Continuous casting is a process that allows
alloys and metals to get stretched, solidified, and shaped without any need of
interruption. Continuous casting
process aims at lessening waste while improving the quality, yield, and
cost efficiency.
A process invented into the steel manufacturing sector in the 1950s as a substitute to ingot molds, the continuous casting machine is now a standard in the production of premium battery grid. With the help cooled water and a series of rollers, the procedure reduces the impurities and offers better thickness ratio. To get a better understanding of the casting procedure, let’s look at the basics molten metals to the finished grid.
- Continuous casting process
In the manufacturing of a continuous grid, molten
lead is ladled in the casting equipment where it will be molded, cooled, and
stretched to form a finished product. While different continuous casting machines will offer
various benefits, the basic procedure is the same. Let’s have a look at the
entire procedure.
Liquid alloy or metal gets ladled into the
tundish that directs the flow of the substance into the molds. The tundish
works as a reservoir, continuing the flow of the substance as the ladle
refills.
The metal is poured into a water-cooled
mold, where it is partially solidified to have a basic grid shape. This is the
main cooling phase.
A semi-solid grid is sent via the strand
guide, continuing to stretch the substance to the required thickness as the
cooling continues in the secondary cooling phase.
A fully solidified grid is sent via
straighteners to obtain the final shape and dimension.
The finished grid is wound into a roll to
be stored.
- Continuous grid casting
system
Continuous grid casting system is designed to
remove lead scrap in grid production. Productive, secure, and more cost-effective,
the system provides flexible grid designs and all the benefits of traditional
gravity casting.
The casting equipment can produce a maximum of 120
feet in 60 seconds, based on the design of the grid, thickness, and metal
composition. The grids are meant to be used in motorcycle and automotive
batteries, industrial machinery, and wound cell batteries.
- Benefits of continuous
casting
Some of the main cast shapes that are
manufactured in strand casting comprise tubular and solid. However, irregular
shapes such as rectangular and hexagonal are cast to match the profile of the
final product.
Because the continuous casting works as a
bottom fed gravity flow manufacturing procedure, it eliminates the probable trapping
of dross and dirt in the process. The foreign substance in the crucible furnace
floats on the top of the melt so that it won’t be part of the process.
Here are some of the benefits of casting
- Reduces the weight of steel
- Quicker machining speeds for
enhanced productivity - Prolonged tool life
- Improved surface finish
- Reduced deburring
- Improved wear resistance
- Improved damping of vibration
and reduced noises - Compact lead-free chips
Final
word
Products obtained in the continuous casting
process can offer cost-effectiveness to alternative casting if the cast
substance shape and size is appropriately selected. Additionally, you need to
make sure you choose a high-quality casting machine.