Continuous horizontal casting: technology, equipment, products

The production line is designed for making round and rectangular section work pieces in various sizes from copper and its alloys using the method of continuous horizontal casting. Steel and cast iron scraps, foundry and conversion pig irons, non-ferrous alloys, non-ferrous metall scraps can be used as a starting material. The billets have the preset structure and physical and mechanical properties. The technology and equipment can be used for production of billets for machine-tool and mechanical engineering industries as well as for hydraulic and pneumatic equipment. Casting material: bronze, cast iron, aluminium. Billet shape: round, rectangular Bronze billet diameter: 25-200 mm. Cast-iron billet diameter: 30-150 mm. Aluminium billet diameter: 40-190 mm. Cast iron billet cross-section: from 30х50 mm to 150х200 mm. The peculiarity of the process of continuous casting of ingots and billets as compared to single time casting methods is temporally and spacially stable position of crystallization front at simultaneous feed of metal and pulling of the ingot. This provides high quality of billets. In comparison with temporary mold casting, continuous horizontal casting results in smaller capital outlays, reduction of casting production cost by 30-50%, 2-4 fold decrease of machining allowance, 2-4 fold increase of labor productivity and up to 90-92% ingot product yield, wear resistance of articles 40 - 50% and hydrodensity 1,5 - 2 times. Most effective are methods of continuous casting with horizontal technical axis. Results of theoretical and experimental research turned out a scientific base for development of equipment for continuous horizontal casting and methods of intensification of the process. On the base of the Institute operates experimental production of continuous-cast billets of cast iron and nonferrous metals.