chromium to steel prevented corrosion, leading to the invention of stainless steel. Production began in Sheffield, UK and Krefeld, Germany.
2) In the 1920s, Brearley saw potential for stainless steel cutlery but struggled to convince employers. The Savoy Hotel in London installed the first stainless steel façade in 1929.
3) Avesta Steelworks in Sweden was the first producer to develop duplex stainless steel for heat and corrosion resistance in the 1930s.
Cast iron is an alloy of iron that contains 2-4% carbon, along with other elements like silicon and manganese. It is classified into gray, white, ductile, and malleable cast iron based on its composition and microstructure. Cast iron has high compressive strength but low tensile strength. It is brittle and not suitable for applications requiring flexibility. Historically, cast iron was widely used in construction for elements like bridges, columns and architectural details from the 18th century onward due to its low cost. However, it is prone to corrosion and cracking over time. Modern applications of cast iron include machine parts and components that require good castability and heat resistance.
The document provides information on various forming processes including rolling, extrusion, shearing, spinning, deep drawing, and forging. It describes the basic principles, key advantages, common materials used, and brief histories for each process. Rolling is used to reduce thickness and increase length of materials like metals. Extrusion forces pre-heated material through a die to form a constant cross-section. Shearing uses blades to make straight cuts in sheet metal. Spinning forms tubular parts by stretching sheet material against a rotating form. Deep drawing stretches sheet metal into cups or pans using a punch and die. Forging shapes heated metal using dies or hammers to develop strength.
Resistance welding processes such as spot welding, projection welding, and seam welding produce coalescence between faying metal surfaces using heat generated by resistance to electric current flow. Spot welding is the most common resistance welding process and involves applying pressure with electrodes to join metal pieces which are heated to plasticity by a large current passed for a short duration. Proper welding parameters like current, time, force and electrode size are needed to produce welds of sufficient size and strength according to standards. Resistance welding is widely used in automotive and appliance manufacturing due to its speed and suitability for automation.
Stainless Steel-classification, properties, application, Problems related to fabrication and service, cause and remedy. Appendix include useful info on Stainless steels.
General discussion on classification, uses of stainless steels, various causes for different problems, failures and rejects related to Stainless Steels, analysis, remedies / cures for such defects.
The increasing role of direct reduced iron (DRI) in global steelmakingdinomasch
Direct reduced iron (DRI) is increasingly being used as a source of low-residual iron in electric arc furnace steelmaking. As steelmaking efficiency has improved through techniques like continuous casting, the availability of high-quality ferrous scrap has decreased. At the same time, electric arc furnace steelmaking has grown in popularity relative to traditional blast furnaces. This has increased demand for scrap and led to price volatility. DRI provides a more reliable and competitive alternative to scrap, avoiding issues like residual contaminants. Major DRI production technologies are Midrex and Hyl, which reduce iron ore to metallic iron below the melting point of iron using reducing gases. Global DRI capacity has expanded significantly in recent decades to meet the growing demand.
Revisiting the history of steel production process and its future direction (...POSCO Research Institute
[Asian Steel Watch] Vol.1(2016.1)
Steel is one of the most fundamental industrial materials that has sustained human civilization for millennia. Backed by rich steelmaking esources and reserves, the steel industry has continued to grow thanks to the superior characteristics of steel materials, economic and efficient mass production, and the evolution of steel technology. While adapting to the changing business environment, the steel industry will continue to develop in step with the progress of human civilization. This article examines the evolution of steel technology throughout history, and forecasts the future development of the steel production process.
Kang, Chang-oh
Former President and CTO, POSCO
The iron and steel industry in India has experienced steady growth since independence. Key developments include the establishment of the first modern steel plant in 1907 in Jamshedpur. After independence, major plants were set up under public sector control. Today, India is the 7th largest steel producer globally, driven by strong domestic demand from infrastructure, real estate, and automobiles. Major integrated producers include SAIL, Tata Steel, and RINL.
60 years of duplex stainless steel applicationsAndré Batista
This document summarizes the 60-year history of duplex stainless steel applications. It discusses the initial development of duplex grades in the 1930s in Sweden and France to address issues with austenitic grades like sensitization. It describes how refinements like lowering carbon content and adding nitrogen improved welding and corrosion resistance of later duplex grades in the 1960-1990 period. The development of high-alloy super duplex grades in the 1980s provided alternatives to super austenitics for demanding offshore applications.
Practical guidelines for the fabrication of duplex stainless steelsFerRy P. RAzi
This document provides a summary of the history and development of duplex stainless steels. It describes how the first duplex grades were developed in the 1930s to address issues with austenitic stainless steels. The invention of argon oxygen decarburization in 1968 allowed for nitrogen alloying, which improved weld zone properties. This led to the second generation of duplex grades in the late 1970s, with grade 2205 becoming widely used. Modern duplex grades are divided into categories based on their alloy content and corrosion performance.
Southern Africa Stainless Steel Development Association and Trade and Investment KwaZulu-Natal held a seminar at the Protea Edward hotel in Durban - 5 Sept 2013
This document provides an overview of the history of metallurgy and developments in metal production. It discusses the Stone Age, Bronze Age, and Iron Age. Key developments include the production of bronze by combining copper and tin, the smelting of iron, and production methods for wrought iron, cast iron, and steel. The document outlines the industrialization of steel production through inventions like the Bessemer converter and adoption of processes like continuous casting. It also discusses how electricity enabled high purity copper and aluminum production through electrolytic refining.
The document provides an overview of the iron and steel industries in India and other countries. It discusses the following key points:
- India has a nearly century-old iron and steel industry that is expanding rapidly due to strong global and domestic demand. Major Indian producers include SAIL, Tata Steel, and RINL.
- The industry can be divided into integrated producers like Tata Steel and secondary producers that use scrap iron. Early plants included Jamshedpur (1907) and later public sector facilities.
- The US industry began in the 1600s and grew significantly in the 1800s, fueled by iron ore deposits and the development of railroads. U.S. Steel became the first billion-
This document provides an overview of the development of steelmaking technology in Japan over the last 100 years. It discusses the transition from traditional steelmaking methods to modern processes using open hearth furnaces and converters. Key developments include the introduction of the basic open hearth furnace in 1914, which allowed for higher quality steel production compared to acidic processes. Production increased during World Wars I and II through expanding capacity and utilizing pig iron and hot metal instead of scrap. However, steelmaking became difficult during WWII due to shortages of raw materials from imports and damage from bombing. The document outlines the technological progression and challenges faced during different periods in helping develop Japan's steel industry.
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
This document summarizes a research project examining the antimicrobial properties of copper and copper alloys and potential applications. The project was undertaken by Jack Buchanan at the University of Dundee in collaboration with Rautomead. Key findings included that copper destroys bacteria through contact killing using copper ions. Higher copper purity alloys were found to have greater antimicrobial effectiveness. Applications identified included use in medical settings, food handling, and reducing hospital-acquired infections. Future work proposed testing methodologies and hypotheses developed to determine optimal alloys for preventing bacterial growth. Potential uses for Rautomead's customers producing high copper alloys without side effects were also discussed.
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
This doctoral thesis investigated improving the capacity and performance of continuous casting equipment to enable the processing of new complex high-performance alloys. The research included comparing the microstructure and mechanical properties of products made by continuous casting versus traditional and established methods. Additional objectives examined the effect of casting speed, alloying elements, water flow rate, pull distance, melt temperature, cleanout cycle, casting direction and super-cooler size on the structure and properties of continuously cast copper rod and lead alloy. Microstructural analysis using optical microscopy, SEM, EDX and tensile testing were employed to evaluate the materials. The research aimed to optimize continuous casting parameters to improve casting quality and efficiency for complex alloy processing.
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
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 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.
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 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
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 Limited is a Scottish company founded in 1978 that designs and sells continuous casting machines for precious metals. It has 50 employees and has sold 360 machines total, 133 of which are for precious metal production. It operates out of several facilities in Dundee, Scotland for R&D, spare parts, and machine assembly. Rautomead is an expert in various types of continuous casting and has sold over 130 machines to mints worldwide for gold and silver casting since 1985. Their technology uses graphite materials and components to cast precious metals without contamination.
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 - 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 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
GraphRAG for Life Science to increase LLM accuracyTomaz Bratanic
GraphRAG for life science domain, where you retriever information from biomedical knowledge graphs using LLMs to increase the accuracy and performance of generated answers
Unlock the Future of Search with MongoDB Atlas_ Vector Search Unleashed.pdfMalak Abu Hammad
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* Importance and benefits of vector search
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* Step-by-step implementation guide
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* Best practices and optimization strategies
Perfect for developers, AI enthusiasts, and tech leaders. Learn how to leverage MongoDB Atlas to deliver highly relevant, context-aware search results, transforming your data retrieval process. Stay ahead in tech innovation and maximize the potential of your applications.
#MongoDB #VectorSearch #AI #SemanticSearch #TechInnovation #DataScience #LLM #MachineLearning #SearchTechnology
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Mike Del Balso, CEO & Co-Founder at Tecton, presents "Full RAG," a novel approach to AI recommendation systems, aiming to push beyond the limitations of traditional models through a deep integration of contextual insights and real-time data, leveraging the Retrieval-Augmented Generation architecture. This talk will outline Full RAG's potential to significantly enhance personalization, address engineering challenges such as data management and model training, and introduce data enrichment with reranking as a key solution. Attendees will gain crucial insights into the importance of hyperpersonalization in AI, the capabilities of Full RAG for advanced personalization, and strategies for managing complex data integrations for deploying cutting-edge AI solutions.
Climate Impact of Software Testing at Nordic Testing DaysKari Kakkonen
My slides at Nordic Testing Days 6.6.2024
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In his public lecture, Christian Timmerer provides insights into the fascinating history of video streaming, starting from its humble beginnings before YouTube to the groundbreaking technologies that now dominate platforms like Netflix and ORF ON. Timmerer also presents provocative contributions of his own that have significantly influenced the industry. He concludes by looking at future challenges and invites the audience to join in a discussion.
Cosa hanno in comune un mattoncino Lego e la backdoor XZ?Speck&Tech
ABSTRACT: A prima vista, un mattoncino Lego e la backdoor XZ potrebbero avere in comune il fatto di essere entrambi blocchi di costruzione, o dipendenze di progetti creativi e software. La realtà è che un mattoncino Lego e il caso della backdoor XZ hanno molto di più di tutto ciò in comune.
Partecipate alla presentazione per immergervi in una storia di interoperabilità, standard e formati aperti, per poi discutere del ruolo importante che i contributori hanno in una comunità open source sostenibile.
BIO: Sostenitrice del software libero e dei formati standard e aperti. È stata un membro attivo dei progetti Fedora e openSUSE e ha co-fondato l'Associazione LibreItalia dove è stata coinvolta in diversi eventi, migrazioni e formazione relativi a LibreOffice. In precedenza ha lavorato a migrazioni e corsi di formazione su LibreOffice per diverse amministrazioni pubbliche e privati. Da gennaio 2020 lavora in SUSE come Software Release Engineer per Uyuni e SUSE Manager e quando non segue la sua passione per i computer e per Geeko coltiva la sua curiosità per l'astronomia (da cui deriva il suo nickname deneb_alpha).
TrustArc Webinar - 2024 Global Privacy SurveyTrustArc
How does your privacy program stack up against your peers? What challenges are privacy teams tackling and prioritizing in 2024?
In the fifth annual Global Privacy Benchmarks Survey, we asked over 1,800 global privacy professionals and business executives to share their perspectives on the current state of privacy inside and outside of their organizations. This year’s report focused on emerging areas of importance for privacy and compliance professionals, including considerations and implications of Artificial Intelligence (AI) technologies, building brand trust, and different approaches for achieving higher privacy competence scores.
See how organizational priorities and strategic approaches to data security and privacy are evolving around the globe.
This webinar will review:
- The top 10 privacy insights from the fifth annual Global Privacy Benchmarks Survey
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We’ll kick things off by showcasing the most commonly used event-based triggers, introducing you to various automation workflows like manual triggers, schedules, directory watchers, and more. Plus, see how these elements play out in real scenarios.
Whether you’re tweaking your current setup or building from the ground up, this session will arm you with the tools and insights needed to transform your FME usage into a powerhouse of productivity. Join us to discover effective strategies that simplify complex processes, enhancing your productivity and transforming your data management practices with FME. Let’s turn complexity into clarity and make your workspaces work wonders!
HCL Notes und Domino Lizenzkostenreduzierung in der Welt von DLAUpanagenda
Webinar Recording: https://www.panagenda.com/webinars/hcl-notes-und-domino-lizenzkostenreduzierung-in-der-welt-von-dlau/
DLAU und die Lizenzen nach dem CCB- und CCX-Modell sind für viele in der HCL-Community seit letztem Jahr ein heißes Thema. Als Notes- oder Domino-Kunde haben Sie vielleicht mit unerwartet hohen Benutzerzahlen und Lizenzgebühren zu kämpfen. Sie fragen sich vielleicht, wie diese neue Art der Lizenzierung funktioniert und welchen Nutzen sie Ihnen bringt. Vor allem wollen Sie sicherlich Ihr Budget einhalten und Kosten sparen, wo immer möglich. Das verstehen wir und wir möchten Ihnen dabei helfen!
Wir erklären Ihnen, wie Sie häufige Konfigurationsprobleme lösen können, die dazu führen können, dass mehr Benutzer gezählt werden als nötig, und wie Sie überflüssige oder ungenutzte Konten identifizieren und entfernen können, um Geld zu sparen. Es gibt auch einige Ansätze, die zu unnötigen Ausgaben führen können, z. B. wenn ein Personendokument anstelle eines Mail-Ins für geteilte Mailboxen verwendet wird. Wir zeigen Ihnen solche Fälle und deren Lösungen. Und natürlich erklären wir Ihnen das neue Lizenzmodell.
Nehmen Sie an diesem Webinar teil, bei dem HCL-Ambassador Marc Thomas und Gastredner Franz Walder Ihnen diese neue Welt näherbringen. Es vermittelt Ihnen die Tools und das Know-how, um den Überblick zu bewahren. Sie werden in der Lage sein, Ihre Kosten durch eine optimierte Domino-Konfiguration zu reduzieren und auch in Zukunft gering zu halten.
Diese Themen werden behandelt
- Reduzierung der Lizenzkosten durch Auffinden und Beheben von Fehlkonfigurationen und überflüssigen Konten
- Wie funktionieren CCB- und CCX-Lizenzen wirklich?
- Verstehen des DLAU-Tools und wie man es am besten nutzt
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AI 101: An Introduction to the Basics and Impact of Artificial IntelligenceIndexBug
Imagine a world where machines not only perform tasks but also learn, adapt, and make decisions. This is the promise of Artificial Intelligence (AI), a technology that's not just enhancing our lives but revolutionizing entire industries.
2. by American Smelting and Refining Company,
was primarily designed for the continuous cast-
ing of phosphorus-deoxidized copper, but it is
widely used today (2008) for a range of cop-
per-base alloys. The Properzi process (Ref 9)
was introduced in Italy in the late 1930s to con-
tinuous cast and roll lead rod used for the man-
ufacture of lead pellets for shotgun cartridges.
The plant is used today (2008) for the high-
volume production of aluminum rod and copper
rod.
Among the first production vertical casting
units to be introduced was the TRI equipment
developed by the Tin Research Institute in
England in 1950 (Ref 10). The equipment con-
sisted of an induction melting unit that feeds a
tundish, which was attached to a graphite mold
in a tapered steel water jacket. Withdrawal of
the product was by means of two grooved rolls
situated below the mold. Following the advent
of the TRI system, a number of vertical casting
processes appeared, such as the Unicast process
introduced by United Wire of Edinburgh. The
TRI and Unicast equipment filled a need for
equipment to produce tin bronze in the form
of rod and tube and also a selection of brasses.
Since the 1950s, United Wire plants have been
installed worldwide, particularly in Britain,
France, Italy, and the United States. Rautomead
has become a major supplier of such equipment
In 1957, the Swiss company Alfred Wertli
(Ref 12) introduced the first industrial horizon-
tal continuous caster for the production of cast
iron rods and later expanded into continuous
casting plants for a full range of copper-base
alloys and shapes—rod, billet, and strip. In the
1960s, Technica-Guss (Ref 13) of Wurzburg,
West Germany, introduced horizontal continu-
ous casting systems tailored to individual cus-
tomer requirements, producing strip, billets,
round bars, tubes, and profiles in a range of
copper-base alloys. In 1989, Technica became
a member of the Mannesmann Demag AG
group as Demag Technica GmbH and today
(2008) is a subsidiary of SMS Meer. The com-
pany is a supplier of horizontal and vertical
casting plants covering large installations for
billet and strip casting to smaller plants for
strip, wire, and tube casting of copper alloys
and precious metals.
Vertical Continuous Casting
(Ref 1, 18)
As noted, the Unicast system was developed
in the 1950s for vertical continuous casting of
bronze and brass rod approximately 16 to 19
mm (0.63 to 0.75 in.) in diameter as feedstock
for the manufacture of fine wire mesh used for
papermaking machines. The unit consisted of
an integrated continuous casting plant in which
the complete process of melting, alloying,
holding, and casting takes place in one self-
contained furnace (Ref 1). The Unicast furnace
differs from the modern version only in
that refractory brick insulation is used through-
out instead of low-thermal-mass insulation.
The integrated melting, homogenizing, and
casting in an all-graphite system produces a
high-quality product with minimal residual-
element impurities and low oxygen level, capa-
ble of being drawn to very fine wire. The initial
casting machines manufactured and used inter-
nally by United Wire were vertical casters of
approximately 1 tonne capacity with coiling
equipment to give workable coils for
subsequent rolling to 5 mm2
(0.008 in.2
) and
then drawn down to suitable wire sizes. United
Wire operates these casting units today (2008)
on a range of brasses, bronzes, and nickel-silver
alloys, producing rod of high quality.
A vertical continuous casting plant for cop-
per alloy tubes and bars consists of a channel-
type induction furnace, positioned on a tilting
frame and feeding into a water-cooled graphite
mold, with microprocessor-controlled with-
drawal system and automatic tube cut-off. Mold
or die change is made without emptying the
holding furnace by incorporating a back-tilting
mechanism, which is also a safety feature in
vertical casting, because the melting unit can
be tilted off the casting position in case of mal-
function. The product range in tubes is 20 to
125 mm (0.8 to 5.0 in.) outside diameter and
in bars 12 to 80 mm (0.5 to 3.1 in.) diameter.
Strand lengths are generally in the range of
3 to 4 m (10 to 13 ft).
Vertical Semicontinuous Slab Casters
Since the original invention of Unicast and
TRI vertical continuous casting, the most com-
monly used plant for slab casting is still the
proven design and low investment costs of ver-
tical semicontinuous casters (Fig. 2). The layout
consists of a casting pit with integrated casting
cylinder, by which the casting table and pro-
ducts are moved up and down. The liquid metal
can be supplied from the melting or holding
furnace via launder into the molds mounted on
top of the oscillating casting machine. It is
common for multiple molds to be mounted in
the casting table; this allows for very high
production rates.
At the end of the casting cycle, the produced
slabs are pulled out of the pit with an overhead
crane and a hydraulic tool for clamping of
the slab (Fig. 2b). This disadvantage can be
avoided by use of a vertical semicontinuous
caster with incorporated discharge device
(Fig. 3). This layout shows a larger casting pit
with integrated casting cylinder and casting
table, to which the discharge device is attached
by a swivel joint. The liquid metal solidifies in
the mold on top of the oscillating casting
machine. When the casting cycle is completed,
the cast slabs are pushed from the vertical posi-
tion slightly to the direction of the discharge
device, and the discharging operation starts.
The vertical semicontinuous slab casters can
be used to cast a wide range of alloys and sizes.
In addition to copper and brass, copper nickel
and other copper alloys are produced. Modern
casters incorporate components such as an auto-
matic melt-level control system to provide
automation and stable casting conditions for a
consistently good product quality. Also, adjus-
table slab molds can be used, by which the cast-
ing width can be varied and thus the inventory
of the molds reduced (Fig. 4). Most often,
copper alloy molds without sleeves are used
for slab casting.
Vertical Continuous Slab Casting
When casting copper slabs, the highest pro-
duction rates and consistent quality product
can be achieved with a fully continuous vertical
caster. The general layout is similar to the semi-
continuous mode; a holding furnace supplies
the liquid metal via an automatic melt-level
control into the molds, which are mounted on
top of the oscillating casting machine (Fig. 5).
The solidified strands pass through the second-
ary water-cooling box and are transported by a
withdrawal unit. After cutting, the products
are tilted by a tilting basket into a horizontal
position and further transported by a roller con-
veyor and lifting system.
Appropriate sensors detect the melt level in
the mold, and the flow of liquid metal is regu-
lated automatically by an electronic control.
The holding furnace is typically induction heated
and has a specific shape for vertical casting, with
an attached launder section or forehearth, thus
supplying the metal by the shortest route into
the mold without splashing.
The solidified slabs are firmly clamped and
transported by the withdrawal unit. The vertical
movable saw clamps to the strands and travels
together with the strands during the cutting
operation. After cutting, the products are taken
over by a tilting basket and tilted into a hori-
zontal position for further transport on
subsequent roller tables.
Fig. 1 Poland and Lindner vertical caster. Source:
Ref 1
1020 / Casting of Nonferrous Alloys
3. Upcasting Methods
The Outokumpu Upcasting Method. The
upward casting process was introduced and pat-
ented in 1969 by Outokumpu O.Y., Finland
(Ref 15), with the first production unit coming
into operation in 1970 for casting oxygen-free,
small-diameter copper rod. This system has all
the technical advantages of casting in the verti-
cal mode and, for small-diameter rod, none of
the disadvantages.
The method consists of a graphite die par-
tially immersed in molten metal, with the upper
part surrounded by a water-cooled jacket (Fig. 6)
(Ref 1). The assembly is located just above
the metal top surface, with the graphite die
only just immersed into the liquid and main-
tained precisely in position by an electronic
level-sensing control. The action of vertical
pulsed withdrawal of the rod raises the metal
beyond the lower extremity of the cooler, and
solidification takes place. In the melting and
transfer system, Outokumpu exposes the liquid
metal to graphite or charcoal, resulting in deoxi-
dation of the melt to a level of the order of 5
ppm oxygen. The machine operates on a multidie
system, casting, for example, 12 mm (0.5 in.)
Fig. 3 Vertical semicontinuous casting plant with
discharge device. Courtesy of Demag
Technica GmbH of SMS
Fig. 4 Adjustable molds for vertical semicontinuous
casting of slabs. Courtesy of Demag Technica
GmbH of SMS
Fig. 2 Vertical semicontinuous casting plant. (a) Layout without discharge device. (b) Slab discharging by overhead crane. Courtesy of Demag Technica GmbH of SMS
Copper Continuous Casting / 1021
4. diameter rods at speeds on the order of 3 m/min
(10 ft/min).
Rautomead Upwards Vertical Casting.
Rautomead International, Dundee, introduced a
modified upwards vertical casting process (Ref
16) based on graphite melt containment technol-
ogy and using submersed dies with inert gas pro-
tection. The equipment is used primarily for the
production of small-diameter, high-purity copper
rod with oxygen levels on the order of 5 ppm at
casting speeds on the order of 4.0 to 4.5 m/min
(13 to 14.5 ft/min). The machine is also adaptable
to alloy systems such as bronzes and brasses in
rod form and also tube. By utilizing an all-graph-
ite containment system and incorporating a spe-
cially designed graphite filter bed, deoxidation
of copper to 5 ppm oxygen is ensured.
Pressure Upcast System. A pressure Upcas-
ter (Ref 19) was developed as a production unit
at Dundee Institute of Technology (now Uni-
versity of Abertay, Dundee). During the casting
operation, an inert gas applied to the sealed
steel furnace casing exerts pressure on the mol-
ten metal in the graphite crucible, raising it into
the graphite die where it solidifies and is with-
drawn through a water-cooled jacket vertically
upward in a conventional pulsed mode. On
reverting to atmospheric pressure, metal drains
to the crucible. The equipment is primarily
intended for casting small-section high-purity
copper rod in the range of 1.5 to 10 mm (0.06
to 0.40 in.) in diameter.
A process using some of the same principles
was explored in the 1970s by Chase Brass to pro-
duce copper and brass rod. A higher throughput
was targeted, and the cast rod was reduced in-line
to wire. The process remains in use to produce
copper bus bar.
Horizontal Continuous Casting
Casting in the horizontal mode facilitates
product handling and generally occupies less
space. There are inherent problems as opposed
to vertical casting that mainly relate to grav-
ity-induced directional cooling, which, in most
cases, can be accommodated in the process pro-
tocols. The horizontal plants produce billets for
subsequent extrusion in copper or brass in sec-
tion sizes between 80 and 400 mm (3.1 and
16 in.) in diameter, operating as single- or mul-
tistrand machines. Smaller horizontal casters
are used for the production of tube, bar, and
sections in a full range of copper alloys.
The Swiss company Alfred Wertli (Ref 12)
introduced the world’s first industrial horizontal
continuous caster for the production of cast iron
rods and later expanded into continuous casting
plants for a full range of copper-base alloys.
State-of-the-art horizontal continuous casting
lines for copper alloys are mostly designed to
cast two narrow strips up to 450 mm (18 in.)
wide or one strip up to 800 mm (32 in.)
wide. Thin-strip withdrawal machines are
designed to cast two strands simultaneously,
or each strand can be independently withdrawn.
Fig. 5 Vertical continuous casting. Courtesy of Demag Technica GmbH of SMS
Fig. 6 Principle of upward casting. Source: Ref 1
1022 / Casting of Nonferrous Alloys
5. The molds can also be configured for billet
casting 100 to 400 mm (9 to 16 in.) in diameter,
bar and tube casting in the size range of 25 to
350 mm (1.0 to 14 in.) in diameter, and for
small-diameter rod and wire 12 to 25 mm (0.5
to 1.0 in.) in diameter.
The original Wertli (Ref 12) concept consists
of a channel-type induction furnace and holding
furnace, together with graphite die and cooler
assembly and runout track with withdrawal
machine and cut-off device. Molten metal flows
from the melting furnace to a holding or casting
furnace that acts as a reservoir of molten metal,
maintaining the required casting temperature.
Water-cooled graphite dies are attached to
the holding furnace or crucible. During the con-
tinuous casting operation, metal flows into the
graphite casting die, where it solidifies. The
solidified strands are intermittently withdrawn
in a pull-pause sequence by means of with-
drawal equipment. After leaving the graphite
die, which is housed within the primary cooler,
the cast strands pass through a secondary cooler
in the form of a water sparge that removes the
surplus heat contained in the solidified casting.
The crucible can be manufactured in a refrac-
tory ceramic or from graphite. Integral ceramic
crucibles are used extensively in induction
melting and casting furnaces. These are the
most energy-efficient furnaces and consist of
melting units feeding a casting unit or a single
induction-heated casting unit. The design varies
depending on the application. The metal type
and production rate will determine the crucible
capacity and power rating. Frequency is chosen
to suit these parameters and is selected from
150, 250, 500, 1000, 3000, and 10,000 Hz.
The high frequencies apply to small crucible
capacity, decreasing for the larger installations.
Induction melting and casting furnaces use
either integral or removable crucible assem-
blies, depending on the casting operation.
Precast ceramic crucibles with graphite sup-
port carriers are used in either induction-heated
or resistance-heated furnaces (Ref 1). The full
range of Rautomead graphite resistance-heated
furnaces use this basic design, ranging from
small table-top units to installations with crucible
capacity of 2500 kg (5500 lb) (copper).
Graphite can only be used in a nonoxidizing
atmosphere; therefore, the crucible and die
assembly must be housed in a sealed furnace
and protected with an inert gas, either nitrogen
or argon. Most high-grade coppers, brasses, tin
bronzes, phosphor bronzes, and aluminum
bronzes can be successfully cast in an all-
graphite crucible and die assembly (Ref 1).
The volume of the crucible is dependent on
the application and may vary in capacity from
several tonnes to 1 kg (2 lb) or less.
A crucible liner or protecting sleeve is fre-
quently fitted, particularly with larger crucibles.
This liner is manufactured in graphite and pro-
tects the main crucible against abrasion and
oxidation. The seal between crucible and graph-
ite die is often made by means of a grafoil gas-
ket sheet or washer. Grafoil consists of graphite
in flexible lamellar form, which is compress-
ible, forming a gastight seal and providing a
liquidtight seal.
Graphite baffles can be fitted within the cru-
cible and held in position between the lower
and upper graphite sleeves or liners (Ref 1). A
baffle with suitable perforations provides an
upper and lower chamber to facilitate melting
and homogenization of the charge in the upper
section prior to this metal entering the casting
die. Another, most important function is to
allow sufficient time for deoxidation of the melt
and thus avoid attack on the graphite die.
Unicast Horizontal Casting System. In the
early 1970s, the first Unicast horizontal casting
plant was installed by Timex Corporation, Dun-
dee, for continuous casting brass rod for watch
case manufacture, operating under conditions
similar to the United Wire vertical casters. This
operation was extremely successful, utilizing as
feedstock 100% internally generated brass scrap.
The recycled scrap from trim and machining
operations on case manufacturing, together with
high-quality press shop and screw machine
residue, made the process economically viable.
The chemistry of the product could be closely
controlled, reducing trace element impurities to
limits unobtainable on purchased stock.
Since its inception in 1978, Rautomead, Dun-
dee, has manufactured a wide range of continu-
ous casting machines for the nonferrous metals
industries, primarily for copper-base alloys and
precious metals. The Rautomead resistance-
heated all-graphite system is based on the
United Wire Unicast technology. The design
has been refined, particularly in the area of
refractory insulation heating element configura-
tion and unit modular construction. The major-
ity of the machines operate in the horizontal
mode, with a few special-purpose machines
casting vertically downward.
The construction of the Rautomead machines
is an integrated all-graphite melt-and-cast sys-
tem. The casters range from small table-top
units with crucible capacities of 2 to 50 kg
(4.5 to 110 lb) (copper) to large billet and strip
casters with crucible capacities to 2500 kg
(5500 lb) (copper).
Strip Casting
The horizontal strip casting process was orig-
inally developed by Technica-Guss, which is
now part of SMS Meer. It has been widely used
in the industry for more than 30 years as a near-
net shape casting process for alloys that are
considered difficult to hot roll, such as nickel-
silver mint alloys and phosphor bronze for
electronic applications.
Horizontal continuous casters are manufac-
tured for casting a range of strip widths. Typi-
cal strip widths are 450 mm (18 in.), 650 mm
(26 in.), or larger, with a common thickness
being between 14 and 20 mm (0.6 and 0.8
in.). The produced coil can be automatically
discharged onto a subsequent discharge table.
A majority of horizontal strip casters are
equipped with an in-line milling machine by
which the top and bottom of the cast surface
is cleaned of oxides and segregations so that a
perfect coil is produced for direct passing into
the cold rolling mill.
Modern strip casters comprise high-perfor-
mance coolers with temperature-sensoring sys-
tems to survey the solidification and apply
nitrogen for reduction of surface oxides. Fur-
thermore, a tight temperature control in the
holding furnace is essential for stable casting
conditions and product quality, which is rea-
lized with the stepless power control of the
inductor by the inverter technique.
A typical casting speed of a horizontal strip
caster is up to 200 mm/min (8 in./min), result-
ing in a production of approximately 6,000
tons/year for strips 650 by 16 mm (26 by 0.6
in.). Due to the limited production rate, many
companies who are using this casting process
operate several machines; even eight machines
are in operation in one company. Horizontal
strip casters are used exclusively for the pro-
duction of copper alloys and, in very few
exceptions, worldwide for copper. To overcome
the limitations of the thin-strip casting process
regarding output and copper casting, SMS Meer
developed a new concept for a vertical strip
caster (Ref 18).
Wertli Strip Casting. The Wertli strip cast-
ing plants include in-line operations such as
milling equipment, traveling shear, coiler, and
die and track friction. Hydraulically amplified
electric drives are used to achieve forces in
the range of 40 to 80 kN (9000 to 18,000 lbf)
while maintaining motion accuracy. The Wertli
drive concept is designed to handle such forces
and accelerations by using backlash-free low-
ratio gears together with a high-precision servo
motor with hydraulic amplification. To achieve
a mechanically backlash-free drive, backlash-
free gears are used between the driving motor
and the rollers that drive the strands. Slippage
between the cast strand and the drive roller is
to be avoided if a precise strand motion must
be maintained over long periods of casting.
The tight gripping of the strands is achieved
by hydraulic press-down cylinders. A cooling
system with an enhanced water-cooled surface
increases heat transfer (approximately 10%)
compared to a conventional copper plate cooler
(Ref 1).
Hazelett Casting Process. The Hazelett
steel belt casting invented in 1920 has been
developed for various product forms and today
(2008) is used in the production of copper wire,
rod, strip, and anode. The metal is usually
melted by induction and is delivered via a
tundish to a straight-through mold formed by
tensioned steel belts and edge dam blocks.
Fast-film heat extraction from the mold is
achieved by a proprietary design for the appli-
cation and removal of high-flow-rate water
cooling. The use of special coatings on the belt
is also important. Strip up to 1.25 m (4.10 ft)
wide and Contirod, a rectangular cast bar at
Copper Continuous Casting / 1023
6. 6 to 60 tonnes/h depending on plant capacity,
can be achieved. The Contilanode process is
used for producing high-quality copper anode.
The cast anode plate can be maintained geomet-
rically to within close limits. Hanger lugs are
cast in shaped recesses and thus become an
integral part of the anode body.
Wheel Casting
Properzi Wheel Casting Technology. Prop-
erzi first used wheel casting technology on cop-
per in the 1950s and commercially introduced
the continuous casting and rolling process for
copper rod in 1963. Molten copper is poured
into a revolving casting wheel from a gas-fired
melting and refining furnace. The copper rim
of the wheel is grooved to receive the molten
metal, which is then retained in the groove by
a steel belt. The solidified metal leaves the
wheel and passes through a rolling mill without
interruption.
The casting wheel has a “U” profile, a shape
that evolved to control solidification and heat
transfer as the metal traversed the cooling seg-
ments of the wheel. A Cu-Cr-Zr alloy mold is
used for the casting of all electrolytic tough
pitch (ETP) copper. The position, alignment,
and adjustment of the individual cooling spray
nozzles located around the wheel are of the
utmost importance in controlling the solidifica-
tion and uniformity of the grain structure of
the cast bar.
A layer of acetylene soot, applied to both
cavity and band, serves as a release agent and
insulator, which provides uniformity of heat
transfer. During each rotation of the wheel,
the soot is stripped by high-pressure water
sprays, then reapplied.
The cast “D” section passes through two two-
high break-down roll stands, followed by six to
eight three-high roll stands to yield product for
rod, narrow strip, trolley wire, and other
applications.
Southwire Continuous Casting Rod
Process. Following some research and develop-
ment with Properzi in approximately 1960, the
Southwire Company of Georgia, United States,
introduced a continuous casting process for the
high-speed production of ETP copper rod. The
process has been described in detail in several
published papers (Ref 20–23). The SCR
process, as it is known, incorporates a continu-
ous melting, holding, casting, rolling, pickling,
and coiling system.
The casting wheel provides a trapezoidal-
shaped casting groove in the periphery of a cop-
per alloy ring. This ring is closed by an endless
steel belt through an arc of approximately 180
to 210
, the belt being held in place by idler
wheels and tensioners. The casting groove and
the contact side of the steel band are coated
with a controlled layer of soot that serves as a
release agent and provides uniformity of heat
extraction. The cast bar passes to the rolling
mill through a trimming and descaling
operation. The mill itself is composed of a
number of roughing, intermediate, and finishing
two-roll stands. The alternating vertical and
horizontal shaft stands produce a repetitive
series of oval-to-round reductions.
In the continuous casting of ETP copper with
oxygen content in the melt of approximately
400 ppm, the dissolved oxygen reacts with the
impurities present during solidification, precipi-
tating these out of the solid solution and result-
ing in improved annealability and electrical
conductivity of the product.
The claim for success of the SRC process is
the ability to control the amount of superheat
to a very close range immediately prior to cast-
ing, generally approximately 25
C (45
F)
above the liquidus. The use of a high-purity
cathode and the close control of temperature
results in solidification in a columnar grain pat-
tern with good bar quality. In subsequent roll-
ing in the SCR process, the high temperature
and severe initial reductions in the first pass
cause dynamic recrystallization. Chia (Ref 24)
described the mode of solidification on SCR
tough pitch copper rod.
Ohno Continuous Casting Process
The Ohno continuous casting concept is
based on the application of the Ohno separation
theory of solidification (Ref 25), with the con-
tinuous cast ingot consisting of unidirectional
solidified structure with no equiaxed crystals.
The process is described by Ohno and McLean
(Ref 26).
The patented process (Ref 27) differs from
conventional techniques in that molten metal is
poured into a heated mold rather than into a
cooled mold or die. The mold is heated exter-
nally and its temperature maintained above the
solidification point of the metal being cast. As a
result, no metal nucleates on the mold surface.
The Ohno process has been adopted by Furu-
kawa, Japan (Ref 28), for the production of
oxygen-free high-purity copper rod. The rod
has a structure characterized by longitudinal
crystals or may even develop into a single crys-
tal in some growth conditions. This special
structural material is used in high-resolution
audio signal transmission, having low impuri-
ties, no grain boundaries transverse to the direc-
tion of signal transmission, smooth surface
finish, and excellent physical properties.
The production casting equipment used is
essentially as shown in Fig. 7, with some refine-
ments, including a melting furnace and a cast-
ing furnace with precise metal-level control,
ensuring constant metastatic pressure on the
solidification front. The high-purity copper
charge is deoxidized using carbonaceous mate-
rial in the melting furnace before transfer to
the casting furnace.
REFERENCES
1. R. Wilson, A Practical Approach to
Continuous Casting of Copper-Based Alloys
and Precious Metals, Institute of Materials
(IOM Communications Ltd.), 2000
2. B.E. Eldred, U.S. Patent 1,868,099, 1932
3. G.E. Sellers, U.S. Patent 1908, 1840
4. L. Laign, U.S. Patent 3023, 1843
5. A.H. Pehrson, U.S. Patent 1,088,171, 1914
6. Hazelett Process, Iron Steel Eng., Vol 43
(No. 6), 1966, p 105
7. Poland and Lindner, U.S. Patent 2,136,394,
1938
8. A. Kreil et al., Asarco Process, Met. Rev.,
Vol 5, 1960, p 413–446
9. Properzi Process, Met. Rev., Vol 6
(No. 22), 1961
10. E.C. Ellwood, J. Inst. Met., Vol 84, 1955–
1956, p 319–326
11. I.E. Ewen, United Wire Unicast Process,
U.K. Patents 894,783, 894,784, and 934,484
12. T.P. Wertu, Alfred Wertli AG, Winterthur,
Switzerland
13. Technica Guss, Wurzburg, West Germany
Fig. 7 Schematic of Ohno continuous casting. Source: Ref 1
1024 / Casting of Nonferrous Alloys
7. 14. Southwire Revolutionizes Non-Ferrous
Rod Production with SCR System,
Vol. 33, Southwire Mag., June 1975
15. M. Rantaneno, Upward Continuous Cast of
Copper Wire, Wire Ind., July 1976
16. Rautomead International, Dundee, Scotland
17. A. Krell et al., Flocast Process, Met. Rev.,
Vol 5, 1960, p 413–446
18. “Copper and Copper Alloy Rolled Pro-
ducts—Trends in Equipment/Auxiliaries
and Applications,” Seminor at Hotel Le
Royal Meridiea (Mumbai), Jan 18–19,
2006
19. R. Wilson, Pressure Upcast, U.K. Patent
GB 2,236,498B, 1992, and U.S. Patent
5,090,471, 1992
20. U. Sinha and R. Adams, Southwire Contin-
uous Rod Process: Innovations for Quality
Improvements, Wire J. Int., June 1993
21. U. Sinha and R. Adams, “Southwire Con-
tinuous Rod: A Method to Produce High-
Quality Rods for Fine Wire Drawing and
Special Applications,” Conference Indian
Copper Development Centre and Winding
Wires Manufacturers Association of India,
Oct 1988
22. G.T. Hudson, “The Production of Copper
Rod by SRC Process,” internal paper,
Southwire Company, Carrolton, GA.
23. L.C. Richards et al., “Continuous Casting—
Its History, Impact and Future,” Metals
Week Copper Conference, Dec 10, 1989
24. H. Chia, International Conf., Inst. Wire and
Mach. Assoc. (Torremolinos, Spain), April
1979
25. A. Ohno, Solidification, The Separation
Theory and Its Practical Application,
Springer Verlag, New York
26. A. Ohno and A. McLean, Ohno Continuous
Casting, Adv. Mater. Process., Vol 4, 1995,
p 43–45
27. A. Ohno, Japan Patent 1,049,148; U.S.
Patent 4,515,204; and Germany Patent
3,246,470
28. K. Nakano, “Continuous Casting of Copper
and Copper Alloys,” RD Division of
Furukawa Electric Company, Japan
Copper Continuous Casting / 1025