Process Of Prepping Copper Alloys
Similar processes are in place when utilizing brass and bronze alloys in a variety of forms. Alternative material forms to wrought copper alloys will be continuous cast, centrifugal cast and sand casts. The design, manufacture and processing of such materials is carried out by professional or specialist metallurgical engineers. The process of prepping copper alloys is briefly outlined as follows.
Molten metal will be poured into a crucible ‘tun-dish’ furnace within a controlled atmosphere. The tundish has the capacity to hold large volumes of molten metal at controlled temperatures above a water cooled graphite die. Any doss collected within the furnace will float to the top of its metal bath where it will subsequently be removed. Cast bars are prepared for these processes. But entrainment of slag within these cast bars is just not possible.
But then again, castings are free of solid inclusions and porosity from gas or shrinkage. The metals enter a freezing zone at appropriate temperatures to allow for shrinkage pores in cast materials to be filled. This happens very quickly before the process of rapid freezing even begins. The segregation or separation of alloying elements is thus avoided. Patented techniques are being introduced to further reduce separations and improve casting strength, generating fine grain structures within the castings.
Newly frozen layers of metal quickly shrink away from graphite dies. A set of electrically driven pinch rolls helps to pull metals apart from the die. Subsequently, dies are gravity filled with molten metal from the tundish. And so it happens that a solidification process begins all over again. By the time castings have achieved its desired length, it will be cut with a flying saw positioned below pinch rolls.
You got a brief outline of the process of prepping alloys through your quick reading here.