CONTINUOUS CAST PRODUCTION METHODS

Anchor Bronze & Metals Continuous Cast bronze is produced in stationary mold continuous casting machines. All of the melting is done via electric induction crucible furnaces. Melting occurs continuously, throughout the course of a production run.

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Molten metal is poured into a crucible tundish furnace having a controlled atmosphere (A) The tundish furnace maintains a large reservoir (B) of molten metal at a controlled temperature above a water-cooled graphite die (C). Any dross entering the tundish furnace quickly floats to the top of the metal bath where it is removed.

Entrainment of slag in the cast bars is not possible. These features guarantee bronze castings free of solid inclusions and porosity from gas or shrinkage.

Metal enters the freezing zone of the die (D) at a temperature in sufficient excess of the liquidus to assure that any shrinkage pores in prior cast material are filled. This is accomplished in a fraction of a second before rapid freezing begins. Severe segregation of alloying elements is thereby avoided. Special patented techniques further reduce segregation and greatly improve casting strength by generating a fine grain structure in the casting.

The newly frozen layer of metal shrinks rapidly away from the graphite die and is withdrawn from the die by a set of electrically driven pinch rolls.

As the newly solidified portion of the casting  leaves the freezing zone, the die is gravity filled (E) with molten metal from the tundish. The solidification process begins again.

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When the casting has attained the desired length, it is cut off with a flying saw positioned below the pinch rolls. This process is used for production of intricate inside diameter and/or outside diameter shapes. The vertical casting process is preferred for the production of precision tubing. Tube concentricity of vertically cast product surpasses that produced by all other metal working processes. Cast product is Medart straightened and dimensional tolerance is checked. Material is cut to standard lengths and cold stamped with their corresponding heat numbers to ensure total mill traceability.