Continuous Casting Brochure

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 SPECIALITY GRAPHITE MATERIALS

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. FOR CONTINUOUS CASTING

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 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 HT12GB0190 E-mail: [email protected] www.mersen.com 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.

2 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 - 2020 - 2020 Brass (Cu-Zn) 2191, 2204 2191, 2114 2220, 2204 2220, 2191 Bronze 2191, 2204 2191, 2114 2204, 2230 2191, 2220 (Core) Phosphorus bronze 2220, 2204 2191, 2220 2220, 2204 2191, 2220 Maillechort (Cu-Zn-Ni) 2230, 2204 2230 2204, 2230 2191, 2204 Nickel-silver Nickel-copper 2230, 2204 - 2204, 2230, 2450 - Red copper, Phosphorus 2191, 2235 2191, 2114 - - deoxidized copper Aluminium - 2191 2220 - Silver, Gold 2191 - 2191 2191 Precious metal alloys 2204, 2450 - 2204, 2450 2204, 2450

3 Typical characteristics

Property Unit 2191 2020 2114 2220 2204 2450 2230

Density g/cm3 1.75 1.77 1.81 1.84 1.85 1.86 1.90

Porosity % 12 9 10 8 8 8 4

Hardness Rockwell 80 (L) 95 (L) 70 (H) 80 (H) 80 (H) 80 (H) 85 (H)

Modulus GPa 10.1 9.2 11.4 11.4 10.1 9.2 11.4 of elasticity

Flexural MPa 44 45 52 58 44 45 58 strength psi 6,400 6,500 7,500 8,400 6,400 6,500 8,500

Compressive MPa 97 99 103 124 97 99 124 strength psi 14,100 14,300 15,000 18,000 14,100 14,300 18,000

Coefficient x 10-6 of thermal /°C 4.2 4.3 5.3 5.5 4.2 4.3 5.5 expansion /°F 2.3 2.4 3.0 3.1 2.3 2.4 3.1

Electrical µΩcm 1,090 1,550 1,240 1,140 1,090 1,550 1,140 resistivity Ωin 0.00043 0.00061 0.00049 0.00045 0.00043 0.00061 0.00045

Thermal W/m°C 116 85 104 112 116 85 112 conductivity BTU-Ft/Ft2Hr°F 67 49 60 65 67 49 65

Average µm 15 15 13 13 15 15 13 grain size in 0.0006 0.0006 0.0005 0.0005 0.0006 0.0006 0.0005

Standard mm 545 x 545 x 1,830 530 x 635 x 1,830 308 x 620 x 915 308 x 620 x 915 308 x 545 x 915 308 x 530 x 915 152 x 620 x 915 block size in 21.4 x 21.4 x 72 20.8 x 25 x 72 12 x 24 x 36 12 x 24 x 36 12 x 21.4 x 36 12 x 20,8 x 36 6 x 24 x 36

Data herein contained are provided for general information purpose only and are not binding. Mersen shall have no liability whatsoever with respect to information contained herein. Duplication, reproduction or translation of any information contained herein, in whole or in part, is strictly prohibited without prior written consent of Mersen.

Our materials are in conformity with the RoHS-Directive (Restriction of the use of certain Hazardous Substances in electrical and electronic equipment). Besides Mersen guarantees the application of the European Community REACH-Regulation (Registration, Evaluation, Authorisation and Restriction of Chemical substances) to all its plants located in Europe.

4 Graphite is well adapted for use as • High thermal conductivity. Holytown, Scotland UK continuous casting dies because of its unique physical characteristics: Typical values of thermal conductivity Material W/m.° K • Non-wetting to most metals due to its low reactivity and low porosity. These characteristics can be tailored to specific 385 Copper

casting requirements through selective 163 Tungsten Chongqing, China processing.

/g) 100 Graphite for Continuous Casting 3

cm 2191 -2 90 Nickel 10 St-Marys, USA 75 Iron 2020

2220 2114 42 Carbon 5 2204 0.7 Brick 2450 2230 Gennevilliers, France

0 0,1 1 10 0.1 Rigid carbon insulation CALCARB®

Cumulative Pore Volume (10 Pore Radius (µ.m) 0 100 200 300 400 500 Main production sites • Capable of withstanding molten metal Industrial or commercial branch temperatures. Graphite sublimates at 3,650°C W/m.° K

and atmospheric pressure. 110 Thermal conductivity

Melting and boiling points 2230 5,900 A WORLD EXPERT 3,370 2220 Tungsten 2204 3,650 Graphite 2191 in materials and solutions 80 2114 3,700 for high temperature processes 2,620 Molybdenum 2020 2,900 2450 1,455 Nickel 2,856 1,062 Gold 0 2,740 500 1,000 1,500 °C 1,535 2,600 1,083 Copper 2,550 • Easy to machine and to polish. 2,300 Boron Boiling point °C 2,355 1,410 Silicium Melting point °C 2,340 232 Tin 2,300 660 Aluminium 2,190 960,5 Silver 907 A GLOBAL PLAYER 420 Zinc Global expert in materials and solutions for extreme needs to enable them to optimize their manufacturing 0 1,000 2,000 3,000 4,000 5,000 6,000 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 Graphite solutions to address its clients specific industries. manufacturing

Fax : +1 814 781-8570 Fax: +33 (0)1 41 85 45 11 Fax: +86 512 5763 9811 HT12GB0190 5 E-mail: [email protected] www.mersen.com 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

Fax : +1 814 781-8570 Fax: +33 (0)1 41 85 45 11 Fax: +86 512 5763 9811 HT12GB0190 E-mail: [email protected] www.mersen.com