Rautomead Limited

Rautomead LimitedPO Box 100Dundee DD1 9QY Scotland Registered Office: Nobel Road

Wester Gourdie Industrial Estatet. (44) 1382 622341 Dundee DD2 4UH, Scotland

f. (44) 1382 622941 Incorporated in Scotland No. 152367

Continuous Casting Technology

www.rautomead.com VAT Reg. No. GB 658 2549 03 Advanced Metals Technology 

Rautomead Technologyfor

CuMg Railway and

Automotive Wire

Rautomead Limited

Introduction to Rautomead

Rautomead Limited

Rautomead LimitedDundee Scotland

Founded 1978Sir Michael NairnChairmanBrian Frame MDappointed 2008

Employees = 50

No Machines Sold = 346First 1978

Of these :-No Vertical Upwards = 76First 1995 (Patent expired 1990)

Rautomead Limited

Rautomead – Nobel Road Factory

Rautomead Limited

Rautomead – Nobel Road Factory

Rautomead Limited

Rautomead – Unit 7A Nobel Road Factory

Rautomead Limited

Rautomead – Unit 7A Nobel Road Factory

Rautomead Limited

RS3000 – 8mm Cu-OF Redraw Rod

Rautomead Limited

RS3000/Mg – 30mm CuMg for HS Railway Contact Wire

Rautomead Limited

RS2500 – 8mm 65:356 Redraw Rod for EDM Wire

Rautomead Limited

RS1000 – Brass for Cold Heading

Rautomead Limited

RT850 – Hollow Bronze Billet for Pump Bearings

Rautomead Limited

RX1100 – 70mm Zinc Billet for Extrusion (Wheel Weights)

Rautomead Limited

RMJ/H025

RMT200

RMJ/V005

RVSIII Tilt

Rautomead Limited

5000 – 10000 Tonnes/Year

Rautomead Limited

Serial Year Customer Model       346 2012 Tecnofil RS 3000/6-22    Peru         345 2012 Anon

BrazilRS 2200/5

       344 2012 Industrial Company Vtoraluminproduct

LLC, RussiaRT 650

       343 2012 Lucas-Milhaupt Inc. RMT 200    U.S.A.         342 2012 Mitsubishi Materials Corp. Metals Co. RS 080    Japan         341 2012 Solar Chemical Applied Materials

Technology (Kunshan) Co. Ltd, TaiwanRVS III/V

       340 2012 Cetusan Abadi Sdn Bhd RVS III    Malaysia         339 2012 Sodick EMD Wire Supply Division RS 2500/8    Japan         338 2012 Shandong Zhaojin Precious Metals Co.

Ltd, ChinaRMJ/H 025

Rautomead Limited

Rautomead Furnace Technology for

Continuous Casting

Rautomead Limited

Rautomead Furnace Technology

Rautomead Technology for Continuous Casting is unique because it uses GRAPHITE for :-

•Casting (Dies and Packers)

•Heating (Low Voltage resistance heating elements).

Rautomead Limited

Rautomead Furnace Technology

Rautomead Technology for Continuous Casting is unique because it uses GRAPHITE for :-•Containment (Crucible & Valve)

•Casting (Dies and Packers)

•Heating (Low Voltage resistance heating elements).

Rautomead Limited

Rautomead Furnace Technology

Rautomead Technology for Continuous Casting is unique because it uses GRAPHITE for :-•Containment (Crucible & Valve)

•Casting (Dies and Packers)

•Heating (Low Voltage resistance heating elements).

Rautomead Limited

Rautomead Furnace Technology

Rautomead Technology for Continuous Casting is unique because it uses GRAPHITE for :-•Containment (Crucible & Valve)

•Casting (Dies and Packers)

•Heating (Low Voltage resistance heating elements).

Rautomead Limited

Rautomead Graphite Furnace Technology for

Continuous Casting CuMg wire rod

Rautomead Limited Experience with copper Magnesium Production Continuous cast rod to Contact & Catenary wires

Rautomead Limited Copper Magnesium (0.14%) Production Continuous cast rod to Small diameter Cable

Rautomead Limited

Contact Wires for High Speed Train Systems - Requirements: Copper Magnesium (0.57%)

• High Conductivity: reduce losses

• High Tensile strength minimises “lift” of contact wire up to 490 N/mm2 maximises design speed. Up to 450km/hr

• Wear resistant maximises operating life

• Resistant to “arc” formation minimises erosion

Rautomead Limited

Catenary and Contact Wire Tonnage Requirement• Single Track:• 120mm2 CuMg Contact

wire: approx 1 tonne /km• Total wire: catenary &

contact: approx 4 – 5 tonnes/km

New Double track line constructions:

• Wire requirement: • 8 – 10 tonnes / km

Rautomead LimitedPossible explanation for present shortage of and high price for CuMg rodChinese Expansion of high speed rail network 12,000 km by 2020

Rautomead Limited

PDL High speed train lines in China under constructionContact wire material: CuMg 0.5 tensile 490 N/mm2

Wuhan to Guangzhou target running speed (max) 350 km/hr970 km catenary/contact wire design speed 450 km/hr

Shanghai to Beijing target running speed (max) 380 km/hr 1320 km catenary/contact wire design speed 450 km/hr

Existing Tianjin-Beijing

Uses Siemens CH3

High speed trains

Rautomead Limited

Customer Reference List for CuMg Contact Wire production: 0.57%• Fujikura Hengtong Aerial Cable China Vertical• Shandong Tian Yuan Copper China Vertical• Xian XD China Vertical• Xian XD China Vertical• CRCEB China Vertical• NKT Changzhou China Vertical• NKT Changzhou China Vertical• NKT Changzhou China Vertical• Nanjing Daqo NKT China Vertical• Lamifil BelgiumVertical• LaFarga LaCambra Spain Vertical• Transkat Russia Vertical• Lamifil BelgiumVertical• HFB Hettstedt Germany Horizontal• HFB Hettstedt Germany Horizontal• HFB Hettstedt Germany Horizontal

Rautomead Limited Copper Magnesium (0.14%) Production Continuous cast rod to Small diameter Cable

Rautomead Limited

Copper magnesium alloy wires

• Higher strength

• Reduce diameter without sacrificing mechanical

performance

• Reduce weight of harness

Rautomead Limited

Copper magnesium alloy 0.14% experience to date• Sample production on Rautomead “in house” RS 080 single strand

upward casting machine.

• RS Upward casting 19mm dia 70 - 75 kg/hr/str (480mm/min)• 1.0 – 2.0 tonne coils• Elongation of “as cast” 28 – 30%

• Test Drawing sequence (for purpose of tests, drawing speed approx 50% of pure copper)• 19 – 8.0mm anneal• 8.0 – 1.2• 1.2 – 0.156 (0.156 765 N/mm2 1094 ohm/km ) within specification • (no material related breaks during drawing)

7 strand finished wire (OD 0.456mm) (780 N/mm2 159.28 ohms/km) within spec.

Rautomead Limited

Copper magnesium alloy 0.14% experience to date• Magnesium addition: a. pure magnesium chips

b. 50:50 master alloy c. cored wire automated feed (available with full production automated cathode feed)

• Magnesium “losses” during production, 0.09% (for either pure Mg or master)

• Composition Control:

Rautomead Limited

High quality feedstock

• Electrorefined copper cathode– LME Grade A

• 50:50 copper magnesium master alloy

• Pure magnesium pieces wrapped in copper foil

Rautomead Limited

Advantages of Upward Vertical Casting for Wire Rod Production• Minimal “downtime” when changing dies• Controlled and consistent metal pressure in the casting die• Concentric cooling of the cast wire rod• Automated feeding and casting system

Rautomead Limited

Horizontal casting of CuMg installed 1991 pre Upward technology

Rautomead Limited

CuMg cast rod, grain structure

Horizontally Cast(Cu-Mg)

Vertically Cast(Cu-Mg)

Rautomead Limited

RS 080 single strand upward casting

Rautomead Limited

Manufacture of CuMg Trolley Wire• Continuous Casting• RS 3000

• Profile Drawing

Rautomead Limited

Rautomead Continuous Casting Technology for CuMg Rod

• Graphite Crucible removes oxygen from copper

• Electric resistance heating no inductor

• Single furnace, melting and casting no metal transfer

• Advanced Cooler design high quality rod

• Accurate control of parameters consistent quality

Rautomead Limited

RS 3000 Graphite Crucible

Rautomead Limited

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1 2 3Time - Hours(Retention time in Graphite)

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Rautomead Limited

Oxygen Reduction – O2 Level Over 12 Month Period

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Rautomead Limited

Heating System - Graphite Heating Element Assembly

Rautomead Limited

Heating System - Graphite Crucible & Heating Elements

Rautomead Limited

Heating Elements & Sight Glass – cold Heating Elements – heated & glowing

Rautomead Limited

Properties of Graphite

• Increasing strength at higher temperatures• High thermal conductivity• High thermal shock resistance• Good electrical conductor• Non-wetting• Easily machined• Relatively soft• High lubricity

Rautomead Limited

Automatic Cathode Feed

Rautomead Limited

Automatic Cored wire feed

Rautomead Limited

Rautomead Cooler Technology

Rautomead Limited

Rautomead Withdrawal Casting Technology

Rautomead Limited

Rod Coiling

Up to 4.0 tonne coil weight

Rautomead Limited

PLC System Control

Rautomead Limited

Plant Monitoring:

remote observation data storage

Rautomead Limited

Thank You www.rautomead.com

Rautomead LimitedPO Box 100, Dundee DD1 9QYScotland U.K.