Semi-Continuous Casting Systems

Vertical DC Casting for Copper Alloys

Semi-continuous (direct-chill) casting is a vertical casting process for producing large-format copper and copper alloy billets, slabs, and hollow billets. Unlike upward continuous casting, the semi-continuous process produces a fixed-length billet in each cast cycle, which is then cut to length and transferred to downstream processing (extrusion, forging, rolling).

The process uses water-cooled copper or aluminum molds. As the billet exits the mold, it is immediately quenched with direct water spray — the "direct-chill" step — which rapidly solidifies the surface and outer zone. This produces a fine-grain structure and tight dimensional tolerances across large cross-sections.

Semi-continuous casting is particularly well-suited for copper alloys including brass, bronze, copper-nickel, and precipitation-hardening alloys such as CuCrZr, where precise composition control and homogeneous microstructure are critical.

Process Advantages

• Produces large-format billets — diameter per project specification
• Suitable for alloys including brass, bronze, CuNi, CuCrZr
• Direct chill water cooling for fine grain structure
• Homogeneous composition across billet cross-section
• Compatible with both cathode and scrap feed

Target Industries

• Copper extrusion companies
• Brass rod and section producers
• Forged fitting manufacturers
• Specialty alloy producers