Technology
Casting Process Overview
From raw cathode copper to finished busbar or rod — the complete upward continuous casting process, step by step.
Raw Material Preparation
Cathode copper (Grade A, ≥99.95% Cu) or selected clean scrap is loaded into the melting furnace. Material traceability records are initiated at this stage.
Induction Melting
The induction furnace heats copper to the casting temperature (typically 1120–1160°C). Electromagnetic stirring ensures a homogeneous melt composition. A protective atmosphere or flux cover prevents oxidation during melting.
Temperature Holding & Transfer
Molten copper transfers to a holding or tundish furnace that maintains constant temperature ±5°C before the casting crystallizer. This buffer stage decouples melting rate from casting speed.
Upward Casting
The graphite crystallizer die is submerged below the melt surface. Solid copper profile is withdrawn upward at controlled speed. The submerged inlet prevents air contact with the melt.
Secondary Cooling
The freshly solidified profile passes through a closed-loop water cooling zone immediately above the die. Cooling rate is controlled to achieve the target grain structure and dimensional stability.
Traction & Withdrawal
Servo-driven traction rolls pull the profile at precise speed. Speed control is closed-loop with feedback from the crystallizer temperature sensors. Multi-strand lines run each strand independently.
Cutting & Coiling
The profile is cut to required length by flying saw or shear. Flat bar is stacked in bundles; rod or strip is coiled on the takeup spool.
Inspection & Documentation
Dimensional check, surface inspection, and conductivity test on each bundle or coil. Production data (speed, temperature, time) logged and attached to the shipment certificate.
Key Process Parameters
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