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
Dirinler was established in 1952 as a machinery repair company and has since expanded to include a foundry, marina, and other industrial companies. It established its first foundry in 1974 and has continued growing its production capacity and capabilities. Dirinler now exports castings to 45 countries and has a annual production capacity of 14,000 tons across its four induction furnaces.
Satinder Chemicals SCL is a reliable import and export company dealing in chemicals and industrial products for over two decades. It provides a wide range of high quality products and customized solutions to its customers. The document lists and describes various industrial products and materials that SCL imports and exports, including refractory materials, ferroalloys, saw blades, grits, electrodes, and fume extraction systems.
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.
This document provides an overview of Autokast Limited, an iron casting company located in Cherthala, Kerala, India. It discusses the company's production processes which include molding, melting, pouring, fettling, and inspection. Autokast produces grey iron and spheroidal graphite iron castings up to 8.5 metric tons for applications in automotive, pumps, valves, and machinery. The training report aims to study Autokast's operations and understand how its various departments work together to manufacture cast iron components.
The document is an internship report submitted by Shoaib Hassan Khan about his 3 month internship at Maple Leaf Cement Factory (MLCF). It provides an overview of MLCF, including its vision, mission, and core values which center around achieving industry standards, stakeholders interests, and conducting business professionally and efficiently. It then discusses the cement manufacturing process at MLCF in detail over several chapters. The report describes the raw material acquisition, different production areas, manufacturing processes, equipment used, and concludes with discussing sources of pollution and their control measures. Overall, the report aims to provide a comprehensive view of the cement manufacturing plant from a mechanical perspective based on the author's learning and experience during the internship.
Development and Progress of V-process in Chinazhang jianman
(1) The document discusses the development and progress of V-process casting in China. It began being studied in 1974 and has grown significantly, with over 500 firms now using the technique.
(2) The key aspects of V-process casting are that it uses vacuum instead of binders in the sand mold. This allows for high dimensional accuracy and surface quality in castings.
(3) The document outlines the history and increasing applications of V-process casting in China. It is now used for castings in various industries such as machinery, rail, automotive, and more. The technology and equipment for V-process casting in China has also advanced greatly.
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.
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.
Dirinler was established in 1952 as a machinery repair company and has since expanded to include a foundry, marina, and other industrial companies. It established its first foundry in 1974 and has continued growing its production capacity and capabilities. Dirinler now exports castings to 45 countries and has a annual production capacity of 14,000 tons across its four induction furnaces.
Satinder Chemicals SCL is a reliable import and export company dealing in chemicals and industrial products for over two decades. It provides a wide range of high quality products and customized solutions to its customers. The document lists and describes various industrial products and materials that SCL imports and exports, including refractory materials, ferroalloys, saw blades, grits, electrodes, and fume extraction systems.
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.
This document provides an overview of Autokast Limited, an iron casting company located in Cherthala, Kerala, India. It discusses the company's production processes which include molding, melting, pouring, fettling, and inspection. Autokast produces grey iron and spheroidal graphite iron castings up to 8.5 metric tons for applications in automotive, pumps, valves, and machinery. The training report aims to study Autokast's operations and understand how its various departments work together to manufacture cast iron components.
The document is an internship report submitted by Shoaib Hassan Khan about his 3 month internship at Maple Leaf Cement Factory (MLCF). It provides an overview of MLCF, including its vision, mission, and core values which center around achieving industry standards, stakeholders interests, and conducting business professionally and efficiently. It then discusses the cement manufacturing process at MLCF in detail over several chapters. The report describes the raw material acquisition, different production areas, manufacturing processes, equipment used, and concludes with discussing sources of pollution and their control measures. Overall, the report aims to provide a comprehensive view of the cement manufacturing plant from a mechanical perspective based on the author's learning and experience during the internship.
Development and Progress of V-process in Chinazhang jianman
(1) The document discusses the development and progress of V-process casting in China. It began being studied in 1974 and has grown significantly, with over 500 firms now using the technique.
(2) The key aspects of V-process casting are that it uses vacuum instead of binders in the sand mold. This allows for high dimensional accuracy and surface quality in castings.
(3) The document outlines the history and increasing applications of V-process casting in China. It is now used for castings in various industries such as machinery, rail, automotive, and more. The technology and equipment for V-process casting in China has also advanced greatly.
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.
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.
Rautomead Limited are UK-based specialists in continuous casting of non-ferrous metals and construction of continuous casting equipment for copper, copper alloys, gold and silver, dental alloys and feed rod for Conform machines.
For a period of over 30 years Rautomead Limited has specialised in the design, manufacture and sale of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries around the world.
Rautomead promote Advanced Metals Technology Collaboration for research and development of new processing technology for non ferrous metals
www.rautomead.co.uk
sales@rautomead.co.uk
Rautomead 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
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
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
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
The document summarizes the wire drawing process. Wire drawing is used to reduce the cross-sectional area of wire by pulling it through progressively smaller dies. There are single step and continuous wire drawing machines. Proper lubrication is important for smooth finishes and long die life. Different types of dies and materials are used depending on the type of wire. Automation using programmable logic controllers allows maintaining constant speed and drawing force for high accuracy and reduced labor costs.
The document discusses the extrusion manufacturing process. Extrusion involves forcing a block of metal through a die to create solid or hollow shapes. There are different types of extrusion classified by direction (direct, indirect), operating temperature (hot, cold), and equipment (horizontal, vertical). Hot extrusion is done at high temperatures using lubrication while cold extrusion is done at room temperature. The document also discusses defects, drawing as a related process, and factors that affect extrusion forces.
This document discusses different types of extrusion processes including forward and backward extrusion as well as direct and indirect extrusion. It explains extrusion can be done hot or cold and describes horizontal and vertical hydraulic presses used for extrusion. Examples of materials that can be extruded include aluminum and uses of extruded parts are mentioned. The principles of extrusion and limitations are summarized.
This chapter discusses various metal extrusion processes. It begins by defining extrusion as forcing a metal billet through a die to reduce its cross-section. Various types of extrusion processes are classified, including direct/indirect extrusion and hot/cold extrusion. Equipment for extrusion like presses and dies are also described. Examples of products made by extrusion and specific processes like tube extrusion are provided. The chapter aims to provide useful background on extrusion processes and their analysis.
Rautomead Newsletter issue 01
continuouscasting.com
For over 30 years Rautomead Limited has specialised in the design and manufacture of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries worldwide.
Rautomead plants are being successfully applied to production of oxygen-free copper, a wide range of copper-based alloys, precious metals and zinc. Forms include wire rod, straight length bars, flats and hollow sections. According to material and section, the casting process selected may be vertical upwards, vertical downwards or horizontal. The machines may be used either as integrated melting, holding and casting machines, or may be arranged to be fed with pre-alloyed molten metal.
The Rautomead Continuous Casting System is based on electric resistance heating of its furnaces, with graphite containment crucibles, graphite heating elements and casting dies. This technology is particularly suited for production of high purity, high quality oxygen-free copper and copper alloy wire rods (copper silver, copper magnesium, copper tin).
The upward casting equipment may be used to manufacture rods of all diameters between 8.0mm and 30mm diameter and is suitable feedstock for wire drawing and continuous rotary extrusion processes. End use applications include: superfine wire, automotive wires, contact wire and trolley wires for high speed trains, data communication cables, CTC and transformer strips as well as enamelled wires.
Rautomead’s R&D facility at the factory in Dundee (casting equipment, technicians, design and operational experience) is available to companies who wish to commission experimental and research work to develop technology and tooling for the manufacture and processing of new alloys and materials. Rautomead’s partnership with the University of Dundee provides access to sophisticated laboratory equipment as well as support with analytical evaluation and academic contributions to the R&D effort
RAUTOMEAD TECHNOLOGY FOR UPWARDS CONTINUOUS CASTING OF COPPER ALLOYSRautomead Limited
RAUTOMEAD TECHNOLOGY FOR UPWARDS CONTINUOUS CASTING OF COPPER ALLOYS
Paper given by Brain Frame, MD Rautomead at teh IWCC technical Seminar, Santiago, Chile, March 2013
Rautomead Newsletter issue 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
This document provides a vocational training report submitted by Prabhat Kumar, an undergraduate student at NIELIT Aurangabad, for their training at Tayo Rolls Ltd from June 8th to July 7th 2015. The report focuses on motor control through a variable frequency drive (VFD) used to control machines in the forge shop. It includes a certificate signed by the training and project supervisors, as well as sections on the company profile, introduction to lathe machines, what a VFD is and how it works, applications of VFDs, and a conclusion.
A project report on study on foundry industry belgaumBabasab Patil
This document provides an overview of the foundry industry and Sujay Enterprises, a foundry company in Belgaum, India. It discusses the facilities, clients, production process, testing capabilities and entrepreneur Chandrashekhar Iti who founded the company in 1982. Sujay Enterprises aims to meet customer requirements by delivering high quality castings on time with excellent service. The company has the infrastructure to produce gray iron and ductile iron castings along with machining and testing facilities.
This document provides an overview and summary of Prajna Prakash Giri's vocational training project on the power distribution system for a 2.0 MTPA integrated steel plant at MECON Limited in Ranchi from May 23rd to July 2nd 2016. It includes an acknowledgments section, table of contents, introduction to MECON and its areas of activities. It then describes the key components of an integrated steel plant including the raw material handling plant, various steel making units like sinter plant, blast furnace, pellet plant, electric arc furnace, and rolling mills. It also provides an overview of the power generation and distribution activities.
Sujit kumar mahato report on bsl (sail)1996kuldeep
Sujit Kumar completed an industrial training report at Steel Authority of India Limited (SAIL) in Bokaro from July 04, 2016 to July 30, 2016. The report provides an overview of SAIL, which operates 5 integrated steel plants and 3 special steel plants. It summarizes Sujit's visits to various departments including the Central Base Repairing Shop, Machine Shop, Foundries, Water Management Department, Raw Material Handling Plant, Coke Oven and By-Product Plant, Sinter Plant, and Blast Furnace. The conclusion states that the practical experience gained valuable knowledge about running a large industry that cannot be learned only from books.
This document provides an overview of the Foundry and Pattern Shop at Bhilai Steel Plant in India. It discusses the key sections and processes within the Foundry, including sand preparation, iron foundry, steel foundry, and non-ferrous foundry. It notes the annual production capacities for iron, steel, and non-ferrous castings. The Pattern Shop produces patterns for the Foundry's metal casting needs. The Foundry utilizes processes like melting, pouring into molds, and removing molds to produce castings in iron, steel, and other metals for use as spare parts and other needs within the plant.
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
processes : from raw bauxite to refractory alumina bricksParth Vaishnav
this pdf describes all process required to convert raw bauxite into alumina bricks.It includes pictures of equipment, data books, etc of the same. This project is undertaken at Dalmia refactories.
This document provides information about Teckno, a company that has been designing, manufacturing, and erecting transmission line towers, substation structures, windmill towers, and cable trays since 1991. It lists Teckno's manufacturing facilities, plant and machinery, quality assurance processes, galvanizing plant, in-house testing facilities, lists of customers in India and abroad, and examples of completed projects. Teckno is self-sufficient in manufacturing and inspection and has the necessary systems, procedures, and documentation in place.
This document provides information about Prashant Kumar's vocational training project on the study of CNC machine control systems at Tata Steel in Jamshedpur, India. It includes an acknowledgements section thanking those who supported the project. The document then covers the history and departments of Tata Steel, including Spare Manufacturing Department where the training took place. It provides technical details about CNC machines and their components like PLC, sensors and advantages of CNC systems.
The document discusses the process of steelmaking at Tata Steel's plant in Jamshedpur, India. It describes the key units involved, including hot metal receiving and desulfurization, basic oxygen steelmaking in converter vessels, secondary metallurgy treatments in ladle furnaces, and continuous casting of final products. It focuses on the secondary metallurgy processes used to refine molten steel and achieve the desired compositions for different grades, such as additions of alloys and slag.
Rautomead Limited are UK-based specialists in continuous casting of non-ferrous metals and construction of continuous casting equipment for copper, copper alloys, gold and silver, dental alloys and feed rod for Conform machines.
For a period of over 30 years Rautomead Limited has specialised in the design, manufacture and sale of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries around the world.
Rautomead promote Advanced Metals Technology Collaboration for research and development of new processing technology for non ferrous metals
www.rautomead.co.uk
sales@rautomead.co.uk
Rautomead 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
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
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
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
The document summarizes the wire drawing process. Wire drawing is used to reduce the cross-sectional area of wire by pulling it through progressively smaller dies. There are single step and continuous wire drawing machines. Proper lubrication is important for smooth finishes and long die life. Different types of dies and materials are used depending on the type of wire. Automation using programmable logic controllers allows maintaining constant speed and drawing force for high accuracy and reduced labor costs.
The document discusses the extrusion manufacturing process. Extrusion involves forcing a block of metal through a die to create solid or hollow shapes. There are different types of extrusion classified by direction (direct, indirect), operating temperature (hot, cold), and equipment (horizontal, vertical). Hot extrusion is done at high temperatures using lubrication while cold extrusion is done at room temperature. The document also discusses defects, drawing as a related process, and factors that affect extrusion forces.
This document discusses different types of extrusion processes including forward and backward extrusion as well as direct and indirect extrusion. It explains extrusion can be done hot or cold and describes horizontal and vertical hydraulic presses used for extrusion. Examples of materials that can be extruded include aluminum and uses of extruded parts are mentioned. The principles of extrusion and limitations are summarized.
This chapter discusses various metal extrusion processes. It begins by defining extrusion as forcing a metal billet through a die to reduce its cross-section. Various types of extrusion processes are classified, including direct/indirect extrusion and hot/cold extrusion. Equipment for extrusion like presses and dies are also described. Examples of products made by extrusion and specific processes like tube extrusion are provided. The chapter aims to provide useful background on extrusion processes and their analysis.
Rautomead Newsletter issue 01
continuouscasting.com
For over 30 years Rautomead Limited has specialised in the design and manufacture of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries worldwide.
Rautomead plants are being successfully applied to production of oxygen-free copper, a wide range of copper-based alloys, precious metals and zinc. Forms include wire rod, straight length bars, flats and hollow sections. According to material and section, the casting process selected may be vertical upwards, vertical downwards or horizontal. The machines may be used either as integrated melting, holding and casting machines, or may be arranged to be fed with pre-alloyed molten metal.
The Rautomead Continuous Casting System is based on electric resistance heating of its furnaces, with graphite containment crucibles, graphite heating elements and casting dies. This technology is particularly suited for production of high purity, high quality oxygen-free copper and copper alloy wire rods (copper silver, copper magnesium, copper tin).
The upward casting equipment may be used to manufacture rods of all diameters between 8.0mm and 30mm diameter and is suitable feedstock for wire drawing and continuous rotary extrusion processes. End use applications include: superfine wire, automotive wires, contact wire and trolley wires for high speed trains, data communication cables, CTC and transformer strips as well as enamelled wires.
Rautomead’s R&D facility at the factory in Dundee (casting equipment, technicians, design and operational experience) is available to companies who wish to commission experimental and research work to develop technology and tooling for the manufacture and processing of new alloys and materials. Rautomead’s partnership with the University of Dundee provides access to sophisticated laboratory equipment as well as support with analytical evaluation and academic contributions to the R&D effort
RAUTOMEAD TECHNOLOGY FOR UPWARDS CONTINUOUS CASTING OF COPPER ALLOYSRautomead Limited
RAUTOMEAD TECHNOLOGY FOR UPWARDS CONTINUOUS CASTING OF COPPER ALLOYS
Paper given by Brain Frame, MD Rautomead at teh IWCC technical Seminar, Santiago, Chile, March 2013
Rautomead Newsletter issue 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
This document provides a vocational training report submitted by Prabhat Kumar, an undergraduate student at NIELIT Aurangabad, for their training at Tayo Rolls Ltd from June 8th to July 7th 2015. The report focuses on motor control through a variable frequency drive (VFD) used to control machines in the forge shop. It includes a certificate signed by the training and project supervisors, as well as sections on the company profile, introduction to lathe machines, what a VFD is and how it works, applications of VFDs, and a conclusion.
A project report on study on foundry industry belgaumBabasab Patil
This document provides an overview of the foundry industry and Sujay Enterprises, a foundry company in Belgaum, India. It discusses the facilities, clients, production process, testing capabilities and entrepreneur Chandrashekhar Iti who founded the company in 1982. Sujay Enterprises aims to meet customer requirements by delivering high quality castings on time with excellent service. The company has the infrastructure to produce gray iron and ductile iron castings along with machining and testing facilities.
This document provides an overview and summary of Prajna Prakash Giri's vocational training project on the power distribution system for a 2.0 MTPA integrated steel plant at MECON Limited in Ranchi from May 23rd to July 2nd 2016. It includes an acknowledgments section, table of contents, introduction to MECON and its areas of activities. It then describes the key components of an integrated steel plant including the raw material handling plant, various steel making units like sinter plant, blast furnace, pellet plant, electric arc furnace, and rolling mills. It also provides an overview of the power generation and distribution activities.
Sujit kumar mahato report on bsl (sail)1996kuldeep
Sujit Kumar completed an industrial training report at Steel Authority of India Limited (SAIL) in Bokaro from July 04, 2016 to July 30, 2016. The report provides an overview of SAIL, which operates 5 integrated steel plants and 3 special steel plants. It summarizes Sujit's visits to various departments including the Central Base Repairing Shop, Machine Shop, Foundries, Water Management Department, Raw Material Handling Plant, Coke Oven and By-Product Plant, Sinter Plant, and Blast Furnace. The conclusion states that the practical experience gained valuable knowledge about running a large industry that cannot be learned only from books.
This document provides an overview of the Foundry and Pattern Shop at Bhilai Steel Plant in India. It discusses the key sections and processes within the Foundry, including sand preparation, iron foundry, steel foundry, and non-ferrous foundry. It notes the annual production capacities for iron, steel, and non-ferrous castings. The Pattern Shop produces patterns for the Foundry's metal casting needs. The Foundry utilizes processes like melting, pouring into molds, and removing molds to produce castings in iron, steel, and other metals for use as spare parts and other needs within the plant.
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
processes : from raw bauxite to refractory alumina bricksParth Vaishnav
this pdf describes all process required to convert raw bauxite into alumina bricks.It includes pictures of equipment, data books, etc of the same. This project is undertaken at Dalmia refactories.
This document provides information about Teckno, a company that has been designing, manufacturing, and erecting transmission line towers, substation structures, windmill towers, and cable trays since 1991. It lists Teckno's manufacturing facilities, plant and machinery, quality assurance processes, galvanizing plant, in-house testing facilities, lists of customers in India and abroad, and examples of completed projects. Teckno is self-sufficient in manufacturing and inspection and has the necessary systems, procedures, and documentation in place.
This document provides information about Prashant Kumar's vocational training project on the study of CNC machine control systems at Tata Steel in Jamshedpur, India. It includes an acknowledgements section thanking those who supported the project. The document then covers the history and departments of Tata Steel, including Spare Manufacturing Department where the training took place. It provides technical details about CNC machines and their components like PLC, sensors and advantages of CNC systems.
The document discusses the process of steelmaking at Tata Steel's plant in Jamshedpur, India. It describes the key units involved, including hot metal receiving and desulfurization, basic oxygen steelmaking in converter vessels, secondary metallurgy treatments in ladle furnaces, and continuous casting of final products. It focuses on the secondary metallurgy processes used to refine molten steel and achieve the desired compositions for different grades, such as additions of alloys and slag.
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.
Design And Fabrication Of Iron Ore Sintering MachineAlbin Cherian
This document is a project report submitted by Albin Kuriachan Cherian and Siddharth Rathod for their Bachelor of Engineering degree. The project involves designing and fabricating an iron ore sintering machine in the metallurgical engineering department laboratory for experimental studies. The report provides background on the sintering process and reviews literature on sintering machine types, process parameters, quality control, and the economics and trends of sintering practice. It then details the design of the iron ore sintering machine to be fabricated, including dimensions, materials, and the fabrication process. The report concludes with the scope for future work and an overall conclusion.
This document summarizes a research article that proposes a new rapid prototyping process called composite metal foil manufacturing (CMFM). CMFM combines laminated object manufacturing and soldering techniques to produce high-quality metal parts directly from CAD models using thin metal foils and solder paste. The researchers developed an experimental setup to demonstrate CMFM and produced test specimens from copper foil. They then evaluated the specimens using lap-shear testing, peel testing, microstructural analysis, and comparison to other methods to validate the effectiveness of CMFM for producing metal prototypes.
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.
Steelcast limited industrial training reportaman1312
Steelcast limited is an India-based company. The company is engaged in the business of steel casting . Its product include carbon steel , low alloy steel , high alloy steel , hadfield manganese steel , and other grade of wear and abrasion resistant steel casting produced by sand molding and shell moulding process . The Company caters to industries , such as earthmoving equipment manufacturing , heavy electrical equipment manufacturing , mining , minerals processing equipment manufacturers , valve manufacturers and general engineering equipment manufacturers.
Exothermic Welding Powder Distributors, Amiable Impex is the Largest and Biggest Suppliers of Exothermic Welding Powder and Exothermic Welding Accessories.
This document provides an overview of Sadanand's 4-week industrial training at the Sheet Metal and Fabrication Shop of Lohia Corp. Limited. It begins with a brief history of Lohia Corp and an introduction to sheet metal. It then describes the key processes in the sheet metal department like shearing, punching, bending, and welding. Several CNC and manual machines used are outlined like the Amada VIPROS 255 CNC press, 340-ton bending press, MIG welding, drilling machines, and Makino A92 machine. The training concluded with Sadanand gaining engineering skills for sack machine production and learning about key production principles and the importance of workers.
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 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%.
Characteristics of Hypoeutectic Cu-Zr Alloy Rods Manufactured by Vertical Upw...Rautomead Limited
The focus in this study is therefore on applying a vertical upwards continuous casting (VUCC) mass-production
method to the pilot-scale manufacturing of Cu-Zr alloy rods. The microstructure and physical characteristics of these
VUCC rods were subsequently investigated and compared with rods produced by CMC. In addition, the wire-drawing
capability of the VUCC rods was examined, and the adaptability of the VUCC method to the mass production of
hypoeutectic Cu-Zr alloys was fully investigated.
2.
EFFECT OF ANTIMONY ADDITION RELATIVE TO MICROSTRUCTURE AND MECHANICAL PROPERT...Rautomead Limited
It is well documented that the addition of antimony in pure lead increases tensile strength and reduced elongation. The goal of the present work is to identify the cause of these phenomena by investigation of the effects of the addition of Sb (1.25%) on the structure of pure continuously cast lead and lead alloy rods. The microstructure and morphology of both pure lead and lead 1.25% antimony were examined by digital optical microscope and scanning electron microscope respectively. Energy Dispersive X-ray Spectroscopy (EDX) was used to identify alloying elements. The results showed that the effect of additions of antimony on mechanical properties of lead-antimony alloys is mainly due to the solid solubility of the antimony element. Homogenized distribution of the antimony results in a decrease in the grain size of the pure lead. These smaller grains mean higher strength so long as there is a homogeneous grain structure
Investigation of the distribution of lead in three different combinations of ...Rautomead Limited
The main objective of this paper was to assess three leaded
brass samples (pending application with Copper Development
Association) using optical microscopy and mass
spectrometry to compare the distribution of lead. Based on
the mass spectrometry data, a great deal of variation was
not found within each of the samples based on five different
sample locations. Optical microscopy, scanning electron
microscopy and energy-dispersive X-ray spectroscopy
confirmed that the lead was homogenously distributed in
brass.
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 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 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.
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
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
Best 20 SEO Techniques To Improve Website Visibility In SERPPixlogix Infotech
Boost your website's visibility with proven SEO techniques! Our latest blog dives into essential strategies to enhance your online presence, increase traffic, and rank higher on search engines. From keyword optimization to quality content creation, learn how to make your site stand out in the crowded digital landscape. Discover actionable tips and expert insights to elevate your SEO game.
Why You Should Replace Windows 11 with Nitrux Linux 3.5.0 for enhanced perfor...SOFTTECHHUB
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One such alternative that has garnered significant attention and acclaim is Nitrux Linux 3.5.0, a sleek, powerful, and user-friendly Linux distribution that promises to redefine the way we interact with our devices. With its focus on performance, security, and customization, Nitrux Linux presents a compelling case for those seeking to break free from the constraints of proprietary software and embrace the freedom and flexibility of open-source computing.
GraphSummit Singapore | The Future of Agility: Supercharging Digital Transfor...Neo4j
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This keynote will reveal how Deloitte leverages Neo4j’s graph power for groundbreaking digital twin solutions, achieving a staggering 100x performance boost. Discover the essential role knowledge graphs play in successful generative AI implementations. Plus, get an exclusive look at an innovative Neo4j + Generative AI solution Deloitte is developing in-house.
Building Production Ready Search Pipelines with Spark and MilvusZilliz
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“An Outlook of the Ongoing and Future Relationship between Blockchain Technologies and Process-aware Information Systems.” Invited talk at the joint workshop on Blockchain for Information Systems (BC4IS) and Blockchain for Trusted Data Sharing (B4TDS), co-located with with the 36th International Conference on Advanced Information Systems Engineering (CAiSE), 3 June 2024, Limassol, Cyprus.
TrustArc Webinar - 2024 Global Privacy SurveyTrustArc
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See how organizational priorities and strategic approaches to data security and privacy are evolving around the globe.
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Climate impact / sustainability of software testing discussed on the talk. ICT and testing must carry their part of global responsibility to help with the climat warming. We can minimize the carbon footprint but we can also have a carbon handprint, a positive impact on the climate. Quality characteristics can be added with sustainability, and then measured continuously. Test environments can be used less, and in smaller scale and on demand. Test techniques can be used in optimizing or minimizing number of tests. Test automation can be used to speed up testing.
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Threats to mobile devices are more prevalent and increasing in scope and complexity. Users of mobile devices desire to take full advantage of the features
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1. continuouscasting.com issue 12 March 20121
RAUTOMEADCOMBINEWITHSMS
TOOFFERNEWCOPPERTUBE
MANUFACTURINGFACTORIES
CONTENTS
PAGE 2-3
Rautomead does well
for Doowell in China
Rautomead leads the
way in China
PAGE 4-6
Rautomead Graphite
Technology Continuous
Improvements
PAGE 6
CuCrZr rod
PAGE 7
Collusion Improves
Extrusion for
Rautomead’s
New Division
BACK PAGE
Continuous Casting
for Gold
Ongoing ties with
Thailand
CONTACT
Rautomead Limited
Nobel Road
Wester Gourdie
Industrial Estate
Dundee DD2 4UH
Scotland,UK
Tel
+44 (0)1382 622341
Fax
+44 (0)1382 622941
Email
sales@rautomead.com
www.rautomead.com
Rautomead combine with SMS Meer’s
Schumag and Copper division to offer a
new copper tube manufacturing process.
SMS Meer are offering the complete
process for the manufacture of copper
tubing. Systems are available for
production of between 4 to 6,000 to 8 to
12,000 tonnes per year of finished tubes.
The Rautomead castube™ upward
vertical casting process produces copper
tube shells that are formed into coils.
These are subsequently processed on
SMS Meer equipment to the finished
products through a Schumag preliminary
draw machine, annealed, and then
drawn further on an MRB spinner block.
Finishing equipment is selected according
to specific factory requirements.
SMS Meer, a part of the SMS group,
are the only supplier to offer complete
turnkey packages of equipment and
know how from copper melting to finished
tube products.
The copper tube mill concept offers
the possibility of new small scale start
up tube manufacturing facilities with
high production efficiency and minimal
investment in equipment and inventory.
It will provide the opportunity to install
this manufacturing capacity in the vicinity
of the consumer or to add additional
capacity to existing traditional tube
manufacturing plants.
2. continuouscasting.com issue 12 March 20122
Continuous casting technology specialist, Rautomead
Limited, of Dundee, Scotland, secured a highly significant
order from Doowell, a major Taiwanese-owned OEM
cable assembly manufacturer with a number of large
manufacturing plants in China including its main facility
in Xiamen employing around 5,000 people. Rautomead has
commissioned an RS 3000/6 upwards-vertical continuous
casting machine for the production of oxygen-free copper
redraw rod.
The Rautomead machine is installed at the Doowell’s
Changsu City factory, not far from China’s economic
powerhouse Shanghai,where the company has a licence to
carry out melting and casting.
DOING IT BETTER
With a need to draw the rod to superfine wire of 0.05mm
diameter, Doowell sees its investment in a Rautomead
oxygen-free copper machine as a way of improving
the quality of redraw rod and improving reliability with
increased productivity. Technical service support during
installation, commissioning and subsequent production
and operation will be provided by Rautomead engineers
from UK supported by the Rautomead office in Shanghai.
The Rautomead engineering team provided free
consultancy service during a visit to Changsu shortly
after the contract was finalised. This service is available
to all customers to advise them about preparing the
factory site and services prior to delivery of the continuous
casting equipment.Correct preparation minimises the time
required for installation and start up during commissioning.
HOW THE EAST WAS WON
Rautomead have supplied several specialist RS model
continuous casting machines to companies in China for the
production of CuMg wire rod used in the manufacture of
contact wire for the network of high-speed trains currently
under construction on the mainland.This machine supplied
to Doowell is the first RS machine to be delivered and
installed in China for the production of high quality CuOF
wirerod. The demands and requirements of rod and wire
product quality being sufficient to justify investment in
European continuous casting technology.
Rautomead does well
for doowell in china
3. continuouscasting.com issue 12 March 20123
RAUTOMEADCONTINUOUSCASTINGBRINGS
CONTINUOUSSUCCESSINCHINA
NOWRAUTOMEADCASTSTHEBESTYOUNGTALENT
Continuous casting technology specialist Rautomead
Limited of Dundee, Scotland has delivered two model
RMJ/H025 continuous casting machines to Shandong
Zhaojin Precious Metals Co. Ltd. of Zhaoyuan City,
Shandong Province, China. The two machines will be used
to manufacture 120 x 35 mm. strip in fine gold and silver
respectively. Rautomead also be supplied two separate
closed circuit primary cooling water systems, one for each
caster to eliminate the requirement for external cooling
water systems. The order represents a significant step in
Shandong Zhaojin’s ongoing expansion plans. Shandong
Zhaojin is one of the largest precious metal refining
companies in China.
CASTING AN EYE EASTWARDS
The contract follows hot on the heels of three other orders
from the Far East for RMJ/H025 table-top continuous
casting machines to cast fine gold and silver strip.
These machines were supplied to the Shanghai and
Shenyang Mints in China, both of which are state-owned
through China Banknote Printing & Minting Corporation,
and to the Royal Thai Mint in Thailand. Crucially, however,
while the Shanghai Mint and Royal Thai Mint orders
represented repeat business for Rautomead, with
the Shanghai Mint having installed the first of its four
Rautomead machines for the processing of gold and gold
alloys way back in 1991, the Shenyang Mint is an entirely
new customer for the innovative Dundee-based operation.
As Rautomead Chairman Sir Michael Nairn explains:
‘There is no doubt in my mind that the well-established
and respected niche carved out by Rautomead technology
elsewhere in the precious metals industry in China was
instrumental in bringing this new customer to us. While
repeat business is always testament to a job well done,
entirely new customers such as Shandong Zhaojin and
the Shenyang Mint are particularly satisfying in providing
clear evidence of the level of trust the company has
achieved in a given market’.
Continuous casting technology specialist Rautomead
Limited of Dundee, Scotland has recently proved its
aptitude for an entirely different kind of casting in
embarking upon a rigorous casting process to identify the
best young talent.
Following on from its recent intake of graduates Colin Bell
and David Murray (the latter of whom is planning to attend
a machine commissioning in Brazil in the next few months
as part of his initial training), the company has taken on
two extremely promising local apprentices, Finlay Mitchell
and Jamie MacPherson,straight from school.
Over the next 4 years the pair will be acquiring a thoroughly
rounded view of the Rautomead operation, beginning by
spending six months with the company’s machine fitters
and a further six months with the electricians.
As with the two graduates,in taking on the two apprentices
Rautomead was looking out not just for a natural talent
and aptitude for the job but also for young people with
a natural willingness, and enthusiasm, for engaging
immediately and directly with the equipment and getting
their hands thoroughly dirty in the process! In fact, so
rigorous is the company’s selection process in identifying
just the right young DNA for the job that Finlay and Jamie
are actually the first apprentices Rautomead has taken
on in over four years, their predecessor having completed
his apprenticeship last summer.
Nor will the two young apprentices be missing out on
their academic studies throughout the period of their
apprenticeship with tuition being provided one day a week
by local Angus College.
4. continuouscasting.com issue 12 March 20124
A TECHNOLOGICAL BREAKTHROUGH
Every successful organization has
its ‘Eureka moment’ and it’s no
different with Rautomead Limited
of Dundee, Scotland. Rautomead
was founded in 1978 to exploit the
technology of continuous casting of
non-ferrous metals. But, from the
outset, Rautomead was not interested
in being a ‘me too’ manufacturer. So,
even though the company’s starting
point was the patented “Unicast”
process, originally developed in the
1950s for the production of semi-
finished brass and bronze bars
used in the manufacture of fine wire
mesh, its introduction of graphite
crucibles became the key element
in transforming a process that was
to score heavily over its competitors
who were still employing outmoded
methods of induction heating
MATERIAL GAINS
The materials for the production
of which this innovative process
was initially developed were leaded
brasses for applications in forged
and machined brass components for
the building, electrical, gas and water
industries, soon to be supplemented
by leaded and unleaded bronzes.
SMALL SCALE, BIG ADVANTAGE
A major problem for brass forging
and machining companies back then
consisted of the fact that scrap and
machining swarf, often 30% or more
of the input material,would need to be
returned to the large brass extrusion
mill for reprocessing before being
re-sold at a premium to the secondary
producer. Rautomead’s solution,
having made the continuous casting
of brasses and bronzes possible on
a relatively small scale, consisted of
locating a continuous casting machine
on the premises of the secondary
producer enabling in-house recycling
with its attendant cost savings.
CASTING FURTHER AFIELD
Aswordofthecompany’stechnological
innovations spread beyond these
shores, and in response to increasing
demand from Malaysia, Australia
and New Zealand, Rautomead
began designing equipment which
could be operated successfully and
safely without the manufacturer’s
intervention and initiating training
programmes for operatives with a high
standard of technical support.
STRIKING GOLD (AND SILVER)
The totally enclosed graphite
containment system lent itself
perfectly to the production of strip and
wire rod production in a wide variety
of gold and silver alloys using a range
of smaller machines which shared the
same basic technical features as their
larger equivalents.
The unique characteristics of the
carbon melt containment process
and the resultant high quality of the
cast product led the Royal Mint to
first appoint Rautomead in 1985 to
continuously cast 22- carat gold strip
for the production of bullion coins.
And, since then, mints around the
world have followed suit making
substantial savings in production
costs and significant improvements in
product yield.
The process has also been widely
used in the manufacture of gold and
silver jewellery alloys, palladium,
gold and silver dental alloys and
lead frame alloys for the electronics
industry, eventually leading to the
development of the RVS and RMJ
table-top machines.
RAUTOMEAD GRAPHITE
CONTINUOUS CASTING
TECHNOLOGY: A CONTINUOUS
PROCESS OF IMPROVEMENT
5. continuouscasting.com issue 12 March 20125
ATTAINING NEW STANDARDS
In the second half of the 1980s interest
was growing in the continuous casting
of high melting point alloys which
were incompatible with a standard
carbon based containment and
casting die system. To meet this
need, Rautomead developed high
alumina ceramic linings for the
melt containment and boron nitride
composites for casting die linings,
while retaining the use of resistance
heatingandagraphitemothercrucible.
DEVELOPING THE CAPACITY
Also in the late‘80s,the larger RX 1100
and RX1400 models were developed
to meet the growing need for larger
capacity horizontal machines with
up to eight strands in production of
Si1.5-3.5Cu silicon-bronze as low
temperature brazing alloys and also
for Mg0.1-0.5Cu trolley wire rod.
These machines have also been
supplied for making copper and brass
extrusion billet in sizes up to 250mm
diameter, including hollow billet for
tube manufacture.
ONWARDS AND UPWARDS
In 1991, the decision was taken to
adapt the process for the continuous
casting of 8mm diameter Cu-OF rod,
using a single combined melting and
casting furnace.
This involved the reorientation of the
process to cast vertically upwards,
using a twin chamber graphite
crucible. The first such machine was
sold in 1994 and, since then, a total
of 45 machines have been supplied to
30 customers in 23 countries around
the world.
REDUCING OXYGEN
Once again, the key differentiating
feature of the Rautomead upwards
vertical process was the use of a
graphite containment system and
electric resistance heating, compared
with channel induction heating with
rammed ceramic furnace linings.
With either system, it is necessary to
reduce oxygen to less than 10 ppm to
achieve an adequate casting die life
and economically-viable performance.
Early design studies, however, proved
that oxygen could be reduced in a
graphite system to close to zero in
a dwell time of around 3 hours with
the Rautomead crucible capable of
providing a dwell time well in excess
of this.
What’s more,the Rautomead system is
virtually failsafe since it is practically
impossible for the operator to make a
product that is not oxygen-free. While
a much smaller furnace can be used
than that required in a single furnace
induction-heated system where the
only means of oxygen reduction is the
metal cover.
LOW VOLTAGE, HIGH PERFORMANCE
Yet another special feature of the
Rautomead furnace design is low
voltage electric resistance heating.
A mains transformer is supplied as
part of the principal equipment which
transforms the voltage down to a
secondary 36 volts.
Operating at low voltage, the system is
remarkably energy efficient, requiring
around 320-330 kWh per tonne of
copper for melting,holding and casting
combined. While the low voltage
required also makes it extremely safe
for the operator.
AN AUTOMATIC CHOICE
The control systems used on
Rautomead upwards vertical casting
machines incorporate a high level of
automation, removing the need for a
full time operator.
Alarmed parameters are accessible
through the main user control console,
sensitive parameters can be locked
off, over 30 production parameters
are constantly monitored, records are
stored in the control system and can
be downloaded to an external computer,
while remote plant monitoring enables
status interrogation by computer
orphone.
A POWERFUL ARGUMENT
Another powerful argument for the
Rautomead design is in the way it
reacts to mains power failure with a
battery-operated emergency hoist
being automatically deployed to lift the
super-coolers from the molten copper
to immediately secure the system.
BRASSES AND BRONZES
The development of the Rautomead
upwards vertical casting process has
naturally led to further applications.
For example, upwards vertical casting
testsimmediatelyshowedasignificant
improvement in the casting speed and
physical properties of Zn30 Cu brass,
Sn5-8 Cu bronze and Zn25 Ni12-18 Cu
nickel silver wire rods.
More recently, the same process has
been harnessed for the production of
binary brasses, Zn40Cu and Zn35Cu,
cast at 8mm instead of 16mm,
reducing downstream working time
and production costs.
There were obvious advantages in
adopting the upwards vertical system
for casting Ni-silver, too, enabling
the simpler, lower cost vertical tooling
to be changed with minimal downtime.
A HIGH SPEED PROCESS
FOR HIGH SPEED TRAINS
Rautomead’s horizontal machines
have been producing Cu-Mg alloys
fortrolleywiresince1990.However,the
horizontal process is relatively slow
and costly. As a result, an extensive
series of tests was carried out in
1997 to investigate the upwards
6. continuouscasting.com issue 12 March 20126
vertical casting of 30mm diameter rod
in Cu-Mg alloys. The totally enclosed
nature of the Rautomead upwards
vertical process and its external
resistance heating source were found
to produce consistent quality Cu-Mg to
tight alloy tolerances.
Cu-Mg is currently the preferred
alloy for the profiled contact wire and
stranded messenger and dropper
wires used in many of the world’s high
speed rail systems (operating at over
300 kms/hour), offering low resistivity
and tensile strength.
THE QUEST CONTINUES
Thispatternofcontinuousimprovement
is testament to Rautomead’s
commitment to the enhancement of
the continuous casting process and its
tireless quest to extend its application
to new materials.
Development projects currently being
undertaken by Rautomead include:
SAVING BRASS: AND THE PLANET
Given the ever-growing demand for
eco-friendly materials, in 2006-7
Rautomead developed a system to
cast Ecobrass to near net shapes and
high quality cast surfaces in order to
avoid further downstream processing
and enable the cast product to be
used as suitable feed material for CNC
machining operations.
Once again, the use of graphite proved
the key to the project’s success
in combining withdrawal pulsing
techniques with careful selection of
graphite grade for the casting die to
achieve a consistent high quality as-
cast surface over prolonged periods.
CRACKING ANOTHER PROBLEM
Since the adoption of 8mm as the
common redraw standard for wire
and cable making, there has been an
increasing demand for higher quality
from as-cast Cu-OF processes.
The problem is that conventional
quality 8mm Cu-OF rod is suitable for
enamelled wire of no more than 1.8mm
diameter.In larger enamelled diameter
wires, standard (HVCT) current tests
have revealed cracks in the magnet
wire. In the light of this, Rautomead
developed a system to produce
rod of the highest quality on a
consistent basis on a multi-strand
production scale.
This work continues with the objective
of optimizing the sequences to
achieve consistently high quality.
CuCrZr ROD. BUCKING
CONVENTION AGAIN
The conventional method for
processing this alloy uses an initial
billet cast vertically downwards by
a direct chill system. This is then
extruded to rod which undergoes
further thermal treatments and
mechanical reductions to make semi-
finished products.
The possibility of reducing processing
costs has led to interest in the
continuous casting of both Cu-Cr
and Cu-Cr-Zr alloys. As a result,
Rautomead has undertaken
development of a vertical casting
system to cast rod between 25 and
30mm diameter at rates from 100 kg/
hr/strand to a structural quality which
lends itself to cold working from the
as-cast state.
The use of graphite has again been the
keyinexploratorytrialstocontroloxide
levels through its naturally reducing
environment.
R&D work continues.
A REDUCTION IN COST, NOT QUALITY
Rautomead’s RS CC model offers a
lower cost alternative to its existing
range of RS upwards vertical casting
machines. But, while the output
capacity might be lower than the
larger RS models, the RS CC provides
the same capabilities for casting high
quality Cu-OF and high Cu alloys.
The machine is configurable to cast
a range from 8 to 22 mm diameter
and is suited for wire and cable
applications as well as input feedstock
for continuous extrusion operations of
Cu-OF and Cu-Ag alloys..
RE-DRAWING THE BLUEPRINT
Zn products have traditionally been
continuous cast in the region of 10
– 22mm diameter while other larger
products of non-round sections
continue to be produced through
extrusion of billets that have been
initially static or continuous cast.
However, Rautomead has developed
a vertical system to cast re-draw
8mm diameter up to rates 105 kg/hr
(5m/min) of suitable qualities for hot-
drawing to smaller wire gauges.
While the continuous casting of Zn
billet is another Rautomead solution
to replace static casting methods in
diameters ranging from 55 to 120mm.
The objective is ambitious but
achievable: the production of as-cast
billet with consistently high surface
quality and high integrity internal
structure with production quality
maintained for long periods.
7. continuouscasting.com issue 12 March 20127
Continuous casting technology specialist Rautomead
Limited of Dundee, Scotland has revealed details of an
innovative 5 year collaboration with Brunel University.
As part of its ‘Advancing Metals Technology’ initiative,
the company has been working in partnership with the
university’s ‘Brunel Centre for Advanced Solidification
Technology’ department (BCAST) to develop an entirely new
process for extruding aluminium alloys in the semi-solid
state that will significantly reduce energy consumption and
improve grain structure.
THE RHEO EXTRUSION PROCESS
The Rheo Extrusion (RE) process is a patented technology
developed at BCAST for the production of high quality, low
costmagnesiumwroughtproducts.Theprocessinnovatively
adapts the established high shear dispersive mixing action
of the twin-screw extruder to in situ production of SSM
slurry with fine, spherical solid particles followed by direct
extrusion of the semi-solid slurry into rods,tube or complex
extruded profiles.
Harnessing Rautomead’s wealth of experience in dealing
with molten metals and using special materials and
techniques, the BCAST team designed and built from
scratch a more “heavy duty” trials machine than previous
models, one designed to process a range of aluminium
alloys in a more production-scale level. This prototype
machine is currently undergoing trials to establish the
viability of commercial production.While currently focussed
on aluminium alloys, a long term objective for the team is
to ultimately use the technology in the higher-temperature
environment of copper and copper alloys.
ADVANCING METALS TECHNOLOGY
‘Advancing Metals Technology’ is a new and scientifically-
based metals research and development division within
Rautomead with a specific focus on the scientific
exploration and development of non-ferrous metals and
processes to drive improvements in metallurgical efficiency
in a wide range of global production processes and end-
user applications.
In addition to pursuing in-
house research projects,
the new division’s mandate
also covers involvement in
a wide range of individual
projects with universities and
research groups in the UK and
overseas of which the ongoing
collaboration with BCAST is a
high profile example. Further
collaborations will be sought
with both existing and prospective customers,with the goal
of providing new and innovative processes and products
within the non-ferrous metals technology market.
Through harnessing its market-leading expertise in the
field of graphite technology and transferring the skills
it has developed in continuous casting as the basis for
these collaborations, the division’s objectives consist of
developing imaginative and economical technological
solutions with operating systems that will offer the end user
significant application improvements in the next generation
of Rautomead machines.
Specific objectives consist of innovating technologies
which are clean, safe and environmentally-friendly, shorten
the manufacturing process,provide economies on the small
to medium scale, recycle materials, reduce operating costs
and enhance product quality.
CASTING AROUND FOR THE RIGHT PARTNERS
The selection of BCAST as a suitable partner represents,
for Rautomead, the result of a long and exhaustive search
for a research partner whose vision and innovative
thinking in the field of academic research would prove
to be the perfect complement for Rautomead’s practical
experience and expertise in the commercial world of
molten metal technology. But the ‘Rheo Extrusion’ project
merely represents the first collaboration between the
university and Rautomead, with a number of other spin-off
projects also currently in the pipeline. While the ‘Advancing
Metals Technology’ division’s search for further suitable
partners, both in academia and industry, continues. As
Rautomead Managing Director Brian Frame remarks: ‘We
have believed for some time that the wide range of skills
we have developed over the years provides the potential
for applications that go way beyond our core business of
continuous casting. And this new initiative, with input from
the relevant research partners,is providing us with a unique
opportunity to demonstrate just that’.
COLLUSION IMPROVES EXTRUSION
FOR RAUTOMEAD’S NEW DIVISION
8. Interest in equipment
for the production of
gold and silver coinage
strip from continuous
casting technologies
specialist Rautomead Limited of Dundee, Scotland has
continued unabated with the company’s announcement of
three particularly significant orders from the Far East.
Rautomead supplied RMJ/H 025 table-top continuous
casting machines for casting fine gold and silver strip to
the Shanghai Mint and Shenyang Mint in China, both of
which are state-owned through China Banknote Printing
and Minting Corporation. Rautomead also supplied an
RMJ/H025 to the Royal Thai Mint in Thailand.
The contracts with the Shanghai Mint and the Royal
Thai Mints are significant because they are repeat
orders confirming the strength of Rautomead’s ongoing
relationships and the contract with the Shenyang Mint is
significant because the Rautomead machine will replace
existing equipment.
A YEN FOR CONTINUOUS CASTING
The Shanghai Mint installed its first Rautomead continuous
casting machine, an RMJ/H025, for processing gold
and gold alloys, way back in 1991 with a second, larger,
RMTmodel casting machine following on in 1994.In 2009/10
the Shanghai Mint opened a new factory facility and, in
an expansion of production capacity, installed a second
Rautomead RMT continuous casting line incorporating
an in-line cut to length saw. The latest new RMJ/H 025
machine was installed during 2011 and is the fourth
Rautomead machine supplied to the Shanghai Mint.
INTEREST IN CONTINUOUS CASTING FOR GOLD
AND SILVER CONTINUES APACE FOR RAUTOMEAD
The Royal Thai Mint installed its first Rautomead RMJ/H 025
model continuous casting machine with in-line cut to
length shear in 1996. During 2010 a second RMJ/H025
machine doubled the installed precious metal continuous
casting capacity at the Mint’s new factory close to the
Don Muang airport in Bangkok. The machine was supplied
complete with an automated ingot feed system as well as
an automated cut to length shear.
MAKING A MINT FOR INVESTORS
Global investment in precious metals continues to boom
with investors looking for less risky alternatives to stocks
and shares. As Rautomead Sales Manager Guy Henderson
remarks“We have seen a considerable increase in enquiries
for our precious metals casting models from all round
the world in recent months. These significant orders from
China and Thailand are further confirmation that demand
is likely to remain strong”.
THE CRUCIAL CRUCIBLE
The Rautomead casting process is based on the use of
a graphite crucible, surrounded by electric resistance
heating elements which provide the power to melt and hold
the metal charge. Heating is by thermal radiation and
heat convection. The interior of the furnace case is filled
with nitrogen gas to protect the hot-working graphite
components. Silver in particular
has a strong propensity to attract
oxygen in the molten state. The
totally enclosed nature of the
Rautomead process, where the
molten metal is in contact only with
the pure carbon surfaces of the crucible
and casting die, is particularly suitable for
casting silver because it eliminates any residual oxygen.
ROBUST, RELIABLE AND SAFE
Though many features of the Rautomead process have been
developed refined and improved over the years, the core
graphite technology remains as it was originally designed,
over twenty years ago. The machines have proved robust,
reliable and safe to operate with many of the early machines
still in daily use today.
CASTING FAR AND WIDE
In all, Rautomead has supplied over 150 continuous
casting machines for the processing of gold and silver
alloys for coinage strip, jewellery, electronics and dental
alloy applications. The special features of these machines,
along with over thirty years’ experience in graphite furnace
technology, have cast Rautomead Limited as the number
one choice for mints all over the world.
ONGOING TIES WITH THAILAND
Rautomead Limited
Nobel Road
Wester Gourdie Industrial Estate
Dundee DD2 4UH
Scotland,UK
Tel: +44 (0)1382 622341
Fax: +44 (0)1382 622941
email: sales@rautomead.com
www.rautomead.com