The Process

Click here to view an animation of the process used at Dens Metals.

Utilising modern continuous casting technology, Dens Metals use both vertical upwards and downwards modes of continuous casting techniques to produce high quality, homogenous, close tolerance products, which have the benefit of reducing the waste and increasing the productivity of our customers.

In the vertical downward continuous casting process stream, using lip axis induction-melting furnaces, our quality-inspected feedstock is melted and analysed to ensure chemical conformity. The analysis of the metal is corrected if required and the metal is then poured directly into a temperature-controlled resistance continuous casting holding furnace.

By means of a bespoke valving system, the metal flow is controlled through a precision machined, graphite die, cooled by a High Conductivity Copper cooling jacket. This provides a highly efficient method of heat extraction, and results in a high integrity continuously cast strand product.

The solidified metal is then continuously cast at a pre-determined speed through the casting die, using strictly controlled electronically actuated strand pulling parameters. To prevent surface damage to the cast material, profiled withdrawal rolls are used which results in products with optimal cosmetic finish.

Virtually all casting dies are manufactured in our in house die shop using Mazak CNC machinery.

The system as configured, is probably the best metallurgical system in the world, for use in the CC processing of a wide spectrum of coppers and its alloys.

Nitrogen Shrouding

A positive pressure of inert atmosphere is maintained in the continuous casting holding furnace, by using Oxygen Free Nitrogen gas. The combination use of pure Nitrogen shrouding with a high purity graphite crucible melt containment system, ensures the expulsion of potentially harmful gases, such as hydrogen and oxygen by displacement. It results in a superior continuously cast material product entirely free from hydrogen porosity, gas and oxide inclusions. Click here to view the full size animation of the process used at Dens Metals.

Finishing

After casting to the lengths required, the products are finished by one or other of the finishing processes of straightening / polishing using our Farmer Norton, Robertson and section straighteners. Final trimming to order length and final inspection now takes place before packing.

Other options such as end chamfering can be offered if required.

In order to provide a more complete service to our cutomers Dens have recently invested in Adige and Forte automatic cutting saws. These allow us to cut material up to 6.1/16" (154mm) in dia and profile into blanks as thin as 4mm to a tolerance of .015" (.4mm).

Quality

Quality

As befits a modern day manufacturing company, Dens Metals is dedicated to supplying a product, of the highest quality to satisfy the demands of our increasingly specialised customer base.

Operating a Quality Management System, approved to ISO 9001:2000, our quality policy is based on the criteria set out by this standard. We have fully documented traceability on all our product from the ordering of the raw materials to delivery of the finished product to our customer. Our experienced and highly trained staff, are focused on manufacturing to the highest standards, at the same time striving to motivate our workforce for continuous improvement.

All material despatched is accompanied by your order number, our order number, the cast number, the product code if applicable, the size, the alloy, the chemical analysis and packing instructions. Mechanical properties, carried out by a NAMAS approved test house are also available on request.