Description of continuous casting and history

In production of our wares we use one of the prospective methods to cast copper alloys - continuous casting. This method of metal casting is most effective, if it is necessary to manufacture semi-finished products of standardized form in large series. This method provides increased control over the process through automation. Equal and continuous supply of metal, its crystallization and removal of the product allows obtaining a homogeneous semi-finished metal product during the casting process. Through the use of intensified cooling with water it is possible to increase the speed of crystallization. Choosing the right speed there can be a focused crystallization in the material (basically lengthwise to the cast axe) achieved and dense bars, semi-finished products and such with a fine structure of crystals and even chemical composition produced.

Continuous casting allows to produce a wide range of different profiles: cylindrical bares, tubes, square bares and tubes, hexagonal profiles, slabs of various thickness and width etc. This method allows achieving any profile form which is possible to flare through the crystallizer.

The advantages of continuous casting

The use of continuous casting gives a range of advantages in comparison to conventional casting in moulds:

• continuous casting is perfect for manufacturing semi-finished products (bars, slabs) of long sizes;
• the microstructure of long semi-finished products is even and due to this there is less possibility for arising of tension in the product and the finished parts made from such products will be more durable;
• continuous casting reduces metal cuttings and loss of metal compared to casting in moulds;
• continuous casting is more economic regarding the energetic consumption;
• there are less workers needed at the production process compared to casting in moulds;
• all operations can be easily automatized and supervised;
• it is easy to modify the quality and properties  of the semi-finished products by changing the cast parameters (the pulling speed of the product, the temperature of the crystallizer’s water);
• continuous casting allows to manufacture metal slabs or bars in large amounts by short time.

 History

The first time the idea about continuous casting appeared in 1857 as Sir Henry Bessemer (1813–1898) received a patent for casting metal between two contra-rotating rollers for manufacturing metal slabs, but that time this method remained without attention. It wasn’t possible to implement this technology over the next 100 years. After that began a rapid development and frequent use of this method.

The original drawing of H. Bessemer which illustrates the principle of producing of metal slabs that is considered to be the first method of continuous casting in the world.