UPCAST Upward Continuous Casting Lines and Furnace Systems

UPCAST upward continuous casting systems for oxygen-free copper rod Cu-OF (1-3 ppm O2), SGTube DHP copper tubes, CuMg catenary alloys, channel induction furnaces, and tooling.

UPCAST Rod Upward Continuous Casting Lines for Cu-OF Copper Rod

UPCAST Rod lines deliver upward continuous casting of oxygen-free copper rod (Cu-OF) and alloys in diameters from 8mm to 30mm. Bypassing hot rolling, the process yields 1-3 ppm oxygen content with superior drawability and electrical conductivity at annual capacities reaching 40,000 tonnes.

Standard wire rod diameter capability covers 8.0mm up to 30.0mm for busbars and overhead catenary.
Dissolved oxygen in oxygen-free Cu-OF rod is consistently maintained between 1 and 3 ppm.
Annual production capacity for multi-strand UPCAST lines reaches up to 40,000 tonnes.
Continuous rod output feeds directly into automated dual coilers without interrupting casting.

UPCAST Channel Induction Melting and Holding Furnace Systems

UPCAST furnace complexes feature channel inductors with single- or double-loop inductors. The modular lineup includes compact single-furnace units up to 12,000 TPA, double-furnace systems up to 40,000 TPA, and triple-furnace configurations for blending cathodes with recycled copper scrap.

Single-furnace units integrate melting and casting operations for capacities up to 12,000 TPA.
Double-furnace layouts separate melting and holding furnaces for high outputs up to 40,000 TPA.
Triple-furnace systems utilize dedicated melting units for both copper cathodes and scrap.
High-efficiency double-loop inductors with transistorized controls eliminate harmonic resonance.

UPCAST Multi-Strand Casting Machines and Individual Coolers

UPCAST multi-strand casting machines equip each strand with an individual cooler and graphite die. Computerized servo drives withdraw solidified shapes vertically upward, enabling simultaneous casting of distinct product dimensions and alloys on a single machine frame without line stoppage.

Every casting strand is fitted with an independent water-cooled jacket and graphite die tooling.
High-precision servo drives execute controlled upward vertical withdrawal of solidified metal.
Changing cooler assemblies or selecting casting programs does not interrupt ongoing strands.
Robust structural machine frames accommodate multiple independent servo withdrawal drives.

UPCAST SGTube Production Lines for Thin-Walled Copper Tubes

UPCAST SGTube lines cast thin-walled seamless phosphor-deoxidized (DHP) copper tubes ready for direct drawing. Eliminating costly extrusion and piercing mills, SGTube technology provides fine-grained microstructure for sanitary, industrial, and ACR refrigeration tube manufacturing.

Direct upward casting of thin-walled seamless DHP copper tube hollows for HVAC and ACR uses.
Cast tube dimensions closely match final sizes, eliminating conventional heavy tube mill steps.
Controlled solidification yields a fine grain structure optimized for cold drawing passes.
Output copper tubes are collected directly on heavy-duty dedicated individual tube coilers.

UPCAST Alloys Casting Systems for CuMg, Bronzes, and Brasses

UPCAST Alloys systems cast specialized non-ferrous alloys: CuMg rod for high-speed railway contact wires, brasses and nickel silvers for fasteners, tin and phosphor bronzes for electronics connectors, and silicon bronze for high-strength fasteners, all protected against alloy vaporization.

Continuous casting of copper-magnesium (CuMg) rod for railway catenary contact wires.
Production of tin and phosphor bronzes for precision mobile phone electrical connectors.
Adaptable casting of brasses, nickel silvers, and silicon bronzes for industrial hardware.
Controlled protective covers prevent volatile alloy burn-off during continuous operation.

UPCAST Automated Coilers, Graphite Tooling, and Spare Parts

To maintain uninterrupted operation, UPCAST supplies automated double coilers, precision water-cooled cooler jackets, high-density graphite crystallizer dies, protective nozzles, thermocouple sleeves, and PreCast furnace refractories engineered to maximize production line uptime.

Automated synchronized double coilers collect wire rod coils without stopping casting flow.
Precision-machined graphite dies maintain tight rod diameter tolerances and smooth surfaces.
Replacement water-cooled copper cooler jackets ensure symmetric rapid heat extraction.
Factory-grade PreCast refractory elements, furnace linings, and replacement channel inductors.

Metallurgical Superiority of UPCAST Cu-OF Rod Without Hot Rolling Stages

UPCAST upward continuous casting systems are engineered to produce high-conductivity oxygen-free copper rod (Cu-OF) featuring residual oxygen concentrations of only 1 to 3 ppm.

Unlike conventional billet casting and hot rolling mills, the UPCAST process solidifies and calibrates the rod directly from the molten pool to finished diameters between 8mm and 30mm. Eliminating hot deformation entirely avoids mill-scale inclusions, surface oxidation, and internal laminations.

The resulting single-phase microstructure provides maximum IACS electrical conductivity and elongation, making it the premier feedstock for ultra-fine magnet wire drawing.

Channel Induction Furnace Architecture and GREENerCAST Energy Innovations

UPCAST furnace complexes utilize electrically heated channel inductors with transistorized stepless power supply regulation.

Three engineered layouts address varied production scales: a compact single-furnace unit combining melting and casting up to 12,000 TPA, a double-furnace setup separating melting and holding furnaces up to 40,000 TPA, and a triple-furnace installation with dual melting units for blending copper cathodes and recycled copper scrap.

The GREENerCAST suite incorporates double-loop inductors and PreCast refractory linings to optimize thermal efficiency and eliminate circuit harmonic resonance.

Multi-Strand Kinematics and Independent Cooler Withdrawal Drives

UPCAST casting machines employ a multi-strand modular design where every strand is fitted with an independent water-cooled jacket and high-density graphite crystallizer die. Microprocessor-governed servo motors pull cast sections vertically upward from the furnace bath.

Independent cooler suspensions allow operators to service, exchange, or retool individual strands without halting continuous production on adjacent lines. The rigid frame accommodates multiple discrete servo withdrawal drives, enabling simultaneous multi-diameter casting of rod and tube products.

Direct Thin-Walled Copper Tube Casting via UPCAST SGTube Technology

The UPCAST SGTube process delivers high-efficiency direct casting of thin-walled seamless phosphor-deoxidized (DHP) copper tubes.

By eliminating heavy extrusion presses and rotary piercing mills, cast tube hollows are produced close to final dimensions with uniform fine-grained metallurgical structures. Cast tubes proceed directly to cold bull-block drawing machines for finishing.

SGTube hollows provide superior internal cleanliness and defect-free wall concentricity for sanitary plumbing, heating, industrial refrigeration, and air conditioning (ACR) applications.

Advanced Non-Ferrous Alloys: CuMg Railway Catenary, Bronzes, and Brasses

Beyond pure copper rod, UPCAST installations are engineered for versatile casting of specialized non-ferrous alloys.

For electrified high-speed railways, the system produces copper-magnesium (CuMg) alloy rod for grooved trolley wires and catenary cables requiring superior tensile strength and electrical conductivity.

For telecommunications and electronics, UPCAST lines cast tin and phosphor bronzes for precision spring connectors, alongside leaded brasses, nickel silvers, and silicon bronzes, with inert gas shrouds preventing oxidation of volatile additions.

Automated Dual Coilers and Proven Industrial Validation at Seval Kablo

Uninterrupted continuous production is maintained by automated synchronized double coilers collecting packaged wire rod coils weighing up to 5,000 kg with seamless basket changeover. Global manufacturing success is exemplified by Turkish cable manufacturer Seval Kablo.

Operating an industrial UPCAST line continuously since early 2020, Seval Kablo confirmed that production metrics perfectly matched computer simulation models, leading to their commercial acquisition and commissioning of a second complete UPCAST production line.

UPCAST and model names are trademarks of their respective owners and are used only to identify the equipment for which we source parts. SpareX is not an official dealer, distributor or representative of UPCAST and is not affiliated with the trademark owner. Origin, documents and warranty are stated for each item in the quotation.