When a water cooled graphite die is immersed in bath of molten copper to
a certain depth, the liquid copper in the die cavity solidifies. As the
solidified segment is drawn upwards by a pinch roll and stepping
mechanism, molten metal fills the die cavity resulting in continuously
cast rod.
Process
Electrolytically
refined copper cathodes are molten in a mains frequency channel
induction furnace under a thick layer of charcoal.
Molten
metal is intermittently transferred in a reducing atmosphere to a
twin chamber channel induction holding furnace wherein the melt
temperature is closely controlled and molten copper is protected
by flake graphite.
Multiple
cooler assemblies housing the casting dies are immersed in the
molten copper and the cast copper rods are continuously cooled in
the cooler tubes to emerge with a temperature less than 50 degree Celsius.
Cast
rod is then coiled in steel baskets in coil weights up to 3.5 MT.
Such
UPCAST rod is then cold rolled to 8mm diameter rod.
