Home > Chemistry > Manufacturing Process
Manufacturing Process United Cast Bar Limited

Title: Manufacturing Process - United Cast Bar Limited

  • Company Name: United Cast Bar Limited
  • Phone:
  • Fax:
  • Address: Aurora, IL 60506
contact supplier

Verified Supplier

Manufacturing Process

Manufacturing Process



The Unibar horizontal continuous casting machine consists of four major units:

  • A holding furnace with liquid-cooled dies.
  • A pulling unit.
  • A notching and breaking device.
  • A control panel that regulates the flow of coolant and the speed of casting, and co-ordinates the function of the other three components of the machine.


As can be seen from the animation, in the closed system a liquid-cooled die is built into the holding furnace so that the liquid metal enters the die without coming into contact with the atmosphere. Because the bar is pulled horizontally, the metal flows more uniformly and is always subjected to a much higher ferrostatic pressure than in sand castings. This, combined with rapid cooling in the die, ensures superior soundness, good surface finish and homogenous structure as well as excellent structural cohesion throughout the section.

As a result, the outside rim (periphery) is solid the moment it leaves the die and cooling system (which conforms the profile shape), while the core remains liquid. Due to the fast cooling, the periphery has very fine graphite in a predominant ferritic matrix with a high material cohesion; much higher than is obtained with sand casting.

It should be noted that the bars, particularly in larger sizes, will have some ‘A’ type graphite while the outer region will have either fine dendritic or rosette type formation.

The lack of porosity, slag and other inclusions are ensured by the Unibar process which, together with other advantages ensures a much better fatigue strength.

The starter bars are inserted into graphite die prior to filling the holding furnace. Liquid metal, on entering the die, freezes on the protruding bolts and is then gradually extracted by means of standard round pulling bars connecting the starting blocks with the drive mechanism. After the newly cast material has passed the pulling mechanism, the pulling bars are disconnected and the material itself is notched and broken into individual bars, which are commonly 2 – 4 metres long. The quality of the material can be readily checked by observing fresh fractures on every length of bar produced.



The Unibar horizontal continuous casting machine consists of four major units:

  • A holding furnace with liquid-cooled dies.
  • A pulling unit.
  • A notching and breaking device.
  • A control panel that regulates the flow of coolant and the speed of casting, and co-ordinates the function of the other three components of the machine.


As can be seen from the animation, in the closed system a liquid-cooled die is built into the holding furnace so that the liquid metal enters the die without coming into contact with the atmosphere. Because the bar is pulled horizontally, the metal flows more uniformly and is always subjected to a much higher ferrostatic pressure than in sand castings. This, combined with rapid cooling in the die, ensures superior soundness, good surface finish and homogenous structure as well as excellent structural cohesion throughout the section.

As a result, the outside rim (periphery) is solid the moment it leaves the die and cooling system (which conforms the profile shape), while the core remains liquid. Due to the fast cooling, the periphery has very fine graphite in a predominant ferritic matrix with a high material cohesion; much higher than is obtained with sand casting.

It should be noted that the bars, particularly in larger sizes, will have some ‘A’ type graphite while the outer region will have either fine dendritic or rosette type formation.

The lack of porosity, slag and other inclusions are ensured by the Unibar process which, together with other advantages ensures a much better fatigue strength.

The starter bars are inserted into graphite die prior to filling the holding furnace. Liquid metal, on entering the die, freezes on the protruding bolts and is then gradually extracted by means of standard round pulling bars connecting the starting blocks with the drive mechanism. After the newly cast material has passed the pulling mechanism, the pulling bars are disconnected and the material itself is notched and broken into individual bars, which are commonly 2 – 4 metres long. The quality of the material can be readily checked by observing fresh fractures on every length of bar produced.

Info you may be interested

©2014 biziup.com