A trend in higher demand of aluminium
wires for industrial purposes has been observed in recent years. The most
popular, basic methods for aluminium wire production include continuous or
semi-continuous casting, extrusion and drawing.
The investigated method involves
drawing of the crystallized metal in a vertical direction upwards toward the
liquid metal in the melting furnace. This method has been so far applied only
for continuous casting of copper and copper alloy wires. The main advantage of
this casting method is the simultaneous operation of several moulds
(crystallizers) immersed in liquid metal and the possibility to stop easily each
of them while the rest of the moulds continue their function. Another advantage
of the upwards continuous casting is the absence of a tundish.
The pilot equipment for vertical
upwards continuous casting of aluminium wires is designed and produced. It
consists of a copper water-cooled mould (crystallizer) up to 14 mm in diameter
and a hydraulically driven drawing mechanism.
Because of the high thermal capacity of
aluminium, the achieved maximum casting speed 280 mm/min is unsatisfactory. A
new mould, with combined indirect and direct cooling for vertical upwards
continuous casting of aluminium wires was designed and produced.
The casting speed of aluminium wires
(Ø14 mm) was increased to 1000 mm/min, using the new mould.
Keywords: upwards continuous casting, mould, aluminium wires, drawing