CAST&DRAW / CAST&FORM
UPCAST OY and ASMAG combined their expertise and created a revolutionary process for copper semi-finished products — taking cost-efficiency to new heights.
With UPCAST®-SGTube technology you will get in just one leap to a point requiring many costly steps with conventional tube production methods.
UPCAST®-SGTube is the latest trailblazing continuous casting technology from UPCAST OY. It is an innovative extension of the baseline UPCAST® system used for casting copper & copper alloy rod. UPCAST®-SGTube process is similar to that used in the baseline system – thus sharing all the same inherent benefits - but differs in the construction of the casting machine, coilers as well as casting machine tooling.
UPCAST®-SGTube supplies thin-walled copper tube with a grain structure enabling the cast tube to be directly worked down with tube drawing machines. As the tube coming from the UPCAST®-SGTube process is in cast condition it is highly recommended to make the first breakdown drawing passes in straight drawing machines followed by inductive in-line annealing. To ensure complete softening a total area reduction of min. 50 % is required before intermediate annealing.
Having the UPCAST®-SGTube process as the first step of your tube production line can mean clear savings to the lifecycle costs. As the cast tube is already rather close to final product sizes UPCAST®-SGTube takes you in just one leap to the same point that requires several shorter but costly steps in existing tube mills. Further savings can be gained through the small footprint of an UPCAST®-SGTube line, being just a fraction of the floor area required by the conventional equipment it will make redundant.
As with UPCAST® lines for rod UPCAST®-SGTube lines are also of modular design allowing tailor-made solutions for each customer’s specific needs. It is possible to choose between single- and double-furnace configurations. With a double-furnace configuration – having separate melting and casting furnaces – it is possible to reach 12,000 tpa output while 9,000 tpa is the upper limit for a single-furnace configuration. If scrap – clean and dry – will form a significant part of the input material then a double-furnace configuration is the preferred choice.
Different sizes of tube can be cast from. The outer diameters cast to date range from 38mm to 60mm while the lower/upper limits for the wall-thickness have been 2mm/3mm respectively. Different tube sizes can be cast even simultaneously when the casting machine is equipped with more than one servo-drive system. The choice of the cast tube size depends - among other things - on the size of the final tube product. The smaller the final tube size is the smaller could also the cast tube size be. As to coil weight UPCAST®-SGTube is extremely flexible with an upper limit of about 1.5 tons. Thus coil weight limitations will actually stem from constraints in downstream equipment.
The main usage of UPCAST®-SGTube is in the casting of phosphor deoxidized (DHP) copper tube for the production of sanitary, industrial as well as air conditioning and refrigeration (ACR) tubing. The process is however not limited only to DHP copper but is suitable also for other copper grades/copper alloys. Oxygen free copper as well as copper nickel alloys have already been successfully cast.
Absence of harmful emissions and need for waste treatment reduces the environmental footprint of UPCAST®-SGTube significantly compared to other existing technologies. In addition to the small environmental footprint other UPCAST®-GREENerCAST features can be found in the baseline UPCAST®-technology such as low lifecycle costs, easy variation of output, use of scrap in the process and unique upgradability. All these benefits are also available for UPCAST®-SGTube copper tube manufacturers. No more costly production stages of traditional tube mills.
Leading edge technology combined with strong commitment to customer support provides all “UPCAST®-family” members, old and new, with unique performance.