THE RAUTOMEAD UPWARDS VERTICAL CONTINUOUS

CASTING PROCESS

by

S a ndy R. Cochra ne , C.Eng., M. Ins t. E., L.R.S .C.

S ir Micha e l Na irn, Bt, M.B.A.

Dire ctors , Ra utome a d Inte rna tiona l Limite d,

Dunde e , U.K.

P a pe r pre s e nte d a t the

Inte rna tiona l Wrought Coppe r Council Confe re nce

Ma a s tricht, Ne the rla nds

Octobe r 1995

(e dite d a nd upda te d Nove mbe r 1996)

1
 THE RAUTOMEAD UPWARDS VERTICAL CONTINUOUS
CASTING PROCESS

BACKGROUND
The Ra utome a d compa ny ha s s pe cia lis e d s ince its ince ption in 1978 in the de s ign a nd cons truction of
continuous ca s ting ma chine s for ma nufa cture of finis he d products in non-fe rrous a nd pre cious me ta ls .
The a pplica tions of Ra utome a d’s te chnology ha s be e n ove r a wide s pe ctrum of indus trie s : a utomotive ,
e le ctronics , je we lle ry, numis ma tics , building products , me dica l a nd ge ne ra l e ngine e ring. Ove r 180
ma chine s ha ve be e n built, the ma jority of which ha ve be e n horizonta l mode ca s ting ma chine s
a lthough, s ome ha ve be e n of the downwa rds ve rtica l type .
A s pe cia l fe a ture of Ra utome a d te chnology is the us e of a fully gra phite line d conta inme nt s ys te m for
the molte n me ta l , us e d in conjunction with s ubme rge d gra phite ca s ting die s with ine rt ga s prote ction.
Ma ny of the ins ta lla tions a re s e t up a s combine d me lting, holding a nd ca s ting units , though s ome of
the la rge r ma chine s a re configure d to be fe d with molte n me ta l from s e pa ra te pre -me lting furna ce s .
The us e of mode rn high qua lity gra phite ma te ria ls ha s prove d to be a thoroughly s a tis fa ctory ba s ic
de s ign fe a ture of the e quipme nt. Gra phite is a s upe rb high te mpe ra ture e ngine e ring ma te ria l, a n
e xce lle nt he a t s us ce ptor which is highly s ta ble a t e le va te d te mpe ra ture s a nd is not we tte d by mos t
liquid me ta ls . It a cts a s a ne utra l to re ducing e nvironme nt for conta ining ma ny ma te ria ls , whe re it
che mica lly re move s s ome of the oxide s which ma y be pre s e nt in me lts a nd is thus conducive to
a voida nce of ma ny inclus ion proble ms a s s ocia te d with othe r ca s ting te chnique s which e mploy ine rt
ce ra mic line d me lt ba th conta inme nt s ys te ms . Ea ch crucible is ma chine d from a s olid block of
gra phite , a nd. with prope r ca re , long life ca n be e xpe cte d. A cus tome r in the bra s s indus try ha s
a chie ve d a life of ove r e ight ye a rs from a s ingle crucible in re gula r da ily production.
Ra utome a d ca s ting furna ce s a re e le ctrica lly he a te d, us ing low volta ge gra phite he a te r e le me nts
a round the crucible . An ine rt ga s a tmos phe re is a pplie d to give prote ction to the he a te rs a nd the
crucible its e lf. P owe r is provide d to e a ch ma chine from a double wound ma ins tra ns forme r, us ing
s olid s ta te thyris tor powe r control a nd re gula tion.
The ca s ting ma chine s a re e xte ns ive ly us e d to ca s t a t ne a r ne t s ha pe , thus a ffording to the us e r the
e conomic be ne fit of a s ignifica nt re duction in the proce s s s te ps to a fina l product. De pe nding on the
ma te ria l, this ma y a ls o e limina te the ne e d for highly ca pita l/la bour-inte ns ive hot me ta l e xtrus ion a nd
hot a nd cold rolling of bille ts a nd la rge r dia me te r wire rods .

Upwards Vertical Continuous Casting

Ove r ma ny ye a rs , Ra utome a d ha d be e n re que s te d to provide continuous ca s ting ma chine s for the
production of 8mm dia me te r high conductivity coppe r rod, but it did not prove pos s ible to produce
this product s a tis fa ctorily by e ithe r the horizonta l or downwa rds ve rtica l proce s s e s . De ve lopme nt of
the upwa rds ve rtica l continuous ca s ting proce s s comme nce d in 1992 a nd it wa s la unche d a s the RS
s e rie s of continuous ca s ting ma chine s a t the Wire Exhibition, Dus s e ldorf in April 1994.

The Design Objective

The funda me nta l de s ign obje ctive wa s to produce a s e rie s of ma chine s for the production of 8mm
dia me te r oxyge n-fre e high conductivity coppe r rod which we re :
- e conomic to ope ra te
- from a ca thode fe e ds tock
- a llowing a ddition of s ome mill a ris ings of s cra p
- ca pa ble of high qua lity a nd cons is te nt producti
on
- re lia ble a nd s a fe
- s imple to us e a nd to ma inta in
- s ma ll to me dium s ca le e .g. 2,000-12,500 tonne s /ye a r, pe r ins ta lle d unit ma chine

2
 Model RS 2200/8/8 Continuous Rod Casting Machine

Basic Criteria

Design
The ba s ic de s ign wa s to be ba s e d on Ra utome a d’s we ll prove n gra phite me lt conta inme nt te chnology
a nd us ing s ubme rge d die s with ine rt ga s prote ction. This is proba bly the be s t me ta llurgica l s ys te m
which e xis ts in the world for me lting, holding, a nd ca s ting ma ny coppe r ma te ria ls . He a ting wa s to be
by low volta ge e le ctric high inte ns ity gra phite he a te r e le me nts , us ing s olid s ta te microproce s s or
control a nd powe r re gula tion, to provide the ultra -s ta ble te mpe ra ture re gime e s s e ntia lly re quire d.

Single Furnace
To conta in the e quipme nt ca pita l cos t a nd to minimis e the la bour re quire d to ope ra te it, the pla nt wa s
de s igne d for inte gra te d s ingle furna ce me lting, holding a nd ca s ting ope ra tion. This brought with it
othe r be ne fits - nota bly the e limina tion of hot me ta l tra ns fe r, with its a s s ocia te d pote ntia l proble ms of
he a t los s a nd oxyge n pick-up. With pure coppe r, the que s tion of a lloy a djus tme nt in a s e pa ra te
me lting furna ce , be fore committing to the ca s ting proce s s did not a ris e .

Oxygen-Free Product
A na tura l cons e que nce of the inhe re nt de s ign of the Ra utome a d e quipme nt by the re ducing e ffe cts of
the gra phite me lt conta inme nt s ys te m, wa s tha t the product wa s wholly oxyge n fre e . This is a n
importa nt e le me nt in contributing to good gra phite ca s ting die ins e rt longe vity, whe re oxyge n a tta ck
from the me lt ca n be one of the ma jor ca us e s of we a r a nd fa ilure . The product ha s typica lly le s s tha n
5 ppm oxyge n conte nt. An inte rna l s pe cia lly pa cke d be d of s ma ll gra phite ring s ha pe s is
incorpora te d into the ba s e s e ction of the crucible , s o tha t the liquid coppe r tra ns fe rring from the
me lting cha mbe r of the crucible to the ca s ting die cha mbe r, pa s s e s through this re gion of high s urfa ce
a re a of gra phite , the re by e ns uring tha t the me lt be come s truly oxyge n fre e .

3
Output
S e ve ra l fa ctors ca me toge the r in de te rmining output. A re te ntion time of the molte n coppe r in the
gra phite crucible s ys te m of a pproxima te ly 3 hours wa s de te rmine d a s ide a l. Crucible ca pa citie s we re
s e le cte d s uch tha t gra phite blocks wide e nough to a cce pt whole coppe r ca thode pla te fe e ds tock could
be us e d. This conve nie ntly a llows for ma chine s of ca pa citie s of 4, 8, a nd 12 s tra nds , e qua ting to
typica l pla nt outputs of 2,500, 5,000 a nd 7,500 tonne s /ye a r of 8 mm dia me te r coppe r wire rod. Ea ch
s tra nd runs a t a minimum ca s ting s pe e d of 3.1 me tre s pe r minute .
From the initia l s pe cifica tion la id out, a whole ra nge of ma chine s ha ve now be e n de s igne d to
a ccommoda te a nnua l output tonna ge s ra nging from 2,000 tonne s upwa rds .

Operating Cost
A prime ope ra ting cos t of not more tha n a pproxima te ly £50 pe r me tric tonne of good qua lity rod
produce d, ba s e d on cos ts a pplica ble in UK wa s cons ide re d ne ce s s a ry for e conomic via bility. The
a ppe ndice s s how s ome typica l prime cos ts to produce .

Features of Rautomead RS Series Casting Machines

Energy Conservation
The furna ce is de s igne d for long pe riods of uninte rrupte d production. It is ins ula te d inte rna lly to a
high s ta nda rd with low the rma l ma s s ins ula tion to a chie ve a n e xte rior furna ce s he ll te mpe ra ture not
e xce e ding 40 de g C a bove a mbie nt. The e nclos e d na ture of the proce s s a ls o contribute s s ignifica ntly
to e ne rgy cons e rva tion. Ene rgy re quire me nt of the mode l RS 2200/8/8 in continuous production of
coppe r rod is a pproxima te ly 370 kWh pe r tonne of rod produce d.

Temperature Control
The furna ce crucible compris e s two dis tinct cha mbe rs - a me lting cha mbe r a nd a holding /ca s ting
cha mbe r. He a ting is bia s e d towa rds the me lt s ide . Two s e pa ra te the rmocouple s a re pos itione d within
the furna ce s ys te m, a nd by us ing a micro-proce s s or ca s ca de control s ys te m for the thyris tor powe r
re gula tion s ys te m, te mpe ra ture s clos e to the ca s ting die pos ition a re ma inta ine d within a ba nd +/- 5
de g C to s e t point. This de gre e of me lt te mpe ra ture control a nd s ta bility is e s s e ntia l for the s ucce s s ful
production of the highe s t qua lity products .

Cathode Feed
Ca thode fe e d is s e mi-a utoma tic, us ing a pick-a nd-pla ce a rra nge me nt. A s uction pa d is us e d to lift
individua l ca thode s from a pile pos itione d clos e to the ma chine a nd to tra ns fe r the s e to a tilting fe e d
ta ble a bove the fe e d orifice of the ma chine . The fe e d ta ble is e quippe d with a pne uma tic cla mping
de vice which holds the tra iling e dge of the ca thode a nd lowe rs it into the molte n ba th in a controlle d
ma nne r. An e le ctronic inte r-link is provide d to pre ve nt ove r-filling of the furna ce .

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Section Through Model RS2200/8/8 Upwards Vertical Continuous Casting Machine

5
Metal Cover

A critica l a s pe ct of ope ra tiona l importa nce is tha t the s urfa ce of the molte n me ta l a t both the fe e d a nd
ca s ting cha mbe rs a re cove re d by a la ye r of fine gra phite powde r, which prote cts the me lt s urfa ce from
oxida tion. This gra phite fla ke powde r a ls o re a cts with oxide s which ma y be pre s e nt on the s urfa ce of
the ca thode - a ll conducive to a chie ving a truly oxyge n-fre e product. The gra phite powde r is a
cons uma ble ite m, with cons umption of a pproxima te ly 1.25 kgs pe r tonne of rod produce d.

Casting Dies
Ca s ting die s a re s ma ll tubula r gra phite ins e rts , ma chine d from high qua lity fine gra ine d ma te ria l.
The s e a re fitte d into s upe r-coole r die a s s e mblie s , compris ing a ca s ting ins e rt, a s e rie s of s e conda ry
ba cke r ins e rts a nd a multiple wa ll coppe r cooling ja cke t, through which cooling wa te r is circula te d.
Ea ch a s s e mbly is cla mpe d into pos ition in a fra me a bove the crucible a nd the lowe r e nd of the ca s ting
die is s ubme rge d to a pre de te rmine d de pth in the molte n me ta l. The fra me is a rra nge d to move up or
down by me a ns of a n a utoma tic optica l le ve l control to ma inta in a cons ta nt imme rs ion de pth, re la tive
to the s urfa ce of the me ta l.

Model RS 2200/8/8 Continuous Rod Casting Machine

elevation, showing cathode feed arrangement

6
Rod Withdrawal
Rod withdra wa l is e ffe cte d by us ing double pinch roll tra ns porte r me cha nis ms , pos itione d a bove the
s upe r coole r die a s s e mblie s . The s e compris e drive n, profile d withdra wa l rolls mounte d on s ha fts ,
oppos e d a nd pre s s uris e d pne uma tica lly by profile d idle r rolls . P ne uma tic pre s s ure is a djus ta ble on
e a ch pa ir of rolls individua lly, thus pe rmitting one s tra nd to be s ta rte d a nd s toppe d inde pe nde ntly of
the othe rs .
In 8 or 12 s tra nd ma chine s , two s e pa ra te drive s a re fitte d, e na bling gre a te r ve rs a tility of production to
be a chie ve d. S ta nda rd withdra wa l drive is in a puls e d fa s hion us ing a va cuum a ctua te d clutch-bra ke
s ys te m, which is ca pa ble of producing we ll ove r 1,000 puls e s pe r minute . For coppe r a lloy work, a
compute r controlle d AC s e rvo drive ma y be a lte rna tive ly s pe cifie d.
The rods e me rging from the ma chine a re fully s oft. Exit te mpe ra ture is cha ra cte ris tica lly le s s tha n
100 de g C a nd the ma te ria l thus ha s a bright cle a n s urfa ce finis h.

Model RS 2200/8/8 Continuous Rod Casting Machine

plan view with cathode feed and coilers

Coiling
J umbo rod coile rs a re provide d a s s ta nda rd e quipme nt to coil the product into we ll orde re d la ye re d
coils of 4 - 5 me tric tonne s to fa cilita te s imple pa y off to the wire dra wing ma chine . Whe re cus tome rs
pre fe r, Ra utome a d offe rs to provide a kit of proprie ta ry compone nts with the ne ce s s a ry dra wings a nd
ins tructions , to pe rmit the coile rs to be fa brica te d a nd a s s e mble d loca lly. Whe re s ma lle r coil we ights
a re re quire d, rod down coile rs with a coil ca pa city of 2.5 tonne s a re a va ila ble a lte rna tive ly.
Coils ma y be ha ndle d e ithe r by fork lift truck or by ove rhe a d cra ne , a ccording to the fa cilitie s
a va ila ble .

7
Other Materials
While the principa l purpos e of the RS s e rie s ca s ting ma chine s is the production of oxyge n-fre e high
conductivity rod, the ma chine s ma y a ls o be us e d for production of s ilve r-be a ring coppe r, a nd othe r
coppe r a lloys . Alloying compone nts ma y be introduce d into the me lt a s s ocia te d with a n ine rt ga s
bubbling fe a ture , whe re by ga s is bubble d from the ba s e of the crucible to provide s tirring a nd
thorough mixing of s ilve r with the coppe r.

While not the s ubje ct of this pa pe r, pa s s ing re fe re nce is a ls o ma de to the production of high coppe r
a lloys , bronze s , bra s s e s a nd nicke l bra s s e s , us ing the Ra utome a d upwa rds ve rtica l ca s ting proce s s .
S ignifica nt re s ults ha ve be e n a chie ve d in the production of ce rta in a lloys , with s ubs ta ntia lly highe r
ca s ting s pe e ds tha n is pos s ible with horizonta l ca s ting. Downs tre a m proce s s ing cha ra cte ris tics of
the s e ma te ria ls a re a ls o e xce lle nt, whe n the y ha ve be e n produce d us ing the optimum ca s ting
pa ra me te rs a nd s e ttings .

Operators
One pa rt-time ope ra tor pe r s hift is re quire d to run the ma chine . The ope ra tor’s principa l function is
to pa trol the proce s s a nd to monitor the pe rforma nce e a ch ma jor compone nt of the ma chine ’s s ys te ms
from the ca thode fe e d through to rod coiling. Ca s ting die s mus t be cha nge d a pprox. e a ch we e k of
production. Coils of rod re quire to be re move d a nd re -s ta rte d a pprox. e ve ry 50 - 60 hours or 5
tonne s . Additiona l pa rt time a s s is ta nce is re quire d to pre pa re s upe r coole r die a s s e mblie s a nd a t s ta rt-
up of the ma chine .

Operating Hours
The RS s e rie s ma chine s run a t the ir mos t e fficie nt on a continuous ba s is , s e ve n da ys pe r we e k. In
norma l circums ta nce s , it s hould not be ne ce s s a ry to s top the ma chine for ma inte na nce a tte ntion more
fre que ntly tha n e a ch s ix months . If, for othe r re a s ons , it is ne ce s s a ry to s top the ma chine , it ma y be
le ft in “s ta nd-by” mode , with the coppe r molte n in the crucible , the ca s ting die s lifte d out of the me lt
a nd the lids clos e d. In this mode , powe r cons umption is a bout 18-20% of the running ra te .

Space Requirements
The Ra utome a d RS s e rie s ma chine s a re compa ct, cons uming little fa ctory floor s pa ce . The mode l RS
2200/8/8 ha s a footprint of only 15 me tre s by 5 me tre s a nd a he ight of 4.5 me tre s . S pa ce re quire d
de pe nds on the me thod of ha ndling of ca thode a nd rod coils , but it is re comme nde d tha t a s pa ce of 15
me tre s by 10 me tre s be a llowe d, with a fa ctory he ight of not le s s tha n 7 me tre s . No s pe cia l
founda tions a re re quire d. A norma l re inforce d concre te floor of 150 mm thickne s s is s ufficie nt.

Environmental Considerations
The Ra utome a d proce s s us e s cle a n e le ctric me lting a nd thus is inhe re ntly cle a n. Me lting of coppe r in
the s ys te m give s off no fume a nd no e fflue nt is produce d. S ound le ve ls a t norma l pos itions occupie d
by ope ra tors do not e xce e d 79 dB(A).

8
DRAWING CHARACTERISTICS TO FINE WIRE

Comparisons with Continuous Cast and Rolled (CCR) Rod

The 8 mm continuous ca s t product from the Ra utome a d RS s e rie s ma chine s is a fully s oft a s -ca s t
product, whe re a s the CCR Rod which ha s be e n rolle d is s lightly ha rde r. Typica l prope rtie s a re :
Rautome ad CCR
as -cas t rod

e longa tion 40% 40%

UTS 175 N/mm 2
220 N/mm2
conductivity 101 - 102 % IACS 101 - 102 % IACS
oxyge n conte nt 0.0 - 4.0 ppm 180 ppm

Rod Break-Down
The 8mm dia me te r rod is typica lly dra wn down initia lly to a n inte rme dia te s ize of from 2.5 mm to
1.5 mm a nd a nne a le d in line on the dra wing ma chine . Oxyge n-fre e coppe r re quire s a highe r
te mpe ra ture for a nne a ling a s compa re d to tough pitch oxyge n conta ining coppe r a nd it is the re fore
ne ce s s a ry to incre a s e the in-line a nne a le r volta ge by 10-15% to a chie ve a fully a nne a le d a nd
re crys ta llis e d me ta llurgica l s tructure .

400 60

350
50

300

40
250 UTS
% Elongation
UTS N/mm 2

ELONGATION

200 30

150
20

100

10
50

0 0
0 10 20 30 40 50 60 70 80 90 100
% Reduction by Cold Work

Cold Drawing Characteristics of Rautomead

8mm Diameter OFHC Rod

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Fine Wire Drawing
Afte r a nne a ling, the wire ma y be furthe r cold dra wn a s re quire d. The product ha s dra wn s ucce s s fully
down to 0.05mm dia me te r product. Be ca us e the production s e que nce comme nce s by me lt a nd ca s t
proce s s ing through a wholly gra phite s ys te m, the comple te a bs e nce of re fra ctory a nd/or coppe r oxide
pa rticle s a s inclus ions in the me ta llurgica l s tructure , yie lds a n ultra cle a n me ta l inte rna l s tructure .
This in turn provide s a product which is highly s uite d to the a voida nce of rod bre a ks in dra wing to
fine wire s ize s .
Typica l prope rtie s of the dra wn wire , in compa ris on with Britis h S ta nda rd 4109 : 1970 a re :
Ra utome a d BS 4109
a s -ca s t dra wn a nne a le d/dra wn
1.50 mm diame te r 1.50 mm diame te r

e longa tion 30% - 32% 30% min

conductivity @ 20 de g C 100.8% - 101.3% 100% min
Though not a re quire me nt of the S ta nda rd, it s hould be note d tha t the UTS of the Ra utome a d rod a t
1.50 mm dia me te r, a fte r dra wing, is in the ra nge 235 - 250 N/mm
2.

Other Processes
The a s ca s t rod coppe r rod product ha s be e n a ls o s ucce s s fully proce s s e d through the Conform
continuous e xtrus ion proce s s , to cre a te a va rie ty of e le ctrica l re cta ngula r s e ctions . The la rge coil pie ce
we ights a re a dis tinct a dva nta ge for high productivity, a nd the Ra utome a d rod fe e ds tock is conducive
to good tool a nd die longe vity, ha ving the a dva nta ge s of no a bra s ive coppe r oxide pa rticle s occlude d
within the micros tructure .

THE RAUTOMEAD PROCESS.

The Ra utome a d Upwa rds Ve rtica l Continuous Ca s ting proce s s , pre s e nts a unique opportunity for
produce rs of wire a nd othe r re la te d products to utilis e a high productivity proce s s , which produce s
la rge pa cka ge we ights of a ne a r ne t s ha pe rod of e xce lle nt qua lity, with no e xpe ns ive inte rme dia te
proce s s ing or ha ndling ne ce s s a ry, prior to norma l wire dra wing.
Truly a proce s s which goe s from “Me lt to Wire ”.

oooooooooooooooooooooooooooooooo

10
S ome s ugge s te d furthe r re a ding a nd re fe re nce s :

Horizonta l Continuous Ca s ting of Coppe r Ba s e d Rods a nd S e ctions : S .R.Cochra ne , From Me lt to

Wire Int’l Confe re nce , Torre molinos , S pa in, 1979.

De ve lopme nts in Continuous Ca s ting of S ome Coppe r Ba s e d Alloys : S .R.Cochra ne , R.W.J ohns on,
Int’l Confe re nce on Ca s ting a nd Forming, Nov 1984, Montre ux, S witze rla nd.

Continuous Ca s ting of S ma ll-S ize d Hollow S e ctions : S .R.Cochra ne , R.W. J ohns on, Int’l Confe re nce
on Tomorrow’s Tube , Birmingha m, Engla nd, J une 1986.

Continuous Ca s ting of High Qua lity Tube S tock: S .R.Cochra ne , M.Na irn, Tube Inte rna tiona l, Ma rch
1988.

The us e of Ce ra mic Ma te ria ls in Continuous Ca s ting, S . R. Cochra ne , S .J ohns , a nd R.Wils on, Int’l
S e mina r in Continuous Ca s ting, Dunde e , S cotla nd, J une 1989

The a uthors would tha nk the ir colle a gue s a t Ra utome a d Inte rna tiona l Limite d, for the ir a s s is ta nce a nd
s upport with this pa pe r.

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diameter 2 cm ELEMENT CONTENT

Inner diameter 0 cm Ag
Casting speed 100 cm/min Al
Density 8.96 gm/cc Au
Liquid Density 7.95 gm/cc Be
Latent heat 49 cal/sec Bi
Specific heat 0.118 cal/sec C
(liquid)
Specific heat 0.092 cal/sec Cd
(solid)
Water in temp. 21 C Co
Water out temp. 44 C Cr
Water flow 21 l/min Cu 100 %
Melt temp. 1140 C Fe
Mean 1083 C In
liquidus/solidus
Metal exit temp. 80 C Mg
Mn
Area 3.141592 sq cm Mo
Mass 46.91445 gms/sec Nb
Qig 6943.432 cal/sec Ni
Qw 8051.61 cal/sec P
Cooler eff. 86.23657 % Pb
Pd
Pt
Rh
S
Sb
Se
Si
Sn
Te
Ti
V
W
Zn
Balance Alloy

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