Introduction

Copper rods are essential raw materials for wire cables, electronic components, and other industries, where quality directly impacts performance and reliability. With increasing demand for high-conductivity, high-purity copper rods, the upward continuous casting and rolling (UCCR) process has emerged as a leading production method. This technology boosts efficiency, reduces energy consumption, and significantly improves rod quality through strict oxygen content control.

Upward Continuous Casting and Rolling Copper Rod Process

Process Overview

The UCCR method is a continuous production technology that directly draws molten copper into rods. Its key advantage lies in minimizing copper-oxygen contact during casting, reducing oxidation, and enhancing final product performance through integrated rolling.

Step-by-Step Process Flow

1.Raw Material Preparation

• Uses 99.99% pure electrolytic copper plates (no additional refining needed).
• Directly fed into the melting furnace.

2.Melting

• Copper plates are melted in a medium-frequency induction furnace at >1160°C.
• Temperature control ensures uniform, impurity-free molten copper.

3.Upward Continuous Casting

• Molten copper flows into a sealed holding furnace and is drawn upward through a crystallizer.
• Protective measures:Covering agents (e.g., graphite powder) Inert gases (CO or H₂) to prevent oxidation.

4.Continuous Rolling

• The cast rod passes through multi-stage rolling mills to achieve desired dimensions.
• Cooling lubricants maintain surface quality.

5.Coiling & Inspection

• Finished rods are coiled and undergo strict quality checks (surface, internal structure, dimensions).

Defective rods are recycled into the melting furnace.

Key Oxygen Control Techniques

Why Oxygen Content Matters

Excess oxygen (as Cu₂O) degrades copper rod performance:

• ↓ Conductivity – Disrupts electron flow, reducing efficiency.

• ↓ Mechanical Strength – Weakens grain boundaries, lowering tensile strength.

• ↓ Workability – Increases cracking risk during processing.

Effective Oxygen Reduction Methods

✅ High-Purity Raw Materials – 99.99% electrolytic copper with pre-melt surface cleaning.
✅ Melting Protection – Covering agents + controlled temperature to minimize oxidation.
✅ Sealed Casting Environment – Prevents air exposure; uses CO/H₂ shielding gas.
✅ Real-Time Monitoring – Infrared spectroscopy oxygen analyzers ensure levels stay within limits (e.g., <10ppm for premium oxygen-free copper).

Precision Oxygen Measurement: The “Health Check”

Advanced oxygen analyzers act like “doctors” for copper rods, providing instant readings. This allows real-time adjustments to maintain optimal oxygen levels.

Real-World Applications & Results

Recent advancements have achieved ultra-low oxygen copper rods:

• 0.48ppm oxygen – Resulting in 102% IACS conductivity & 344.4MPa tensile strength.

• <5ppm oxygen via gas-shielded coating – Enhancing conductivity and workability.

Conclusion

The upward continuous casting and rolling process is a high-efficiency, energy-saving copper rod production method, with oxygen control being critical for performance. By optimizing raw materials, melting, casting, and monitoring, manufacturers can produce high-conductivity, durable copper rods. As technology evolves, this method promises even greater advancements in copper processing.