High Pressure Continuous Casting Unit

The quality of the casting process is the crucial variable for the quality of the final product. Through deep research and testing, Hydron developed a new technolgy - the high pressure continuous casting.
Hydron's continuous caster HP-CCU-112 continuously casts melted alloy into a round shaped semi-procuct, which is cut into billets of required length by integrated buzz saw.

HP-CCU-112 Features:

• Hydron's unique high-pressure casting technology boosts both quality and output values
• Integrated buzz saw - replaces two units, eliminates discards
• Automatic billet take-up system
• Esily movable - can serve several melting pots
• Hydraulically powered - economical and effective
• Casts all solder alloys - lead-free, babbit

Unit Description:

Hydron's High Pressure Continuous Casting Unit is the next breakthrough in the casting technology designed by the Hydron research team. The machine produces high density billets of tin-lead and leadfree solder alloys and required geometry.

Hydron produces CCU-112 casting units in two sizes:

• Medium CCU-112/72 with the billet diamter equal to 72 mm, perfect for wire and bar production (coupled with Medium Extrusion Press HEP-112/72)
• Heavy CCU-112/116 with the billet diamter equal to 116mm, perfect for anode and heavy bar production (coupled with Heavy Extrusion Press HEP-112/116).
• Other sizes available as well as units with a changable billet geometry are available upon request

Quality: The unit utilizes two important technologies which highly improve the quality of the billet: the idea of continuous casting as well as the high pressure intensifier. Thanks to this, the billets are flawless and oxides-free and are characterized by a higher denisty, which is important during extusion and, especially, during the drawing phase, allowing for a higher-quality final products.

Automation: One of the main objectives was to reduce the necessity for the operator. Included pump automatically loads the melted alloy from the furnace into the feeding pot of the CCU. Billets are automatically casted, cut and placed onto a pallet or into a specialized container, which can later be transported to the extrusion press. ALternalively, the billets can automatically be loaded into the HEP-112 Extrusion Press.
The press uses the programmable logic controllers and an specialized alarm system to enable quick respond to any process variations. Casting speed is fully controlled.

Efficiency: The unit is the most efficient on the market, enabling solder producers to achieve higher outputs then ever before. The casting process is automatically optimized, according to the temperture in the crystalizing chamber, with a variable dwell time. Billet cutting is independent from casting and does not stop the process.
The unit is also equipped with stepless speed control and frequency inverter.

Environment: While high outputs and efficiency are crucial for production levels and profits, taking care of our environment is crucial to everyone. That is why we constantly redesign our units to consume less resources and energy and produce less scrap. This casting unit is powered by HSS-112, our special energy-efficient electro-hydraulic supply system. Also, due to the fact that the casting time is reduced, the costs of alloy melting are lowered.

Please do not hesitate to contact us if you have any questions about our equipment.