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Large Split Water-Cooled Copper Crucibles for Vacuum Melting Furnaces | Large Split Water-Cooled Copper Crucibles | PETROL STEEL
PETROL STEEL offers custom-made large split water-cooled copper crucibles for Vacuum Induction Melting (VIM) furnaces, Vacuum Induction Skull Melting (ISM) furnaces and cold-crucible levitation melting systems. We process and export non-ferrous metals with over a decade of experience, using TU1 oxygen-free copper or T2 high-purity copper. We manufacture large copper crucibles with 0.5kg to 200kg capacity and with Φ100mm to Φ1500mm diameter by integral forging/spinning or precision rolling and welding processes. The products are extensively used in high purity melting and precision casting of titanium zirconium alloys, high temperature superalloys, high entropy alloys, rare earth permanent magnet materials and metamaterial elements.
Product Overview and Technical Principles of PESCO Large-Scale Split Water-Cooled Copper Crucibles
In conventional vacuum melting processes, high temperature melts are prone to interfacial reactions with the refractory materials, using alumina, magnesia or graphite crucibles. These reactions introduce oxygen, carbon and non-metallic inclusions into the alloy severely compromising performance of high-purity targets , aero-engine alloys and substrates for metamaterials . The solution to this problem is the use of large-scale copper crucibles with a design that includes forced-circulation water cooling and a split, slotted structure. The insulating slots (axial or radial) interrupt the closed path of the induced currents in the copper walls and thus remove the electromagnetic shielding, allowing the high- or medium-frequency alternating magnetic fields to pass through the crucible and affect the furnace charge. At the same time, the inner crucible wall is cooled by water continuously, and the temperature is close to the room temperature. Under the action of electromagnetic confinement force (magnetic compression or levitation effect), the molten metal is in a non-contact or semi-levitation state with the copper wall, and only a micron-sized "skull" (solidified crust) is formed at the bottom. This prevents contamination of the melt by the crucible, and allows material purity control to levels of 99.995% (4N5 grade) or better.
Selection of Materials and Physicochemical Characteristics of Large-Scale Split Water-Cooled Copper Crucibles from PETROL STEEL CO., LTD
The TU1 oxygen-free copper (Cu ≥ 99.97%, O ≤ 0.003%) or T2 pure copper (Cu ≥ 99.90%) is recommended for the body of PETROL STEEL large-scale copper crucibles. Complied with GB/T 5231, ASTM B152 and EN 13601 standards. TU1 oxygen-free copper has very low oxygen content, resistant to hydrogen embrittlement and grain boundary oxidation during repeated thermal cycling; electrical conductivity ≥101% IACS, thermal conductivity ≥390 W/(m·K), fast conducting induction heat, then transferred to cooling water, temperature increase of the crucible body is less than 40 °C during long melting operation. CuCrZr (chromium-zirconium copper) alloy may be used for applications requiring a higher strength or high-frequency and current conditions. It has a yield strength ≥260 MPa and softening temperature of 550°C, ideal for high-capacity, continuous operations.
Design of the Structure and Setting of Parts of Large Split Water-Cooled Copper Crucibles at PETROL STEEL CO., LTD
A typical large copper crucible includes a cylindrical body, a bottom head (or open bottom), flange connections, and internal spiral or annular cooling channels. The cylindrical body is divided circumferentially into 4, 6, 8, or 12 segments (depending on the diameter and induction frequency), with high temperature mica sheets or polyimide insulating gaskets placed between the segments; the gap width is generally kept between 0.3 mm and 1.0 mm to balance the electromagnetic penetration with mechanical strength. The cooling system adopts a bottom-in/top-out dual-flow circuit design, and flow-directing baffles are set at critical positions to guarantee the uniform wall temperature field and avoid local overheating which results in abnormal skull thickening or melt adhesion to the walls. It is recommended that the flange and cylindrical body should be made by integral forging to avoid the risk of longitudinal welding. If it is made by rolled plate welding, all the welds shall be subjected to X-ray inspection (NB/T 47013.2-2015, Class II) and hydrostatic pressure test at 1.5 times of the working pressure.
Manufacturing process and quality inspection of large-scale split water-cooled copper crucibles of PESCO
Depending on the operating conditions, PETROL STEEL offers two manufacturing methods for customers to choose from: 1. Integral Forging & Power Spinning--Large format oxygen free copper ingots are multi-directional forged and hot spun to make the cylinder body. This achieves fine grain structure, no longitudinal welds and excellent thermal fatigue resistance. Suitable for large capacity or high frequency skull melting furnaces (diameter >300mm). 2. CNC precision plate rolling and TIG welding—T2 copper plates are CNC rolled into cylinders and welded under protection of inert gas. This method is more economical and suitable for small-to-medium-sized units or R&D equipment. All copper crucibles shall be subject to the following procedures after completion: ultrasonic testing of the inner wall (JB/T 4730.3 Class II); hydrostatic pressure holding test (0.6~1.0 MPa for 30 minutes, no leakage); flatness inspection of the flange sealing surface (≤0.05 mm); water flow rate calibration. The shipment is accompanied by documentation comprising Material Test Certificate (MTC), non-destructive testing (NDT) reports and dimensional inspection reports.
Typical technical parameter ranges (can be customized based on drawings)
Applicable melting capacity: 0.5kg – 200kg (Titanium based)
Crucible inner diameter: φ60 mm – φ1200 mm (larger sizes on request)
Cylinder wall thickness: 8 mm – 25 mm (based on capacity and inductive coupling calculations)
Number of segments 4 / 6 / 8 / 12 (custom configurations available)
Cooling water pressure needed: 0.25 – 0.6 MPa
Cooling water flow: ≥ 3 m3/h (capacity dependent)
Ultimate vacuum level: < 6.7E-4 Pa
Maximum melting temperature (melt) = 3600°C (water-cooled copper wall)
Note: the specific dimensions and layout of the water circuit should be designed for type of furnace of the customer, parameters of the induction coil, frequency of the power supply and capacity of the crucible.
Important Areas of Application for PETROL STEEL Large-Format Split Water-Cooled Copper Crucibles:
PETROL STEEL large copper crucibles are widely used in the production of following high-value-added materials: achieve true “contamination-free cold-wall melting”: 1. Smelting of reactive metals: titanium, zirconium, hafnium, tantalum, niobium, and their alloys without reacting with ceramic crucibles, which would form brittle intermetallic compounds; 2. Specialty alloy R&D – nickel-based/cobalt-based superalloys, high entropy alloys (HEAs) and titanium-aluminum intermetallics – utilizing intense electromagnetic stirring to improve compositional homogeneity and suppress segregation; 3. Preparation of precursors for functional materials and metamaterials – alloys for metasurface elements, high-purity master alloys for graded-index media, ferrite pre-alloys; 4. Semiconductors and sputtering targets--melting and casting of high-purity copper, aluminum, titanium and tantalum target billets under strict controls on trace impurities and gas content in sputtered thin films; 5. Rare earth permanent magnet materials Vacuum melting of NdFeB and SmCo master alloys to minimize rare earth burn-off and oxide inclusions.
Large-scale split water-cooled copper crucibles of PESCO: Customization and export services
Backed by a strong technical team, PETROL STEEL gives full support based on furnace drawings, dimensions of the induction coil or parameters of the melting process provided by the customer. We help with segment count simulation, cooling circuit optimization and thermal stress analysis and we produce engineering drawings for client approval prior to production. We can make custom products according to your drawings (DXF/DWG/STEP formats) and produce designs with non-standard tapered structures, multi-layer cooling channels, and integrated vacuum flanges (KF or CF series). Export products are packed in wooden crates, vacuum packed with anti-rust oil, with material certificates and inspection reports in English. We provide vacuum equipment to manufacturers and research institutions in Europe, North America, Japan, South Korea and South East Asia. We provide flexible cooperation models and accept various trade terms, including FOB, CIF and DDP.
Request Professional Product Quotes and Technical Support
PETROL STEEL offers custom-made large split water-cooled copper crucibles for Vacuum Induction Melting (VIM) furnaces, Vacuum Induction Skull Melting (ISM) furnaces and cold-crucible levitation melting systems. We process and export non-ferrous metals with over a decade of experience, using TU1 oxygen-free copper or T2 high-purity copper. We manufacture large copper crucibles with 0.5kg to 200kg capacity and with Φ100mm to Φ1500mm diameter by integral forging/spinning or precision rolling and welding processes. The products are extensively used in high purity melting and precision casting of titanium zirconium alloys, high temperature superalloys, high entropy alloys, rare earth permanent magnet materials and metamaterial elements.
Product Overview and Technical Principles of PESCO Large-Scale Split Water-Cooled Copper Crucibles
In conventional vacuum melting processes, high temperature melts are prone to interfacial reactions with the refractory materials, using alumina, magnesia or graphite crucibles. These reactions introduce oxygen, carbon and non-metallic inclusions into the alloy severely compromising performance of high-purity targets , aero-engine alloys and substrates for metamaterials . The solution to this problem is the use of large-scale copper crucibles with a design that includes forced-circulation water cooling and a split, slotted structure. The insulating slots (axial or radial) interrupt the closed path of the induced currents in the copper walls and thus remove the electromagnetic shielding, allowing the high- or medium-frequency alternating magnetic fields to pass through the crucible and affect the furnace charge. At the same time, the inner crucible wall is cooled by water continuously, and the temperature is close to the room temperature. Under the action of electromagnetic confinement force (magnetic compression or levitation effect), the molten metal is in a non-contact or semi-levitation state with the copper wall, and only a micron-sized "skull" (solidified crust) is formed at the bottom. This prevents contamination of the melt by the crucible, and allows material purity control to levels of 99.995% (4N5 grade) or better.
Selection of Materials and Physicochemical Characteristics of Large-Scale Split Water-Cooled Copper Crucibles from PETROL STEEL CO., LTD
The TU1 oxygen-free copper (Cu ≥ 99.97%, O ≤ 0.003%) or T2 pure copper (Cu ≥ 99.90%) is recommended for the body of PETROL STEEL large-scale copper crucibles. Complied with GB/T 5231, ASTM B152 and EN 13601 standards. TU1 oxygen-free copper has very low oxygen content, resistant to hydrogen embrittlement and grain boundary oxidation during repeated thermal cycling; electrical conductivity ≥101% IACS, thermal conductivity ≥390 W/(m·K), fast conducting induction heat, then transferred to cooling water, temperature increase of the crucible body is less than 40 °C during long melting operation. CuCrZr (chromium-zirconium copper) alloy may be used for applications requiring a higher strength or high-frequency and current conditions. It has a yield strength ≥260 MPa and softening temperature of 550°C, ideal for high-capacity, continuous operations.
Design of the Structure and Setting of Parts of Large Split Water-Cooled Copper Crucibles at PETROL STEEL CO., LTD
A typical large copper crucible includes a cylindrical body, a bottom head (or open bottom), flange connections, and internal spiral or annular cooling channels. The cylindrical body is divided circumferentially into 4, 6, 8, or 12 segments (depending on the diameter and induction frequency), with high temperature mica sheets or polyimide insulating gaskets placed between the segments; the gap width is generally kept between 0.3 mm and 1.0 mm to balance the electromagnetic penetration with mechanical strength. The cooling system adopts a bottom-in/top-out dual-flow circuit design, and flow-directing baffles are set at critical positions to guarantee the uniform wall temperature field and avoid local overheating which results in abnormal skull thickening or melt adhesion to the walls. It is recommended that the flange and cylindrical body should be made by integral forging to avoid the risk of longitudinal welding. If it is made by rolled plate welding, all the welds shall be subjected to X-ray inspection (NB/T 47013.2-2015, Class II) and hydrostatic pressure test at 1.5 times of the working pressure.
Manufacturing process and quality inspection of large-scale split water-cooled copper crucibles of PESCO
Depending on the operating conditions, PETROL STEEL offers two manufacturing methods for customers to choose from: 1. Integral Forging & Power Spinning--Large format oxygen free copper ingots are multi-directional forged and hot spun to make the cylinder body. This achieves fine grain structure, no longitudinal welds and excellent thermal fatigue resistance. Suitable for large capacity or high frequency skull melting furnaces (diameter >300mm). 2. CNC precision plate rolling and TIG welding—T2 copper plates are CNC rolled into cylinders and welded under protection of inert gas. This method is more economical and suitable for small-to-medium-sized units or R&D equipment. All copper crucibles shall be subject to the following procedures after completion: ultrasonic testing of the inner wall (JB/T 4730.3 Class II); hydrostatic pressure holding test (0.6~1.0 MPa for 30 minutes, no leakage); flatness inspection of the flange sealing surface (≤0.05 mm); water flow rate calibration. The shipment is accompanied by documentation comprising Material Test Certificate (MTC), non-destructive testing (NDT) reports and dimensional inspection reports.
Typical technical parameter ranges (can be customized based on drawings)
Applicable melting capacity: 0.5kg – 200kg (Titanium based)
Crucible inner diameter: φ60 mm – φ1200 mm (larger sizes on request)
Cylinder wall thickness: 8 mm – 25 mm (based on capacity and inductive coupling calculations)
Number of segments 4 / 6 / 8 / 12 (custom configurations available)
Cooling water pressure needed: 0.25 – 0.6 MPa
Cooling water flow: ≥ 3 m3/h (capacity dependent)
Ultimate vacuum level: < 6.7E-4 Pa
Maximum melting temperature (melt) = 3600°C (water-cooled copper wall)
Note: the specific dimensions and layout of the water circuit should be designed for type of furnace of the customer, parameters of the induction coil, frequency of the power supply and capacity of the crucible.
Important Areas of Application for PETROL STEEL Large-Format Split Water-Cooled Copper Crucibles:
PETROL STEEL large copper crucibles are widely used in the production of following high-value-added materials: achieve true “contamination-free cold-wall melting”: 1. Smelting of reactive metals: titanium, zirconium, hafnium, tantalum, niobium, and their alloys without reacting with ceramic crucibles, which would form brittle intermetallic compounds; 2. Specialty alloy R&D – nickel-based/cobalt-based superalloys, high entropy alloys (HEAs) and titanium-aluminum intermetallics – utilizing intense electromagnetic stirring to improve compositional homogeneity and suppress segregation; 3. Preparation of precursors for functional materials and metamaterials – alloys for metasurface elements, high-purity master alloys for graded-index media, ferrite pre-alloys; 4. Semiconductors and sputtering targets--melting and casting of high-purity copper, aluminum, titanium and tantalum target billets under strict controls on trace impurities and gas content in sputtered thin films; 5. Rare earth permanent magnet materials Vacuum melting of NdFeB and SmCo master alloys to minimize rare earth burn-off and oxide inclusions.
Large-scale split water-cooled copper crucibles of PESCO: Customization and export services
Backed by a strong technical team, PETROL STEEL gives full support based on furnace drawings, dimensions of the induction coil or parameters of the melting process provided by the customer. We help with segment count simulation, cooling circuit optimization and thermal stress analysis and we produce engineering drawings for client approval prior to production. We can make custom products according to your drawings (DXF/DWG/STEP formats) and produce designs with non-standard tapered structures, multi-layer cooling channels, and integrated vacuum flanges (KF or CF series). Export products are packed in wooden crates, vacuum packed with anti-rust oil, with material certificates and inspection reports in English. We provide vacuum equipment to manufacturers and research institutions in Europe, North America, Japan, South Korea and South East Asia. We provide flexible cooperation models and accept various trade terms, including FOB, CIF and DDP.
Request Professional Product Quotes and Technical Support
If you are choosing big copper crucibles for vacuum induction melting furnaces, cold crucible levitation furnaces or vacuum skull melting furnaces please contact sales team at PETROL STEEL. Please fill in the data for estimated capacity, inner diameter needs, segmentation preferences and cooling water connection sizes. We will revert to you within 24 hours with a technical proposal and a very competitive quote.
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For more info and the price of large copper crucibles for vacuum melting furnaces and the specifications, please send us the inquiry; you will get the quick reply soon.
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