Core Applications of Self-lubricating Copper Alloy Components in Continuous Casting Machines

I. Mold Oscillation Frame Bearings: The Ultimate Solution Against 1600°C Thermal Radiation

The mold oscillation device in continuous casting machines has long faced the challenge of copper plate thermal deformation compressing the bearings, leading to waveform distortion in oscillation and billet shell cracking, resulting in steel leakage. The innovative solution employs a CuAl10Fe3 nickel aluminum bronze matrix with a 30% gradient graphite inlay, where the graphite density is higher on the surface layer than in the inner layer, forming a lubrication gradient. Structurally, a honeycomb microporous oil-storage structure (with a pore depth of 0.1mm and a pore diameter of 0.3mm) is designed to automatically release a lubricating film upon heating. This is complemented by a 1.2mm-wide thermal expansion compensation slot that precisely absorbs the 0.15mm/100°C thermal deformation of the copper plate. Compared to traditional bearings, the temperature resistance limit has increased from 250°C to 950°C, the oscillation deviation has been optimized from ±0.8mm to ±0.1mm, and the steel leakage accident rate has decreased from 1.5 times per month to 0.1 times per year. After application on the Ansteel 2150 continuous casting machine, annual steel leakage losses were reduced by RMB 28 million, and the bearing service life reached 36 months.

II. Segment Guide Roller Copper Bushings: Black Technology for Absorbing Water Vapor and Iron Oxide Scale

Under the conditions of 600°C billet radiation, 80°C high-pressure water mist, and abrasion from HV800 hardness iron oxide scale, traditional copper bushings experience a monthly wear of 1.5mm. The solution adopts a CuSn12 phosphor bronze matrix reinforced with ZrO₂ ceramic fibers for wear resistance, combined with a 25% graphite + MoS₂ inlay layer for self-lubrication. Spiral drainage grooves (with a depth of 0.3mm and a pitch of 5mm) improve drainage efficiency by 80%, and surface laser micro-pits (Φ0.2mm) actively trap abrasive particles to prevent plowing wear. After implementation, the monthly average wear decreased to 0.06mm, the replacement frequency was extended from once per month to once every 3 years, and the billet scratch rate was sharply reduced from 18% to 0.5%. The Baosteel silicon steel production line saved RMB 5.1 million in annual maintenance costs and reduced downgraded billet products by 2.3%.

III. Cutting Car Track Copper Plates: "Energy-Absorbing Armor" for Heavy-Load Impacts

To address the track crushing problem caused by peak vibrations of 200MPa and thermal deformation during flame cutting, a three-layer composite copper plate was developed: a 20mm Q345 steel plate base layer for impact resistance, a CuZn40Al sintered copper alloy intermediate layer for heat conduction and vibration absorption, and a working surface with graphite capsule array self-lubricating units. Validated through 10⁷ cycles of 200MPa pulse testing according to ISO 4381 standards, the annual wear decreased from 12mm to 0.4mm, the wheel service life extended from 8 weeks to 100 weeks, and the track straightness maintained at ≤0.2mm/10m. Shagang's application demonstrated that the cutting car positioning accuracy remained stable at ±0.3mm for 3 years, and spare part costs decreased by 87%.

IV. Secondary Cooling Zone Pinch Roll Bearing Housings: "Water-Repellent Guardians" in Water Mist

The high-humidity environment in the secondary cooling zone leads to an average of 2.1 rust-induced seizures per month in traditional bearing housings. The innovation employs a CuNi10Fe matrix with a nano-hydrophobic coating (contact angle > 150°), paired with a centrifugal water-shedding structure (automatic drainage at speeds > 30rpm). Actual tests showed zero rust-induced seizures, a reduction in roll surface pitting depth from 0.8mm/month to 0.02mm/month, and lifetime maintenance-free seal replacement. The operating rate of Shougang's continuous casting machine increased from 82% to 96%, resulting in an annual increase in crude steel production of 370,000 tons.

V. The Irreplaceable Genes of Copper Alloys

King of Thermal Conductivity: With a thermal conductivity ≥90 W/m·K (5 times that of steel), it rapidly dissipates frictional heat.

Abrasive Particle Prison: The soft matrix encapsulates over 95% of abrasive particles, preventing secondary wear.

Corrosion-Resistant Barrier: The tin/nickel passivation film provides 10 times the Cl⁻ corrosion resistance of steel.

Anti-Adhesion Shield: Graphite releases a carbon film upon heating, preventing high-temperature metal adhesion.