Rautomead Continuous Casting Equipment and Tooling

Rautomead upward vertical and horizontal continuous casting systems for oxygen-free copper wire rod CuOF, railway trolley wires CuMg, CuCrZr alloys, bronzes, and brasses.

RS 3000 Upward Continuous Casting Lines for CuOF Wire Rod

Rautomead RS 3000 series upward vertical continuous casting lines produce oxygen-free high-conductivity copper wire rod from 8.0mm to 30mm diameter. Operating on LME Grade A cathodes, the system keeps oxygen content below 5 ppm with annual output between 1,000 and 40,000 tonnes.

Standard rod diameter manufacturing capability covers dimensions from 8.0mm to 30.0mm.
Total residual oxygen content inside solidified copper rod stays consistently under 5 ppm.
Annual plant production capacity for multi-strand RS systems spans 1,000 to 40,000 tonnes.
Automated dual coilers form high-density packaged wire rod coils weighing up to 5,000 kg.

CuMg Trolley Wire Rod Continuous Casting Systems RS 3000/5

Rautomead RS 3000/5/CuMg continuous casting machines deliver integrated melting, alloying, and casting of copper-magnesium trolley wires for high-speed railway networks. Featuring a twin-chamber graphite crucible and 360 kVA heating, the line outputs up to 500 kg alloy rod per hour.

Five-strand casting design enables synchronized production of five alloy rod strands.
Alloy feedstock rod dimensions for high-speed railway catenary range from 19mm to 30mm.
Maximum hourly continuous casting pull rate reaches 500 kg of copper-magnesium per hour.
Electric graphite resistance heating system operates at 360 kVA connected load capacity.

RSL Sealed Lid Continuous Casting Systems for CuCrZr Alloys

Rautomead RSL sealed-lid continuous casting lines use inert gas shielding to eliminate oxidation of volatile elements in CuCrZr alloys. The RSL 1400 model casts 25mm to 30mm rod across 2 strands at 250 kg/hour per strand, yielding as-cast tensile strength of 202 MPa.

Solid cast CuCrZr alloy rod dimensions range continuously between 25mm and 30mm diameter.
Twin-strand crystallizer setup achieves continuous withdrawal rates of 250 kg/hour per strand.
As-cast mechanical properties demonstrate 202 MPa tensile strength and 57% ductile elongation.
Annual production capability of the RSL 1400 sealed-lid line reaches 3,500 to 4,000 tonnes.

RT Series Horizontal Continuous Casting Lines for Bronzes and Brasses

Rautomead RT 650 and RT 850 horizontal continuous casting lines produce solid bars, hollow billets, and profiles in tin, leaded, and aluminium bronzes from 20mm to 250mm diameter. Patented Quick Die Change tooling enables rapid changeovers between alloys and section geometries.

Continuous product diameter spectrum spans from 20mm up to 250mm for solid and hollow shapes.
Versatile casting formats include solid bars, heavy-walled hollow tubes, and hex profiles.
Annual manufacturing output for RT horizontal casting configurations covers 500 to 5,000 tonnes.
Patented Quick Die Change mechanism minimizes tooling replacement intervals during alloy shifts.

Supercooler Casting Die Tooling and Water-Cooled Assemblies

Rautomead Supercooler crystallizer assemblies deliver uniform radial heat extraction from the solidification front via copper-alloy cooling blocks and graphite inserts. The controlled thermal gradient eliminates centerline porosity, alloy segregation, and hot cracking in cast rod.

High thermal conductivity copper alloy blocks provide optimized heat transfer gradients.
Multi-channel liquid coolant distribution eliminates directional solidification stresses.
Individual coolant flow and temperature tracking is maintained across every casting strand.
Uniform microstructure crystallization eliminates macro-segregation and central porosity.

Isostatic Graphite Crucibles, Dies, and Mechanical Spare Parts

Rautomead manufactures isostatic graphite crucibles, calibrated dies, resistance heaters, and withdrawal drive rollers at its Dundee plant. High-precision mechanical and thermal components ensure operational reliability and dimensional stability throughout continuous casting campaigns.

Dense isostatic graphite material delivers high resistance to non-ferrous melt erosion.
Precision machining of casting dies guarantees strict dimensional and profile tolerances.
Pulsed pinch drive rollers deliver smooth pull grip without surface scratching or slipping.
Electric graphite heating elements maintain uniform thermal stability across the crucible.

Metallurgical Advantages of Graphite Resistance Melting Technology

Rautomead continuous casting systems are engineered around electric graphite resistance furnaces featuring high-purity isostatic crucibles. Unlike coreless or channel induction furnaces, resistance heating ensures quiet molten metal holding without electromagnetic turbulence.

The graphite crucible inherently establishes a reducing atmosphere within the furnace chamber, capturing residual oxygen and eliminating molten copper oxidation.

Consequently, cast CuOF wire rod consistently maintains dissolved oxygen levels below 5 ppm without phosphorus deoxidizers, fulfilling stringent specifications for ultrafine enamelled magnet wire and high-purity electrical conductors.

Five-Strand RS 3000/5 Technology for High-Speed Railway Contact Wires

The Rautomead RS 3000/5/CuMg continuous casting machine is purpose-built to meet the stringent mechanical and electrical specifications demanded by high-speed rail catenary infrastructure.

Featuring an integrated twin-chamber crucible, the system combines primary copper cathode melting with closely controlled magnesium alloying in the casting chamber. Five independent strands draw 19mm to 30mm diameter alloy rod concurrently at rates up to 500 kg per hour.

Inert gas shrouding eliminates magnesium burning, delivering uniform alloy distribution and superior tensile strength exceeding 500 MPa.

RSL Sealed Lid Technology for Volatile Chromium-Zirconium Copper Alloys

Direct continuous casting of high-performance CuCrZr alloys has historically been hindered by rapid atmospheric oxidation of chromium and zirconium.

Rautomead RSL series continuous casting systems overcome this challenge through a sealed-lid design operating under pressurized argon shielding, combined with an automated Affival cored wire powder feeder. Alloying powders are delivered directly beneath the melt surface to prevent vapor loss.

The RSL 1400 line casts 25mm to 30mm rod across two strands, bypassing traditional heavy billet casting and hot extrusion processes entirely.

Horizontal RT Series Casting for Engineering Bronzes, Billets, and Tubes

Rautomead RT 650 and RT 850 horizontal continuous casting lines provide versatile manufacturing solutions for engineering alloys, bronze billets, and heavy hollows.

Tooling mounts horizontally to the crucible base, enabling continuous withdrawal of solid rounds, hexagonal bars, and hollow tubes from 20mm to 250mm diameter. Clean metallurgy across tin bronzes, gunmetals, and aluminium bronzes is ensured by quiescent gravity separation in the furnace.

The patented Quick Die Change system permits rapid transition between alloys and section profiles with minimal machine downtime.

Supercooler Heat Extraction Physics and Solidification Front Stability

The Rautomead Supercooler assembly comprises a precision-machined copper-alloy heat exchanger enclosing high-density graphite crystallizer dies. Solidification rates and radial heat dissipation dictate grain refinement and centerline integrity.

Symmetrical multi-channel water flow stabilizes the freeze line within the die throat, eliminating thermal shock and hot tearing.

Per-strand water metering ensures thermal equilibrium, resulting in dense, pore-free metallurgical structures capable of undergoing extreme downstream cold drawing without wire breakage.

Digital Pulse Kinematics and Motion Programming with Rautocast Software

Strand withdrawal from continuous casting dies is executed by high-torque servo drives regulated by proprietary Rautocast automation software.

Rather than continuous pulling, withdrawal proceeds via micro-pulsed cycles: a defined forward stroke is followed by a programmed dwell period for skin freeze, accompanied by a calibrated microscopic reverse push.

Motion kinetics adapt dynamically to alloy composition, cross-sectional diameter, and real-time furnace telemetry, preventing shell rupture and delivering unblemished surface finishes.

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