Copper braids
Assemblies manufactured to the supplied configuration and design.
View product →Electrical and thermal conduction
Contact plates for electric furnaces
Efficient current transfer, controlled cooling and dimensional accuracy for electrode systems in critical industrial applications.
Contact plates are critical-duty conductive components that establish the electrical interface between the power-supply system and electric-furnace electrodes. In Söderberg systems, the plates are positioned around the electrode and held under pressure to transfer current; in other configurations, they form part of the electrode-holder assembly and contact graphite electrodes.
01 / 79Electrical efficiency and thermal control
A correctly dimensioned contact surface promotes uniform current transfer and helps control electrical resistance at the electrode interface. Inadequate geometry, uneven wear, residue, insufficient cooling or poor contact may contribute to localized heating, electrical losses and abnormal discharges.
Manufacturing therefore requires control of the material, curvature, grooves, finish, cooling channels and mounting interfaces. Copper’s electrical and thermal conductivity, contact pressure, circuit integrity and dimensional accuracy must be considered together. When specified, the surface may be silver-plated or receive conductive silver, as well as other treatments developed for the equipment’s operating conditions.
Engineering applied to performance
Each furnace has its own current, electrode type and diameter, pressure system, temperature, cooling and operating-regime conditions. Itametais performs thermal, fluid-flow and electrical simulations to assess the main factors of the assembly:
- Current distribution.
- Thermal behavior of the plate.
- Areas of localized heating.
- Water distribution.
- Fluid velocity.
- Pressure losses.
- Internal channel geometry.
- Compatibility with the electrode and the existing assembly.
These analyses support the development of new components and the improvement of contact plates already used by the customer.
Purpose-built configurations
Itametais manufactures high-conductivity copper contact plates from drawings, specifications or technical samples. Construction is defined from the equipment, material, geometry and operating conditions.
- Cast or forged copper construction.
- Manufacture to drawing, specification or technical sample.
- Curved surface compatible with the electrode diameter.
- Grooves or channels in the contact surface.
- Silver plating, conductive silver or other surface treatments, when specified.
- Machined internal channels closed with plugs.
- Embedded tubes or coils.
- Channels formed during component manufacture.
- Cooling circuits and other configurations defined by the approved design.
- Solutions for Söderberg or graphite electrodes.
- Applications in electric arc furnaces and submerged-arc reduction furnaces.
- Steelmaking, ferroalloy production and other electric-furnace applications as specified by the project.
These features are not necessarily combined in a single plate. The configuration depends on the specification, furnace and electrode type, operating conditions and design compatibility.
Manufacturing, restoration and improvement
In addition to manufacturing new components, Itametais performs reverse engineering, restoration of used plates, rebuilding of contact surfaces, and modifications or improvements to the cooling circuit. The technical assessment considers the material condition, geometry, wear, channel integrity and compatibility with the equipment. The feasibility and scope of restoration are defined only after this assessment. Not every used component is technically suitable for restoration.
Quality control
Contact-plate reliability depends on copper quality, cooling-circuit integrity and the accuracy of functional surfaces. Itametais quality control includes:
- Electrical conductivity verification in IACS.
- Hydrostatic testing.
- Industrial radiography.
- Ultrasonic testing.
- Liquid penetrant testing.
- Dimensional inspection.
- Electrical testing or contact-resistance measurement.
These inspections and tests make it possible to assess the material, internal channels, joints, leak tightness, critical dimensions and the electrical performance expected for the application.
Benefits for the operation
When the material, geometry, cooling and surfaces are specified for the application, the assembly can contribute to the system’s electrical and thermal performance. Results also depend on installation, operating regime and equipment maintenance.
- Promotes efficient current transfer and more uniform current distribution.
- Contributes to reducing electrical losses at the contact interface.
- Helps control heating and areas of thermal concentration.
- Allows cooling to be matched to the conditions defined in the project.
- Promotes stable contact with Söderberg or graphite electrodes.
- Dimensional accuracy contributes to mounting compatibility.
- Integrated engineering, manufacturing and inspection contribute to operational reliability.
- Restoration and suitable construction features may facilitate maintenance when technically feasible.
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Do you need to manufacture, restore or improve a contact plate?
Send us the drawing, sample or equipment data. Our team can assess the material, contact surface, cooling circuit and electrical requirements of the application. To support the assessment, include, when available, the furnace type, electrode type and diameter, material, electrical and operating conditions, and required quantity.