In Part 1, we covered two foundational steps for durable copper mould tubes: choosing the right material and controlling machining precision—both critical for avoiding early flaws. Now, we turn to the final pre-service step: proper installation. Even well-machined, high-quality tubes fail quickly if installed poorly. We’ll also summarize the core takeaways and preview in-service practices to extend tube life.

3. Ensure Proper Installation: Align, Seal, and Balance Loads

Installation directly impacts how copper mould tubes handle in-service stress. Focus on three key precision metrics:

-Central alignment: Use a laser aligner to keep the deviation between the copper mould tube center and caster roll center ≤0.5 mm. Misalignment causes billet drift, increasing one-sided wear by 30%–50%—proper alignment can even double service life.

-Cooling circuit sealing: For the tube’s cooling system, use silicone rubber seals that withstand 150°C and 2.0 MPa (size deviation ≤0.1 mm). Maintain a gap of ≤0.1 mm between the water tank and tube to avoid stagnant flow (which leads to overheating) or deformation from tight fits.

-Foot roller coordination: Keep the distance between the tube’s lower end and foot rollers at 5–10 mm. Ensure axis parallelism of ≤0.3 mm per meter—poor parallelism causes billet bulging or pulling-induced scratches on the tube.

Core Takeaways: Three Foundational Steps for Longevity

The service life of copper mould tubes depends on three interconnected pre-service steps:

1. Material selection: Match the alloy to casting speed and steel grade (e.g., Cu-Ag for medium speed, Cu-Cr-Zr for high speed).

2. Machining precision: Eliminate flaws with a smooth inner wall, uniform thickness, and properly treated ends.

3. Installation accuracy: Ensure alignment, leak-free sealing, and coordinated foot roller setup to avoid uneven stress.

Get these three steps right, and doubling the service life of copper mould tubes—from the typical 300–500 heats (pure copper) to 800–1200 heats (with Cu-Cr-Zr alloy and proper pre-service control)—is easily achievable.

Next: In-Service Maintenance for Longer Life

Pre-service steps set the stage, but in-service control further maximizes tube life. Upcoming content will cover:

- How to adjust cooling water flow and pressure to avoid overheating or thermal fatigue.

- Tips for stable casting speed control to reduce wear from billet thickness fluctuations.

- Early defect detection (e.g., eddy current testing for cracks) to prevent sudden failure.

Stay tuned to keep your copper mould tubes running longer and more reliably!