Copper Continuous and Semi-Continuous Casting Process with MAGMA CC

The Continuous and Semi-Continuous casting process is pivotal in the production of semi-finished copper products. During this process, liquid metal is introduced into an intensively cooled mold. Concurrently, metal is withdrawn from the mold, requiring the establishment of a stable solidified shell at the mold's exit. MAGMA CC, a fully integrated turn-key solution, is instrumental in simulating and optimizing both vertical and horizontal casting processes.

Key features:

  • Robust solutions for copper production in Continuous and Semi-Continuous casting processes.
  • Design process conditions for optimized flow and solidification, enhancing product quality.
  • Integrated simulation of casting stresses, including cracks and hot tears, for comprehensive process evaluation.
  • An integrated process chain for casting with subsequent forging and rolling processes.

Process Simulation Capabilities Include:

  • Realistic representation of the entire casting process, assessing flow conditions during start-up and strand withdrawal.
  • Consideration of forced and natural convection in the liquid metal and mushy zone.
  • Determination of the stationary temperature distribution in the strand and mold, allowing the evaluation of influencing parameters.
  • Accurate prediction of the sump profile and assessment of optimal process parameters for improved energy efficiency.
  • Calculation of the solidification front to prevent bleedout and evaluation of thermal gradient and cooling rate.
  • Assists in achieving high productivity, cost, and energy efficiency, reduced porosity, shrinkage, and optimization of launder and nozzle design.
  • Virtual design and optimization of the casting process.
  • Stop and Go casting capability for enhanced process control
Publicación en el área de fundición continua

Autonomous Mathematical Optimization of Continuous Casting Processes


Wilfried Schäfer, Götz Hartmann, Erik Hepp, MAGMA GmbH, Aachen, Germany
Dieter G. Senk, Sonja Stratemeier, IEHK RWTH Aachen University, Germany

The publication introduces a numerical simulation based optimization strategy, following rigorous thermodynamic and thermo mechanical models as well as a strictly methodic approach.

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