Hazelett's twin-belt copper strip-casting machine incorporates the latest mechanical, electrical, and process improvements and delivers ever increasing production volumes, product range, and quality.  The Conti-M® process, which currently produces all major copper grades, was developed jointly with Mansfelder Kupfer und Messing GmbH.

The technology incorporated into the Hazelett copper strip casting machine has evolved over decades of innovative engineering and design as well as process experience developed with our industrial partners.

*Conti-M is a registered trademark of Mansfelder Kupfer und Messing, GmbH


Hazelett twin-belt caster - core machine

Open pool metal feeding schematic

open pool metal feeding

When casting high temperature metals, such as copper and steel, open pool feeding, including its submerged tube variant, is used. In this case, the upper belt pulley is offset downstream. Metal flows from an open trough, or tundish, over a wier, or through tubes, into a standing pool of molten metal formed at the convergence of the belts. Metal flow is regulated in the open pool feeding system by means of a laser pool level sensor.

Mold interface

Molten metal solidifies adjacent to the belts, forming a shell which becomes a liquid sump as the slab proceeds down the mold. Solidification is normally complete approximately 70% to 80% down the mold length. The critical area of the mold is the interface between the solidifying metal and the moving, water-cooled belts

Cast metal solidifies on the Matrix™ coated belt, forming a shell

Magnified cross section of the mold interface

The key components of the mold interface include the permanent, ceramic-based Matrix™ belt coating and the belt overcoating applied before or during casting. 

matrix™ Coating

The Matrix™ ceramic or ceramic metallic-based coating is thermally sprayed onto the belt surface, which has been grit blasted to a specific topography. Metallic and ceramic powders are blended and applied at the desired thickness, morphology, porosity, topography, and thermal transfer characteristics according to the alloy to be cast, producing an extremely wear-resistant coating.

ESP™ Coating

Hazelett aluminum strip casters feature the ESP™ coating system, which is a unique patented ElectroStatic Powder deposition system. This allows a continuously controlled application of very fine powders, including fumed silica. The application rate can be adjusted for alloy and plant atmospheric conditions

Schematic diagram of ESP™ coating system

Mold shaping

The Hazelett® twin-belt caster is unique among moving mold casters in that all four mold surfaces are independent. This allows the mold surfaces to be tapered to remain in contact with the cast product as it shrinks. The high velocity, fast-film cooling water, which is continuously applied to the backside of the belt, impinges the belt at a slight angle, creating a force on the belt. This force acts to press the belt against the surface of the strip or slab as it shrinks, keeping the belt in intimate contact with the product throughout the mold.

High pressure cooling water forces belts against cast copper strip