SPECIALITY
GRAPHITE MATERIALS
FOR
CONTINUOUS
CASTING
HORIZONTAL CONTINUOUS CASTER
Cooling system
Graphite die
Solidification front
Continuous casting
is a metallurgical process which allows continuous
control of the transformation from a liquid metal to
a solid state in order to directly obtain semi-finished
products like:
• wires,
• rods,
• tubes,
• strips,
• custom sections.
The graphite “die” used in this transformation, permits:
• the shaping of the metal,
• the heat extraction necessary to transform the metal
from liquid to solid state.
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The selection of the best graphite grade for
your application…
… depends mainly on the composition of the alloy to be cast: grey
iron requires a graphite resistant to wear abrasion; brass, a graphite
relatively dense but with enough open porosity to allow zinc to
evaporate in the area of the solidification front; non-ferrous alloys
containing elements like nickel or cobalt need high
density graphite to reduce chemical attack of the
graphite die...
The other parameters which determine the choice
of the grade are:
• the size and shape of the cast section,
• the speed of casting,
• the total amount of alloy to cast,
• casting orientation (i.e, vertical or horizontal).
In addition to the graphite grade chosen, the casting results are
also a function of die design, quality of machining, and the specific characteristics of the casting installation. Our
grades have been developed in conjunction with foundrymen to obtain the proper blend of physical characteristics
for continuous casting. We can provide technical services to assist you in finding a suitable graphite for your
application. However, in many cases optimal grade selection can be made only through actual trials.
The following application chart should be used only as an indicative guide for grade selection.
Recommended grades
Cast alloy Wire casting Billet casting Strip casting Tube casting
Grey and ductile iron - 1940 1940 1940
Brass (Cu-Zn) 2236 - 2554 2236 - 2554 2236 - 2554 1940
Bronze 2236 - 2554 2236 - 2554 2236 - 2554 2236 - 2554
Phosphorus bronze 2220 - 2236 2220 - 2236 2220 - 2236 2236 - 2220
(Core)
Maillechort (Cu-Zn-Ni) 2230 - 2554 2230 - 2554 2554 2220 - 2236
Nickel-silver
Nickel-copper 2230 - 2554 2230 - 2554 2230 - 2554 2554
Red copper, Phosphorus 1940 1940 - 2220 2230 -
deoxidized copper
Aluminium 1940 1940 - 2220 1940 - 2220 -
Silver, Gold 2236 - 2554 - 2230 - 2554 -
Precious metal alloys 2236 - 2554 - 2236 - 2554 2236 - 2554
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Graphite is well adapted for use as continuous casting dies because
of its unique physical characteristics:
• Capable of withstanding molten metal • High thermal conductivity.
temperatures. Graphite sublimates at 3,650°C
and atmospheric pressure.
Typical values of thermal conductivity
Melting and boiling points Material W/m.° K
5,900
3,370 Tungsten
3,650 Graphite
3,700 385 Copper
2,620 Molybdenum
2,900 163 Tungsten
1,455 Nickel
2,856
1,062 Gold
2,740
1,535 100 Graphite for Continuous Casting
2,600
1,083 Copper
90 Nickel
2,550
2,300 Boron Boiling point °C
2,355 75 Iron
1,410 Silicium Melting point °C
2,340 42 Carbon
232 Tin
2,300
0.7 Brick
660 Aluminium
2,190
960,5 Silver
907
420 Zinc 0.1 Rigid carbon insulation CALCARB®
0 1,000 2,000 3,000 4,000 5,000 6,000
0 100 200 300 400 500
Graphite manufacturing
GRINDING
SIEVING
RAW MATERIALS
(natural graphite, cokes, recycled graphite)
BLENDING / MIXING
GRINDING
ANTICORROSION EQUIPMENT
SIEVING (graphite tubes and blocks -
(different grades) heat exchangers)
EXTRUDING / SPINNING
BAKING 1,000°C
ISOSTATIC or UNIAXIAL
COMPRESSION
COATING 1,500°C
MACHINING
GRAPHITIZATION PURIFICATION
3,000°C 2,000°C
CARBON BRUSHES
AND COMPONENTS
FINAL TESTS
SEMI-FINISHED PRODUCTS
GRAPHITE COMPONENTS
FOR HIGH TEMPERATURES
5
Holytown, Scotland UK
Chongqing, China
St-Marys, USA
Gennevilliers, France
Main production sites
Industrial or commercial branch
A WORLD EXPERT
in materials and solutions
for high temperature processes
A GLOBAL PLAYER
Global expert in materials and solutions for extreme needs to enable them to optimize their manufacturing
environments as well as in the safety and reliability process in sectors such as energy, transportation,
of electrical equipment Mersen designs innovative electronics, chemical, pharmaceutical and process
solutions to address its clients specific industries.
Contact for America Contact for Europe Contact for Asia
MERSEN USA St-Marys MERSEN France Gennevilliers MERSEN Kunshan Co. Ltd.
Graphite Materials Division 41 rue Jean Jaurès - BP 148 No. 29 South Taihu Road,
215 Stackpole Street F-92231 GENNEVILLIERS CEDEX Kunshan, Jiangsu Province
HT12GB0190
St Marys, PA 15857-1488, USA FRANCE 215334, CHINA
Tel. : +1 814 781 -1234 Tel.: +33 (0)1 41 85 43 00 Tel.: +86 512 5763 9808
Fax : +1 814 781-8570 Fax: +33 (0)1 41 85 45 11 Fax: +86 512 5763 9811
E-mail: ht.graphite@mersen.com
www.mersen.com
