Melting and Casting – A Critical Stage in the Copper Tube Manufacturing Process

In the HVAC and refrigeration industry, copper tubes are essential components that directly participate in the operation of cooling systems. However, not everyone fully understands the production stages and raw materials required in the copper tube manufacturing process to produce air conditioning copper tubes that meet international quality standards and satisfy diverse installation demands.

Through the article below, Ruby Copper invites readers to explore the Melting and Casting stage – the very first step in the copper tube manufacturing process behind high-quality copper tubes in Vietnam.

I. What is the Melting and Casting Process in Copper Tube Manufacturing?

In English, the process is called “Melting and Casting,” a metal forming process widely used throughout the metal industry. In the copper tube manufacturing process, melting and casting are essential steps that transform raw copper into billets ready for further production stages.

Specifically, “Melting” refers to the process of transforming metal from a solid state into a liquid state. Since metal is naturally rigid and hard, it must be melted to allow it to be formed into various shapes during the copper tube manufacturing process.

The next stage is “Casting,” where molten metal is shaped into billets according to required specifications. The molten metal is poured into molds, where cooling takes place using different methods such as exposure to workshop temperatures, compressed air, or water cooling systems, depending on the technology used in the factory.

The final product of the melting and casting stage is a solidified metal shape known as a cast billet. After the process is completed, the billet is removed from the mold and transferred to the next stage of the copper tube manufacturing process.

II. Copper Tube Manufacturing Process Technology at Ruby Copper Factory

There are many metal casting methods used worldwide in the copper tube manufacturing process, including:

• Gravity Casting: One of the earliest casting methods in the metal industry. Molten metal is poured directly from the furnace or ladle into molds made of steel or sand-core steel.
• Centrifugal Casting: A method where molten metal is poured into a rotating mold. The centrifugal force distributes the molten alloy evenly along the mold walls, where it solidifies.
• Extrusion Casting: A method in which liquid metal is poured into a pressure chamber and forced into the mold cavity under high pressure. The solidified casting is then removed from the mold.

As one of Vietnam’s leading copper tube manufacturers, Ruby Copper operates a modern production line featuring one of the most advanced technologies in the copper tube manufacturing process today: horizontal continuous casting.

Continuous casting is a rapid casting method performed in a production line system. During the process, molten metal is continuously poured into molds equipped with circulating cooling systems while cast billets are continuously withdrawn.

Advantages of Horizontal Continuous Casting in the Copper Tube Manufacturing Process

• Horizontal continuous casting is a state-of-the-art production technology highly suitable for the copper tube manufacturing process.
• This technology allows air conditioning copper tubes to be produced with high productivity, significantly optimizing production costs compared to traditional casting methods.
• Most importantly, horizontal continuous casting produces high-quality billets with excellent dimensional consistency and uniform properties throughout the entire billet length.

Overall, continuous melting and casting is currently considered the most advanced, efficient, and suitable technology used in the copper tube manufacturing process for air conditioning systems, refrigeration applications, water supply systems, and medical applications.

III. Overview of the Copper Tube Manufacturing Process at Ruby Copper

As the name “Continuous Casting” suggests, billets are produced continuously day and night. The melting and casting line at Ruby Copper’s factory typically only stops for maintenance or facility upgrades. This continuous operation increases productivity, optimizes production costs, and delivers greater value to consumers throughout the copper tube manufacturing process.

Melting and casting is one of the most important stages in the copper tube manufacturing process. This importance is reflected in Ruby Copper’s strict selection of raw materials:

• The primary raw material used in the continuous melting and casting process is Cathode Copper Class 1 (refined electrolytic copper cathodes), with a minimum copper purity level of 99.95% — the highest classification standard according to LME rankings.
• The cathode copper used by Ruby Copper is imported from the world’s most reputable copper producers, all of whom are listed on the London Metal Exchange (LME), ensuring copper purity of at least 99.95%.
• During casting, molten copper is strictly controlled and protected using professional measures to maintain maximum purity. Additionally, a controlled amount of Cu-P alloy is added to remove harmful oxygen gas during casting. As a result, products such as air conditioning copper tubes, medical copper tubes, and water copper tubes are classified internationally as Cu-DHP (Phosphorus-deoxidized copper).

The casting process continues until the billet reaches the required length standard. The billet is then cut and transferred to the next stage of the copper tube manufacturing process.

After undergoing rigorous melting procedures and being manufactured according to the Japanese copper tube standard JIS H3300, the original copper cathode material is transformed into premium Ruby Copper tubes that continue to expand their presence in international markets.

Ruby Copper products comply with many international export quality standards, including ASTM B280, B68, B88, EN 12735, and AS/NZS 1571.

As a leading enterprise in the construction and medical materials industry, both Ruby Copper factories are built on a large scale and equipped with modern machinery imported from world-leading manufacturers to optimize the copper tube manufacturing process.

Beyond advanced equipment and infrastructure, every stage of the copper tube manufacturing process at Ruby Copper is strictly monitored by industry experts and highly skilled engineers.

Ruby Copper is proud that its copper tube products are highly appreciated by both domestic and international customers for their quality and aesthetics, and are trusted by installation technicians, distributors, and reputable construction contractors worldwide.