Why is Graphite dies and molds the first choice for Continuous Casting?
Continuous Casting can be considered as a heat extraction process as it involves removal of superheat and latent heat of solidification.Graphite dies and molds are critical to the process and allow the metal processing from the molten state to the solid state, while forming semi-finished products.
Since Graphite has the ability to oppose the wetting by molten metals and, it renders utility as a mold material for strip dies, tubular dies, and other molds used in continuous casting processes for copper and copper alloys (brass, bronze, and nickel silver), aluminum alloys, cast iron, precious metals, and a variety of other metals.
Another vital factor that makes Graphite a popular choice for Continuous Casting is its ability to self-lubricate. Graphite is a strong lubricant, it generates low friction between the mold and the cast material.Thus allowing for smooth extraction of the casting.
Unique Characteristics of Graphite for Continuous Casting process-
- High Thermal Conductivity: the heat transfer is the key to convert the metal from a liquid to a solid state
- Competent for withstanding molten metal temperatures: graphite sublimates at 3,650°C at atmospheric pressure
- Low Coefficient of Thermal Expansion (CTE): This provides dimensional solidity
- High thermal shock resistance
- Graphite is a self lubricant
- Good machinability
- Good mechanical strength (tensile strength, compressive strength, flexural strength)
Typical Value
of Thermal
Conductivity Material W/m °K
Boiling Points
Grade selection is highly significant in Continuous Casting. The factors that determine the selection of the grade of graphite are:
- Casting speed
- Size and shape of the part to be casted
- Quantity of alloy
- Casting orientation (vertical or horizontal)
Expo offers a wide range of specialized graphite grades from Toyo Tanso (Japan), such as IG-11, IG-70 & IG-15. Because of their reliable material qualities such as high thermal conductivity, low C.T.E etc., they can be used for continuous casting of gold, silver, copper, copper-nickel alloys and other precious metals.
Toyo Tanso Grades/ Advantages-
Grades/Advantages
IG-11
This basic grade has provided solutions to casters throughout the world for over 20 years. It can be used to cast a wide range fo different alloys and presents a smooth sliding surface.
IG-70
Medium density, high resilience and higher thermal conductivity than IG-11.
IG-15
Highest in density and thermal conductivity. Presents a smooth sliding surface and rapid cooling.
Toyo Tanso Isotrophic Physical Properties
| Grade | IG-11 | IG-70 | IG-15 |
| Bulk Density - gr/cc | 1.77 g/cm3 | 1.83 g/cm3 | 1.90 g/cm3 |
| Shore Hardness | 51 | 58 | 60 |
| Electrical Resistivity µΩ - in | 433 | 394 µΩ - in | 375 µΩ - in |
| Flexural Strength MPa - psi | 5655 | 6817 | 7830 |
| Comprehensive Strength MPa - psi | 11310 | 14924 | 15000 |
| Tensile Strength - psi | 3625 | 4497 | 4200 |
| Elastic Modulus | 10 GPa | 11.8 GPa | 11.8 GPa |
| CTE (350°C - 450°C) | 4.5 x 10-6/°C | 4.6 x 10-6/°C | 4.8 x 10-6/°C |
| Thermal Conductivity W/m - °k | 120 W/m - °k | 128 W/m - °k | 140 W/m - °k |
Continuous Casting Products & Applications-
Graphite can be utilized with various continuous casting techniques - both for horizontal and vertical orientation. The products which can be produced are:
- Cooling Plates
- Strip casting dies
- Casting moulds
- Bars
- Semi-finished products (round/square materials)
- Counting Plates
- Crucibles
- Pipes
- Wire
The alloys which can be manufactured by continuous casting using Graphite Molds & Dies are given below:
- Oxygen-Free Copper
- Brasses and leaded brasses(Cu-Zn, Cu-Zn-Pb )
- Silicon bronzes (Cu-Si-Sn)
- Silver and silver alloys (Ag)
- Coinage alloys (Cu-Ni)
- Copper-nickel alloys and Nickel Silvers (Cu-Ni)
- Bronze( Bz)
- Aluminum-tin alloys (Al-Sn)
- Gold and gold alloys (Au)
Benefits of Graphite Mold for Continuous Casting-
- Better dimensionally precise castings are accomplished at a much lower rate than in sand casting and investment casting.
- The shape is expandable and does not twist or oxidize, subsequently it tends to be utilized more than once.
- Graphite molds which are effectively machinable can be made and altered rapidly.
Our Clients
World-renowned companies like Devu tools, Dietech India, MothersonSumi Systems, Kangaro, Seco Warwick, and many others have entrusted us in supplying their Graphite needs. And now it’s your turn to take the benefits of our quality services!
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