Self-Lubricating Solutions for Billet Casters: Graphite-Plugged Bronze Bushings

1. The Challenge: Extreme Casting Environments

Billet casters operate under brutal conditions: high static loads, intermittent slow-motion, scale dust, water vapor, and temperatures up to 100°C. Traditional grease lubrication fails here due to leakage and carbonization.

The Solution: High-strength copper alloy bushings with embedded solid lubricants (Graphite), designed for maintenance-free, dry friction, or boundary lubrication environments.

2. Application Matrix: Where to Install

3. Comparison Matrix: Straight Bushing vs. Flange Bearing

4. Technical Specifications & Material Solution

Our graphite-copper sleeves utilize a High-Tensile Brass (CuZn25Al6Fe3Mn3) matrix embedded with SL1 Solid Lubricant.

• Lubrication Type: Graphite (Maintenance-free, no oil/grease required).

• Max Static Pressure: 25 N/mm² (High load-bearing capacity).

• Max Dynamic Pressure: 2 N/mm² (Intermittent motion).

• Sliding Speed: 0.01 m/s (Ultra-low speed optimization).

• Working Temperature: Up to 100°C (Stable thermal performance).

• Tolerance Class: E7 (High-precision fit for mechanical alignment).

5. Critical Mating Requirements (Shaft Standards)

To ensure the formation of the graphite transfer film and maximize service life, the mating shaft must meet these criteria:

• Surface Hardness: ≥ 180 HB (Prevents shaft scoring).

• Surface Roughness: Ra ≤ 0.8 μm (Smooth surface reduces graphite consumption).

• Recommended Fit: f7 or h7 (Optimized for E7 bushing tolerance).

6. Why Choose Graphite-Plugged Bronze for Billet Casters?

1. Zero Maintenance: Eliminates the need for manual greasing in hard-to-reach areas (e.g., oscillation frames).

2. Anti-Seize Performance: Graphite provides a constant lubricating film even during long periods of standstill under load.

3. Corrosion Resistance: The copper alloy base withstands the heavy water spray environment of the cooling segments.

4. Operational Safety: Reduces fire hazards by eliminating flammable grease near hot billets.

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Looking for a custom sizing or material alternative (Tin Bronze/Aluminum Bronze)? Contact our engineering team for a CAD-ready solution.