Rautomead Continuous Casting Technology for Strip Production

•

0 recomendaciones•503 vistas

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

Tecnología

Technology for
Copper Strip Production
Applications include
Continuous casting
1. Continuous Casting: cathode to round rod
2. Continuous Rotary Extrusion:
round rod to strip or shaped wire
3. Roll/Draw straighten cut to length:
hard and half hard lengths of strip
Copper busbar
Continuous casting
Rotary extrusion
Draw/straighten
Transformer
Copper profilesCopper strips
Paper wrapped stripTransformer strip
Rod coils up to 5,000 kg
Cathodes
n Busbar Strip
n Transformer Strip
n Commutator Sections
n Shaped Wires
n Lightening Conductors
n Copper Profiles
n Cathode to round rod:
12.5mm, 16mm 25mm diameter
n CuOF CuAg
n Clean, bright rod surface without wax
or protective coating
n Up to 5,000 kg coil weight
n Recycling “extrusion process flash”

Continuous Rotary Extrusion
Draw/Roll straighten and cut to length
Turnkey Project Management
n Round rod to shaped section
n Machine model extrusion
wheel diameter determined by
product dimensions
n Production: 500 – 3,000 kg/hr
depending on model and
product dimensions
n Recommended feedstock:
oxygen free copper rod
n Continuous production of strip
section shape up to 5,000 kg
n For Busbar manufacture
n Automated production.
Equipment specification influenced
by the level of desired automation
n Strip lengths up to 6.0m long
Available on request from Rautomead
n Project definition consultancy
n Specification of equipment scope of supply
n Coordination of equipment purchase, delivery,
installation, start up and commissioning
n Co ordination of Technical service support
Cut to length
Continuous extrusion line
Continuous rotary extrusion machine
Project Finance
Financing of Turnkey Project investment over 3 – 5 years is available (conditions apply)
Photographs courtesy: BWE Ltd, Hanaka, HMP, Meltech Confex, Metelec (Gindre Duchavany), Tusco Trafo
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
June2011

Más contenido relacionado

Más de 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.

Computational fluid dynamic simulations of solidification for enhancing speed...

Rautomead Limited

Report:- Copper has been utilised throughout early human existence as a disinfectant used to clean wounds and prevent infection. However, following the birth of antibiotics and pharmaceutical drugs, the use of copper as an antimicrobial material severely declined. Copper as an antimicrobial surface agent is now beginning to re-emerge in medical institutions due to the rise of viruses and drug resistant bacteria, known as “superbugs”, over the past century. Yet, many institutions are hesitant on the reimplementation of copper as a surface agent. This project aims to demonstrate the antimicrobial effectiveness of copper and its alloys against an E. Coli O157:H7 strain as well as displaying the potential applications that an antimicrobial copper surface agent can be applied to. Henceforth, the purpose of this project is to formulate a systematic literature review, whereby the results from other research papers will be compared and adopted into a novel concept of attempting to track bacterial transmission through the use of a video-based monitoring system.

Examination of anti-bacterial properties of Cu and Cu alloys and potential ap...

Rautomead Limited

Presentation:- Copper has been utilised throughout early human existence as a disinfectant used to clean wounds and prevent infection. However, following the birth of antibiotics and pharmaceutical drugs, the use of copper as an antimicrobial material severely declined. Copper as an antimicrobial surface agent is now beginning to re-emerge in medical institutions due to the rise of viruses and drug resistant bacteria, known as “superbugs”, over the past century. Yet, many institutions are hesitant on the reimplementation of copper as a surface agent. This project aims to demonstrate the antimicrobial effectiveness of copper and its alloys against an E. Coli O157:H7 strain as well as displaying the potential applications that an antimicrobial copper surface agent can be applied to. Henceforth, the purpose of this project is to formulate a systematic literature review, whereby the results from other research papers will be compared and adopted into a novel concept of attempting to track bacterial transmission through the use of a video-based monitoring system.

Examination of anti-bacterial properties of Cu and Cu alloys and potential ap...

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.

Continuous Casting of Dilute Copper Alloys for Drawing to Wire in Specialist ...

Rautomead Limited

PHD Thesis for Ehsaan-Reza Bagherian Summary The analysis in this PhD thesis illustrated that the metallurgical and mechanical properties of components mainly produced by continuous casting are acceptable, and that this method could be a replacement production method for materials such as lead alloys and various copper alloy rod, e.g. CuMg and CuAg.. However, in the case of Deoxidized High Phosphorus (DHP) copper tubes, the performance of the as-cast material was significantly lower than that of from extrusion or planetary rolling process.

To enable the processing of new complex high performance alloys by improving ...

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%.

Effect of water flow rate casting speed alloying element and pull distance on...

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.

Characteristics of Hypoeutectic Cu-Zr Alloy Rods Manufactured by Vertical Upw...

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

EFFECT OF ANTIMONY ADDITION RELATIVE TO MICROSTRUCTURE AND MECHANICAL PROPERT...

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.

Investigation of the distribution of lead in three different combinations of ...

Rautomead Limited

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.

BWE conform process (Continuous Rotary Extrusion)

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

Copper continuous casting

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.

Analysis and quantification of grain size in various dhp copper tubes manufac...

Rautomead Limited

On first reading, it might seem strange that Rautomead, a leading company specialising in continuous casting technology, should publish a Practical Guide on wire drawing practice in the copper wire and cable industry. Since 1994, Rautomead has supplied over fifty oxygen-free copper (Cu-OF) rod casting machines to companies all over the world, the majority of whose previous experience had been exclusively in using only tough pitch copper (Cu-ETP) rod. By its nature, the behaviour of Cu-OF in the initial stages of rod breakdown from 8mm as-cast rod is a little different from Cu-ETP. Minor changes to die drafts in older rod breakdown machines are recommended to achieve greater area reductions than may have been used previously. Rautomead is fortunate to have David Bluck as a member of the company’s technical staff. David has many years previous experience of technical management in the wire drawing industry and has been able to assist Rautomead customers both in the introduction of Cu-OF rod into their existing wire drawing lines and more generally in optimising performance of their wire drawing operations. This Practical Guide is designed to encapsulate the most common issues Rautomead has encountered in copper wire drawing, to classify the types of faults occurring and to offer practical guidelines as to how these should be overcome. The information in this advisory paper is given in good faith and with the objective of providing practical assistance. It is intended to supplement the place of technical information which may be provided for their equipment by wire drawing equipment manufacturers. Sir Michael Nairn Chairman Rautomead Limited

Rautomead Limited Wire drawing booklet

Rautomead Limited

Rautomead Limited Newsletter Issue 12 continuouscasting.com For over 30 years Rautomead Limited has specialised in the design and manufacture of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries worldwide. Rautomead plants are being successfully applied to production of oxygen-free copper, a wide range of copper-based alloys, precious metals and zinc. Forms include wire rod, straight length bars, flats and hollow sections. According to material and section, the casting process selected may be vertical upwards, vertical downwards or horizontal. The machines may be used either as integrated melting, holding and casting machines, or may be arranged to be fed with pre-alloyed molten metal. The Rautomead Continuous Casting System is based on electric resistance heating of its furnaces, with graphite containment crucibles, graphite heating elements and casting dies. This technology is particularly suited for production of high purity, high quality oxygen-free copper and copper alloy wire rods (copper silver, copper magnesium, copper tin). The upward casting equipment may be used to manufacture rods of all diameters between 8.0mm and 30mm diameter and is suitable feedstock for wire drawing and continuous rotary extrusion processes. End use applications include: superfine wire, automotive wires, contact wire and trolley wires for high speed trains, data communication cables, CTC and transformer strips as well as enamelled wires. Rautomead’s R&D facility at the factory in Dundee (casting equipment, technicians, design and operational experience) is available to companies who wish to commission experimental and research work to develop technology and tooling for the manufacture and processing of new alloys and materials. Rautomead’s partnership with the University of Dundee provides access to sophisticated laboratory equipment as well as support with analytical evaluation and academic contributions to the R&D effort

Rautomead Newsletter issue 12

Rautomead Limited

Rautomead Newsletter issue 11 pink continuouscasting.com For over 30 years Rautomead Limited has specialised in the design and manufacture of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries worldwide. Rautomead plants are being successfully applied to production of oxygen-free copper, a wide range of copper-based alloys, precious metals and zinc. Forms include wire rod, straight length bars, flats and hollow sections. According to material and section, the casting process selected may be vertical upwards, vertical downwards or horizontal. The machines may be used either as integrated melting, holding and casting machines, or may be arranged to be fed with pre-alloyed molten metal. The Rautomead Continuous Casting System is based on electric resistance heating of its furnaces, with graphite containment crucibles, graphite heating elements and casting dies. This technology is particularly suited for production of high purity, high quality oxygen-free copper and copper alloy wire rods (copper silver, copper magnesium, copper tin). The upward casting equipment may be used to manufacture rods of all diameters between 8.0mm and 30mm diameter and is suitable feedstock for wire drawing and continuous rotary extrusion processes. End use applications include: superfine wire, automotive wires, contact wire and trolley wires for high speed trains, data communication cables, CTC and transformer strips as well as enamelled wires. Rautomead’s R&D facility at the factory in Dundee (casting equipment, technicians, design and operational experience) is available to companies who wish to commission experimental and research work to develop technology and tooling for the manufacture and processing of new alloys and materials. Rautomead’s partnership with the University of Dundee provides access to sophisticated laboratory equipment as well as support with analytical evaluation and academic contributions to the R&D effort

Rautomead Newsletter issue 11

Rautomead Limited

Rautomead Newsletter issue 03 continuouscasting.com For over 30 years Rautomead Limited has specialised in the design and manufacture of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries worldwide. Rautomead plants are being successfully applied to production of oxygen-free copper, a wide range of copper-based alloys, precious metals and zinc. Forms include wire rod, straight length bars, flats and hollow sections. According to material and section, the casting process selected may be vertical upwards, vertical downwards or horizontal. The machines may be used either as integrated melting, holding and casting machines, or may be arranged to be fed with pre-alloyed molten metal. The Rautomead Continuous Casting System is based on electric resistance heating of its furnaces, with graphite containment crucibles, graphite heating elements and casting dies. This technology is particularly suited for production of high purity, high quality oxygen-free copper and copper alloy wire rods (copper silver, copper magnesium, copper tin). The upward casting equipment may be used to manufacture rods of all diameters between 8.0mm and 30mm diameter and is suitable feedstock for wire drawing and continuous rotary extrusion processes. End use applications include: superfine wire, automotive wires, contact wire and trolley wires for high speed trains, data communication cables, CTC and transformer strips as well as enamelled wires. Rautomead’s R&D facility at the factory in Dundee (casting equipment, technicians, design and operational experience) is available to companies who wish to commission experimental and research work to develop technology and tooling for the manufacture and processing of new alloys and materials. Rautomead’s partnership with the University of Dundee provides access to sophisticated laboratory equipment as well as support with analytical evaluation and academic contributions to the R&D effort

Rautomead Newsletter issue 03

Rautomead Limited

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 Newsletter issue 01

Rautomead Limited

Our precious metals continuous casting machines have graphite crucible and resistance heating technology for high purity high quality continuous cast material. Machines may be used as batch casting machines or continuous casting, they may be feed with either liquid metal, alloyed grain or virgin metals depending on production quantity and cast section. A wide range of machine sizes and specifications are available for precious metals processing, including gold and silver based alloys for: jewellery, as sheet, rod and tube electronics industry as lead frame alloys and contact materials dental industry minting industry, as bullion coinage strip Bonding wire rod, 99.999 purity gold Examples of finished final products which can be manufactured using these continuous casting machines for precious metals include: Gold and silver coins Medals Gold bonding wire Jewellery, silver picture frames, silver cutlery Dental alloys Electronic lead frame material Sputtering targets for glass coating Silver flutes

Rautomead precious metals continuous casting technology

Rautomead Limited

Rautomead rs cu of technology

Rautomead Limited

RAUTOMEAD TECHNOLOGY FOR UPWARDS CONTINUOUS CASTING OF COPPER ALLOYS

Rautomead Limited

Más de Rautomead Limited (20)