Atmosphere Controlled Continuous Casting Furnace with Secondary Charge Function for Induction Melting and Metal Alloy Wire Production

Product Overview

This high-performance system represents the pinnacle of metallurgical engineering, designed specifically for the induction melting and continuous casting of high-purity alloys under strictly controlled environments. By integrating induction heating with a sophisticated pulling mechanism, the equipment enables researchers and industrial manufacturers to produce consistent rods, plates, and wires from various metallic compositions. The core value proposition of this unit lies in its ability to maintain material integrity through either vacuum or inert gas shielding, preventing oxidation and contamination during the critical melting and solidification phases.

Primarily utilized in advanced material science laboratories and industrial R&D facilities, this system is an essential tool for the preparation of specialized metallic wires used in additive manufacturing (AM) and high-performance alloy development. It serves industries ranging from aerospace and automotive to electronics and biomedical engineering, where the precision of the casting profile and the purity of the alloy are non-negotiable. The ability to handle diverse alloys with melting points up to 1700ºC ensures that this equipment remains versatile across a wide spectrum of experimental and production-scale applications.

Built with industrial-grade components and a robust stainless steel melting chamber, this unit is engineered for long-term reliability under demanding thermal cycles. Every aspect of the design, from the secondary charge function to the integrated water-cooling circuit, is optimized for operational safety and performance consistency. Procurement teams and laboratory managers can rely on this system to deliver repeatable results, ensuring that experimental data and pilot production runs meet the highest international standards of technical excellence.

Key Features

• Secondary Charge and Stirring Function: The stainless steel chamber is equipped with a specialized secondary charging port that allows for the addition of alloying elements during the melting process without breaking the atmosphere. The integrated stirring function ensures chemical homogeneity throughout the melt, which is critical for complex alloy formulations.
• Precision Continuous Casting Mechanism: This system features a sophisticated pulling-down mechanism located in an air-tight chamber below the melting zone. With an adjustable pulling speed of 8 to 100 cm/min, operators can finely tune the solidification rate to achieve the desired microstructural properties in the cast profile.
• High-Temperature Induction Melting: Utilizing advanced induction technology, the furnace reaches a maximum working temperature of 1700ºC. This method provides rapid, efficient heating and excellent temperature uniformity, making it suitable for a wide range of ferrous and non-ferrous alloys.
• Advanced Atmosphere Management: Designed for both vacuum and inert gas operations, the equipment includes a double-stage rotary vane vacuum pump and precise gas flow controls. This allows for processing in high-purity Argon or Nitrogen environments to eliminate oxidation risks.
• Integrated Thermal Insulation & Graphite Crucible: Each unit comes with a standard set of high-density graphite crucibles and specialized thermal insulation. The 2-liter capacity crucible is optimized for a 5 kg stainless steel-based melting capacity, ensuring efficient heat retention and material compatibility.
• Touch Screen Digital Control: The system utilizes a modern touch screen interface coupled with a high-accuracy PID controller. Monitoring is facilitated by a B-type thermocouple, providing the user with real-time data and +/- 2ºC temperature stability for critical thermal processes.
• Closed-Loop Cooling System: To ensure continuous operation and component longevity, a 58L/min recirculating water chiller is integrated into the system. This 17K BTU/hr unit manages the thermal load of the induction coils and chamber walls effectively.
• Versatile Casting Profiles: The equipment is capable of producing a variety of shapes, including wires from φ6-30mm and plates up to 70mm in width. This flexibility allows researchers to produce feedstock directly for subsequent drawing, rolling, or 3D printing processes.
• Automatic Winding Capability (Optional): For high-volume wire production, an optional automatic winding device can be integrated. This device is capable of handling up to 20kg of cast wire, streamlining the transition from casting to storage or further processing.

Applications

Technical Specifications

Why Choose TU-RL11

• Integrated Process Control: This system combines melting, stirring, secondary charging, and continuous casting into a single, unified atmosphere-controlled environment, reducing the risk of contamination between process steps.
• Industrial Grade Reliability: Built with high-spec stainless steel and premium induction components, the unit is designed for continuous operation in demanding R&D and pilot production settings, ensuring a long service life and high ROI.
• Unmatched Precision: The combination of B-type thermocouple monitoring and a high-accuracy pulling mechanism allows for the production of alloys with superior microstructural uniformity and dimensional stability.
• Turnkey Solution: Unlike systems that require separate procurement of chillers and pumps, this unit comes as a complete package, including the necessary vacuum pump and water cooling system, allowing for immediate deployment upon installation.
• Versatile Scaling: While perfectly sized for laboratory research, the 5kg capacity and optional 20kg winding device make it an ideal bridge between experimental material discovery and full-scale industrial production.

For technical consultations regarding your specific casting profiles or to receive a formal quotation, please contact our engineering team today to discuss how this advanced system can elevate your material processing capabilities.