AU635311B2 - Continuous caster mold and continuous casting process - Google Patents

Continuous caster mold and continuous casting process Download PDF

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Publication number
AU635311B2
AU635311B2 AU61287/90A AU6128790A AU635311B2 AU 635311 B2 AU635311 B2 AU 635311B2 AU 61287/90 A AU61287/90 A AU 61287/90A AU 6128790 A AU6128790 A AU 6128790A AU 635311 B2 AU635311 B2 AU 635311B2
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AU
Australia
Prior art keywords
mold
molten metal
continuous
lining
heat
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AU61287/90A
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AU6128790A (en
Inventor
Kazumi Daitoku
Chiyokatsu Hamaguchi
Kazuya Kudo
Fujiya Nogami
Kazuo Seki
Tomoharu Shimokasa
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Nippon Steel Corp
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Nippon Steel Corp
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Priority claimed from JP8353090A external-priority patent/JPH03285741A/en
Priority claimed from JP17028990A external-priority patent/JPH0459153A/en
Application filed by Nippon Steel Corp filed Critical Nippon Steel Corp
Publication of AU6128790A publication Critical patent/AU6128790A/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/04Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
    • B22D11/0401Moulds provided with a feed head
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/04Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
    • B22D11/059Mould materials or platings

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)

Description

Our Ref: 334355 635-311 FORM
AUSTRALIA
Patents Act COMPLETE SPECIFICATTON
(ORIGINAL)
Application Number: Lodged: Complete Specification Lodged: Accepted: Published: Priority: Related Art: Applicant(s): Address for Service: Nippon Steel Corporation 6-3 Otemachi 2-chome Chiyoda-ku
TOKYO
JAPAN
ARTHUR S. CAVE CO.
Patent Trade Mark Attorneys Level 10, 10 Barrack Street SYDNEY NSW 2000
V
Complete specification for the invention entitled "Continuous caster mold and continuous casting process".
The following statement is a full description of this invention, including the best method of performing it known to me:- 1 5020 03 6 7p:mmb CONTINUOUS CASTER MOLD AND CONTINUOUS CASTING PROCESS Background of the Invention Field of the Invention This invention relates to molds of curved, vertical and horizontal continuous casters for casting slabs, blooms and billets and continuous casting processes using said molds, and more particularly to molds and continuous casting processes that prevent the occurrence of breakout and produce very clean castings free of oscillation marks, surface and other defects.
Description of the Prior Art Molten steel or other molten metal poured into a mold of a continuous caster leaves it as hot cast product after cooling and solidifying with the extraction of heat ;therefrom. Fig. 1 shows how a solidifying shell is formed and grows. Molten metal 5 is poured into a mold 1 where cooling water passed through cooling water piping 4 contained in the mold cools the liquid metal by removing heat therefrom. Then, a solidifying shell 7 is formed and grows where the metal contacts the inner wall of the mold 1 i. A powder 18 sprinkled over the liquid metal 5 protects its surface from an oxidizing atmosphere. Infiltrating between the inner wall of the mold 1 and the solidifying shell 7 as a part of slag 19, the powder 18 serves as a lubricant to prevent the sticking of the solidifying shell 7. The shell 7 solidifies and contracts as it descends through the mold 1 while forming localised air gaps between itself and the inner wall of the mold as a result of the bulging of the shell 7 caused by the recuperative action thereof until the leaving of a cast product therefrom.
When the powder 18 is used in continuous casting, the mold 1 is oscillated so that the powder 18 is fed along the inner wall of the mold i- But this oscillation leaves oscillation marks on the solidifying shell 7 and causes other surface defects by entrapping the powder 18 therein.
There are some conventional continuous-caster molds 0367p:mmb 2 that have ceramics and other materials of low heat conductivity affixed to the inner wall thereof. For example, molds 1 proposed in Japanese Provisional Patent Publication Nos. 173061 of 1983 and 195742 of 1986 have such materials affixed from the upper end to the lower end or middle thereof, including the point where solidification of molten metal starts, with a view to slowly cooling the molten metal 5 or the solidifying shell 7. Also, Japanese Provisional Patent Publication No. 13445 of 1983 proposes a mold 1 which has such wear-resistant materials as ceramics and stainless steel affixed to the inner wall thereof, including the vicinity of the lower end thereof, in order, to prolong the mold life.
In the molds proposed in Japanese Provisional Patent Publication Nos. 173061 of 1983 and 195742 of 1986, solidification starts at the surface of the molten metal.
.Therefore, the need for the powder 18 and, as a consequence, the problems of oscillation marks and powder entrapment remain unremoved. On the other hand, the wear-resistant materials disclosed in Japanese Provisional Patent Publication No. 13445 of 1983, which are used to protect the lower end of the molds used in atmospheres of very high temperatures, have no effect on the solidification of the "oured molten meta.. Accordingly, the problems of oscillation marks and powder entrapment again remain unsolved, For the affixing of ceramics to the surface of other substance, Japanese Provisional Patent Publication No. 93474 of 1989 discloses a method in which a layer of fine particles or fine powder of substances, which are strongly reactive and adhesive to ceramics and the substance to which the ceramics are affixed and whose particle size is smaller than the roughness of the surfaces to be joined together, and whose thickness is larger than the surface roughness, is inserted between them, with adhesion accomplished by subsequent application of pressure and heat. Japanese Provisional Patent Publication No. 120579 of 1983 discloses a method of joining such inorganic substances as ceramics 0367p:mmb -3and glass to such metals as platinum and copper. In this method, a paste containing 20 to 80 Dercent by weight of a powder of the inorganic material and 30 to 20 percent by weight of a powder of the metal to be joined together is applied to both materials which are then joined together by the application of heat.
But the conventional joining methods involving the application of pressure and heat are unsuitable for use on continuous-caster molds because they are too large to assure uniform heating. In a mold in which metal and ceramics are joined together, the ceramics are in contact with molten metal and the metal with cooling water, whereby a temperature difference arises therebetween. Because there is a considerable difference between the coefficients of linear expansion of the metal, inorganic adhesive and ceramics, the inorganic adhesive that cannot absorb thermal stress causes cracks and nicks at joint boundaries, during the casting operation in which the mold is repeatedly exposed to heat, thereby lowering the adhesive strength and creating a danger of peeling. Inorganic adhesives mixed i with metal powder also involve the danger of cracking and peeling resulting from the difference in their coefficients of linear expansion. Conventional adhesives, in addition, do not have high enough heat conductivity to permit sufficient heat extraction between the mold and molten metal oand, therefore, do not permit the formation of adequately thick and stable solidified shells. To prevent breakouts, as a consequence, it becomes necessary to lower the casting speed, which results in the lowering of productivity. If the thickness of the ceramics is reduced to achieve the extraction of a greater amount of heat, a decrease in mechanical strength and the shortening of mold life through wearing may result.
Summary of the Invention An object of this invention is to permit the production of high-quality castings by lining the inner wall of the mold with pieces of ceramics that function like e solid p
-V
4> LJ 61 0367p:mmb 4 lubricant, with the thickness thereof varied in the direction in which the castings are withdrawn or in that direction and breadthwise, thereby eliminating the need for using lubricant powders.
Another object of embodiments of this invention is to provide longlife ceramics-lined continuous-caster molds that are free from the lowering of adhesive strength, thermal stress absorption ability and poor heat conductivity that might occur when the ceramics-bonding adhesives used with conventional molds are heated.
In order to achieve the above objects, a continuouscaster mold according to this invention comprises a water-cooled inner mold wall of copper or a copper alloy that is lined throughout with pieces of nitride ceramic taken from the group consisting of boron nitride and silicon nitride, and the thickness of the lining is varied in the direction which the cast metal is withdrawn from the mold.
The thickness of the lining may be varied either stepwise or progressively. The thickness of the lining is varied to prevent the formation of air gaps between the surface of the lining and the solidifying shell and to cool and the steel being cast according to the desired pattern, and/or to start solidification of the molten metal below the molten metal surface level.
Friction in continuous-casting processes can be reduced by designing the uppermost ceramics lining of embodiments of the invention, which comes in contact with the molten metal surface, so that solidification of the molten metal starts below the molten metal surface, with the inner wall of the mold tapered by considering the static pressure of the molten metal- between the molten metal surface and the point of solidification.
In the continuous-caster mold according to embodiments of this invention, the molten metal and solidifying shell are slowly cooled, so that the sticking of the solidifying shell to the mold wall is reduced. The friction-free continuous-caster mold according to this invention permits making castings of exrellent surface quality without employing mold powders and mold oscillation. Because *r U b*
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U
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0367p:mmb 5 solidification starts below the molten metal surface, the solidifying shell is free of defects that have conventionally resulted from the surface level changes at the point where solidification begins. As such, casting can be performed with the mold directly connected to a tundish.
Embodiments of this invention also provide a mold lined with ceramics whose thickness 'is varied in the direction of casting and also made variable breadthwise (the direction perpendicular to the casting direction) and a continuous casting process that assures solidification of the molten metal will start at the same level throughout the entire periphery of the mold and also uniform cooling even in the corners of the mold by use of the mold just described.
Embodiments of this invention furthermore provide a mold having a continued internally curved heat-insulating zone and cooling zone in the upper part thereof and a continuous casting process that withdraws the shell formed by initial solidification of the molten metal with reduced friction by use of the mold just described.
Furthermore, in embodiments of this invention, the ceramics are bonded in the inner wall of the continuous-caster mold of this invention with organic adhesives mixed with metal powder or metal fibers. Also, the ceramics are affixed to the inner wall of the continuous-caster mold of this invention with organic adhesives, with metal wire netting interposed therebetween.
The organic adhesives used with the molds of this invention are epoxy, silicone, phenol and other similar resins that withstand heat of from 70 to 260CC. Also, surface irregularities 'are provided on the surface of the molds of copper or copper alloys that are bonded to the ceramics with organic adhesives alone or mixed with metals, with the projecting portions of the irregularities held in contact with or in the vicinity of the ceramics.
While the ceramics lining securely affixed to the inner wall of the continuous-casting molds of this invention gives longer service life, the excellent heat extraction characteristic permits high-speed casting just like the conventional molds. In addition, the ceramics lined over .1 6 5 I. I
/STRI(
1 r Li) 1 M7- 0367p:mmb 6 the mold wall provide self-lubrication.
Brief Description of the Drawings Fig. 1 is a sectional view showing the condition of metal being cast in a conventional continuous-caster mold; Fig. 2 is a vertical cross-sectional view showing a continuous-caster mold according to this invention; Fig. 3 graphically shows how the heat extraction in the mold shown in Fig. 2 changes in the direction of casting, compared with that of a conventional mold; Fig. 4 is a partial vertical cross-sectional view of a mold according to this invention showing a curved portion of the inner wall thereof; Fig. 5 graphically shows the relationship between the ferrostatic pressure of molten steel and the mold taper; Fig. 6 and are perspective views showing the S: ;conditions of ceramics affixed to the inner wall of copper molds; Fig. 7 shows the tolerable smoothness of the bonded area; Fig. 8 is a vertical cross-sectional view showing a continuous-caster mold lined with pieces of ceramics; Fig. 9 and are vertical cross-sectional views showing continuous-caster molds directly connected to a tundish viewed from the broad mold face side and the narrow mold face side, respectively; Fig. 10 graphically compares the thickness of the solidifying shell formed in a mold of this invention to the solidifying shell formed in a conventional mold; Fig. 11 is a partial cross-sectional view on an enlarged scale of a continuous-caster mold according to this invention; Fig. 12 is a partial cross-sectional view on an enlarged scale of a continuous-caster mold according to this invention, in which copper plates having surface irregularities are used in place of the wire netting used in the embodiment shown in Fig. 11; Figs. 13 and 14 schematically illustrates the cross- 0367p:mmb 7 sectional configuration and the planar appearance of the bonding layers shown in Table Fig. 15 is a schematic cross-sectional view of a bonding layer formed with an organic adhesive mixed with metal powder; Fig. 16 and graphically show the relationships between the ratio of the cross-sectional area occupied by metal, the shear stress and the index of heat conductivity and Fig. 17 is a cross-sectional view of a mold that is 'lined with thicker ceramic in the proximity of the ends of the broad face than in the middle portion thereof.
Description of the Preferred Embodiments Fig. 2 shows a continuous-caster mold 1 according to this invention which has an inner wall 2 fabricated from copper having good heat conductivity and a cooling box 3 provided therebehind. The cooling box 3 incorporates cooling water passages 4 to pass cooling water that cools and solidifies the molten metal 5 poured into the mold 1.
To the inner wall 2 are affixed ceramic tiles 6b and 6d whose thickness is varied in the direction in which the .metal being cast is withdrawn, which is indicated by arrow P, thus making up an inner lining 6. Ceramic blocks 6a having a greater thickness than the tiles are provided on top of the tiles and extend over the top of the inner wall 2 to serve as a heat-insulating layer. The inner wall 2 may also be made of either a copper alloy or covered with a layer of an alloy or chromium, nickel or other metals.
The ceramics are made from such materials as boron, nitride (BN) and silicon nitride (Si 3
N
4 that have resistance to abrasive wear, heat and thermal shock, heat conductivity and lubricating property. Lining the inner wall 2 with the ceramic tiles 6b and 6d prevents the sticking of the solidifying shell 7, which forms when the molten metal 5 solidifies, to the surface of the inner wall 2 or the risk of more serious breakouts in which the inner molten metal flows out through the ruptured shell.
0367p:mmb 8 Elimination of the need for using lubricating powders between the inner wall and the solidifying shell 7 prevents the entrapment of powders due to molten metal level variations and the occurrence of other surface defects.
Although lubricating powders are unnecessary in operation, a molten metal surface heat insulator 17 is used to provide the heat insulation and the maintenance of temperature required by the molten metal 5 poured from a pouring nozzle 16.
The ceramics tiles 6b and 6d affixed to the inner wall 2 are so smooth-surfaced that the casting are withdrawn smoothly. Consequently, the cast products have smooth, defect free surfaces.
The ceramic tiles 6b and 6d affixed to the inner side of the inner wall 2 keep the molten metal 5 out of direct S. contact with the inner wall 2, while serving as a heat insulating layer that permits the molten metal 5 or the solidifying shell 7 to cool slowly. Therefore, the shrinkage which the solidifying shell 7 has undergone in the mold 1 is made up for by creep. Protected from rapid cooling and solidification, the solidifying shell 7 does not shrink to such an extent as to form air gaps. This results S- in a solidified shell of uniform thickness which, in turn, permits high-speed withdrawing.
The amount of heat transfer through the inner wall of the continuous caster mold 1 lined with the ceramic tiles 6b and 6d changes in the casting direction P. Heat extraction at the top of the mold 1 where the thick ceramic blocks 6a are provided is practically negligible. Heat extraction can be varied by changing the thickness of the ceramics 6a to 6d according to the requirement of individual operations.
Curve in Fig. 3 shows a heat extraction curve for a plain carbon steel that is attained by changing the thickness of the ceramic liners 6a to 6d so that the amount of heat extra'tion decreases progressively from the top in the initial solidifying stage. This heat extraction pattern is equivalent to the most common one in the conventional Av, -B "^9 0367p:mmb 9 continuous casting with mold powders.
Curve shows a heat extraction pattern for steels that are cast at slow speed with slow cooling, such as chromium-containing stainless steels and some other alloy steels. The thickness of the ceramic liners 6a and 6d is reduced in that order to provide increasingly greater heat extraction downward. Curve shows a uniform heat extraction pattern that has proved effective for high-speed casting with slow cooling. The pattern according to curve is obtained by varying the thickness of the ceramic tiles 6b and 6d downward from the top end of the mold so that uniform heat extraction is achieved throughout.
In all of the above patterns, solidification of the molten metal 5 poured into the continuous-caster mold 1 begins dt a solidification starting point 9 below the molten metal suiface 8. Preferably, the solidification starting point 9 should be at least 30 mm below the molten metal surface 8. If the distance is less than 30 mm, the molten metal may entrap the heat insulating mold powder sprinkled over the surface of the molten metal. Also, the influence of the variation in the molten metal surface may make it difficult to achieve the solidification below the surface level, which leads to the formation of a defective solidifying shell containing layers mixed with the heat insulating mold powder and containing high percentages of floating non-metallic inclusions. By assuring that :solidification of the molten metal begins at a point at least 30 mm below the molten metal surface 8, the formed shell 7 has a stable surface quality without being influenced by surface level variations. Preferably, the casting operation should be carried out with a suitable heat extractin pattern and a corresponding lining taper that will provide the desired solidification and contraction for each individual type of steel.
The thickness of the solidifying shell 7 increases progressively as the rate of heat extraction changes through the continuous-caster mold 1 in the casting direction P, 0367p;:mmb 10 whereby the solidifying shell 7 is always in contact with the inner surface of the mold. In the conventional continuous casting with mold powders, powder feed is not always uniform but sometimes becomes interrupted, with the resulting localised heavy cooling causing the shrinkage of the solidifying shell and forming air gaps. This tendency becomes more pronounced toward the lower end of the continuous caster m-ld 1. The mold of this invention, by contrast, always provides such an ideal condition similar to the one obtained in a uniformly powdered conventional mold that the solidifying shell 7 is kept out of direct contact with the inner wall 2 and, therefore, always fits the inner profile of the mold.
The thickness of the ceramics is increased in the upper part of the continuous caster mold 1 that is exposed to high temperatures and decreased in the lower part where the surface temperature becomes relatively lower. This arrangement permits keeping the temperature on the mold wall side of the ceramic tiles 6b and 6d at a relatively low level. As a consequence, the adhesive that bonds together in the inner wall 2 and the ceramic tiles 6b and 6d is not m| exposed to high temperatures that might cause its deterioration.
Heat extraction in the conventional mold, in contrast, changes as indicated by the S-shaped curve A in Fig. 3 because of the formation of air gaps. The molten metal 5 is cooled immediately below the molten metal surface 8, forming a solidifying shell 7. The solidifying shell 7 that forms and grows too rapidly tends to form an air gap between itself and the inner wall of the continuous caster mold 1 as illustrated in Fig. 1. This results in a sharp reduction in heat extraction. Though the air gap can be made smaller by increasing the withdrawal speed of the casting, but the withdrawal speed should not be increased beyond a certain limit because of the risk of breaking the powder film and increasing the frictional resistance.
In the continuous caster mold 1 lined with the ceramic eX7 s\ 0367p:mmb 11 tiles 6b and 6d, the molten metal 5 and the solidifying shell 7 are slowly cooled, which results in castings having good surface quality. Because the ceramic tiles 6b and 6d allow the solidifying shell 7 to move forward smoothly, the casting is smoothly withdrawn from the continuous caster mold 1 without using any powder or other lubricants. The obtained castings are free of surface defects that might result from the entrapment of powders and oscillation marks. Very clean castings having stable surface properties can be obtained bc.:ause the formation of the solidifying shell 7 begins at a point below the molten metal surface 8 that is unaffected by any changes at the surface level.
The ceramic block 6a mounted on top of the continuous caster mold 1 and the ceramic tiles 6b and 6d lined over the inner wall 1 are fastened as shown in Fig. 2. The uppermost ceramic block 6a is pressed against the top surface of the S.inner wall 2 by means of a clamp 10. The ceramic tiles 6b and 6d are bonded to the front surface of the inner wall 2 with a ceramics-type adhesive 11. Here, there is the risk that the ceramic tiles 6b and 6d may slip downward under the influence of frictional force F that arises between the solidifying shell 7 and the inner surface of the mold when the casting is withdrawn downward. But this risk can be avoided by providing steps on the inner wall 2 to support the lower ends of the ceramic tiles 6b and 6d as illustrated in Fig. 2a.
The molten metal superheated to a temperature 20 to 50°C above the liquidus temperature is usually poured into the mold at a temperature 5 to 30 0 C above the liquidus temperature. The ceramic block 6a on top of the continuous castei mold 1 functions as heat insulating layer that prevents the escape of heat from the molten metal so that the solidification thereof begins below the molten metal surface. Assuming that the temperature of the molten metal in the mold is 5 to 30 0 C above the liquidus temperature, therefore, the heat insulating layer of the ceramic block 6a should preferably have a thickness of 30 to 300 mm, though 0367p:mmb 12 this value varies with the heat conductivity of the ceramics.
The casting having a square cross section like a bloom is cooled more strongly in the proximity of the corners of the mold than elsewhere. In a mold in which such overcooled areas exist, metals that tend to solidify and shrink heavily, like peritectic steels 0.08 to form an air gap between the inner wall of the mold and the casting when it solidifies and shrinks as a result of overcooling. This results in an increase in the resistance to heat extraction and the blocking of shell growth. Then, the solidified shell re-melts and ruptures, with the molten metal inside blowing outside to cause surface defects known as bleeding marks in the proximity of the corners of the cast strand. But the air gap resulting from over-cooling can be prevented by using thicker ceramics at the corners of the mold than in the middle portion thereof. The casting having a rectangular cross section like a slab is cooled more strongly in the proximity of ends of the broad face (close to the narrow face) of the mold than in the middle thereof. As a consequence, solidification starts at different depths below the molten metal surface along the broad face of the mold. But this irregularity in the starting point of solidification can be smoothed out around the periphery of the mold by using thicker ceramics in the proximity of ends of the broad face than in the middle portion thereof as in the case of the bloom. By so doing, bleeding marks, cavities and other surface defects resulting from overcooling can be prevented. To prevent the occurrence of such surface defects, the difference in the thickness of ceramics should preferably be between 0.3 to mm, though this range varies with the cooling capacity of the mold, the condition of the metal flow in the mold and other factors. If the thickness difference exceeds 3.0 mm, the cooling rate will become so slow that the solidifying shell fails to grow fast enough to attain adequate strength to prevent skin ruptures. If the thickneF; difference is under 0.3 mm, on the other hand, it will become impossible
;C/
0367p:mmb 13 to prevent the occurrence of bleeding marks, cavities and other surface defects.
Fig. 17 shows a preferred embodiment that is lined with thicker ceramic in the proximity of the ends of the broad face than in the middle portion thereof. The ceramic tiles 6f affixed to the middle portion of the inner wall 2 of the mold are thinner than the ceramic tiles 6g and 6h in the proximity of the ends of the inner wall 2.
The solidifying shell is pressed against the ceramic lining by the static pressure of the molten metal.
Therefore, a frictional force arises between the cast strand and the ceramic lining when the strand is withdrawn from the mold as shown in Fig. 4. On the other hand, the thickness of the solidifying shell is still thin in the initial solidification region immediately below the point where solidification begins. To prevent the breaking of the cast strand by the withdrawing force, it is necessary to reduce the frictional force by ensuring that solidification proceeds in such a manner that the surface of the shell and the ceramic lining are softly in contact with one another.
Such a condition can be attained by forming a curved portion 6R on the ceramic lining 6 throughout the entire periphery of the mold as shown in Fig. 4, with the curved portion 6R containing the solidification starting point 9, and having the arc extending in the withdrawing direction and the angle defined by the top and bottom ends of the arc limited to degrees or less. The strand withdrawing force exerts a •component of force acting in the direction of the radius of curvature of the curved portion 6R or a force to pull the solidifying shell away from the surface of the mold lining against the static pressure of the molten metal. This reduces the frictional force that works on the shell during the initial stage of solidification. This permits carrying out a smooth casting within the limit in which the initially formed solidifying shell remains unruptured. The radius of curvature r of the curved portion 6R should preferably be between 30 and 300 mm. If the radius of curvature is under 0367p:mmb 14 mm, the amount of the heat extracted decreases as the withdrawal proceeds, which can result in re-melting and double solidification. Also, the region in which the frictional force does not work decreases to lessen the effect of the reduced frictional force. If the radius of curvature r exceeds 300 mm, in contrast, the static pressure of the molten metal keeps the solidifying shell pressed against the surface of the mold lining, thereby nullifying the effect of the reduced frictional force. This can lead to skin ruptures and breakouts.
To ensure that the solidifying shell 7, which begins to form at the point 9 below the molten metal surace 8, moves forward smoothly over the ceramic tiles 6b and 6d, it is preferable to appropriately taper the inner surface (facing the inside of the mold) of the ceramic tiles 6b and 6d with respect to a vertical line. Fig. 5 shows an appropriate pattern chosen by considering the influence of the static pressure of the molten metal on the solidification below the molten metal surface. If H 1 is the distance between the solidification starting point 9 and the molten metal surface 8 the thickness of molten metal layer) and T 1 is the index of taper on the inner surface of the mold between the upper and lower ends of the mold (derived by dividing the differ:ence between the clearance at the top and the clearince at the bottom by 2, compared with the base figure of 0 that is obtained when the mold wall is vertical), the .optimum relationship between H 1 and T 1 from the view point of friction is obtained in the hatched region. When the index of distance H 1 is large and the molten metal exerts a great static pressure, the index of taper T 1 should be increased on a negative side to expand the inner surface of the mold downward. When the index of distance
H
1 is small, the index of taper T 1 should be increased on the positive side to expand the inner surface of the mold upward to promote the growth of the solidifying shell 7.
During the initial stage of solidification in which the shell is not yet strong enough, care should be 0367p:mmb 15 taken to avoid skin ruptures. Provision of a taper corresponding to the amount of creep deformation (bulging) which the solidifying shell 7 undergoes under the influence of the static pressure of the molten metal in the casting direction P without impairing the cooling condition reduces the friction due to the static pressure of the molten metal. When the continuous caster mold 1 is directly connected to the tundish as described later, provision of a taper holds down an increase in the friction caused by the static pressure of the molten metal, too. This taper adjustment reduces the frictional resistance of the continuous caster mold i, thereby permitting high speed casting in spite of solid lubrication.
When the distance between the molten metal surface and the solidification starting point is 30 mm or above, the taper index T1 should preferably be kept between -2.0 and more preferably between -1.5 and If the taper index T 1 is smaller than the inner surface of the mold is kept out of contact with the solidifing shell that deforms (through creeping and bulging) under the influence of the static pressure of the molten metal, whereby the mold loses its ability to support the solidifying shell and extract heat therefrom. When taper index T 1 exceeds +1.8, the frictional force between the inner surface of the mold and the solidifying shell increases, with a resulting increase in mold wear and decrease in mold life. The solidifying shell then becomes more susceptible to constraint by the inner surface of the mold and breakouts and cannot be formed by high-speed casting.
A taper having an appropriate angle with respect to horizontal lie n is provided on the inner surface of the mold used for horizontal continuous casting.
As shown in Fig. 2, the ceramic tiles 6b and 6d are attached to the inner wall of the continuous caster mold 1.
A one-piece ceramic lining, like the break ring of horizontal continuous casters, may be provided on the continuous caster mold i. But such a larger cer3mic lining 0367p:mmb 16 involves various limitations on making, installation and use. For the mold of vertical continuous casters, therefore, it is preferable to use a lining consisting of smaller tiles as shown in Figs. 6 and Fig. 6 (a) shows a width-adjustable mold and Fig. 6 shows a fixed-width mold. In either mold, small sized ceramic tiles are provided in an irregular pattern, on the inner side of the mold wall 2 and make up an inner lining on the broad face la and the narrow face lb. Whilst conventional mold powders cannot provide uniform lubrication throughout, with the overall powder mold contact ratio standing at about percent at best, the tile lining assures very good heat extraction.
With the ceramic tiles a arranged in an irregular pattern as shown in Figs. 6 and 6 for example, a running bond, the surface irregularities of the joints between the individual tiles may seem to offer an obstacle to the formation of the solidifying shell. It has been experimentally proved, however, that sound shells can be formed smoothly if the horizontal distance e and the thickness f of the joint between adjoining ceramic tiles a are kept at 0.5 mm or under. The joint thickness not larger than 0.5 mm prevents the penetration of the molten metal .between the ceramic tiles. It is also preferable to keep the joint thickness f at 0.1 mm or under where the ceramic tiles are in contact with the molten metal.
The preferable size of the ceramic tiles is between *and 300 mm in both width and length. Tiles smaller than mm in width and length result in more joints per unit area, which, in turn, increases the frictional resistance between the inner surface of the tile-lined mold and the steel being cast, decreases the heat which can be extracted, and adds complexity to the lining work. If the width or length e, aeds 300 mm, it becomes difficult to affix ceramic tiles the inner wall of the mold with a unifoi adhesive zorce. When thermal stresses are built up by repeated heating and cooling, some of the ceramic tiles will come off 1 ci 0367p:mmb 17 the inner wall of the mold, thereby shortening the service life of the mold. Limiting the size of the ceramic tiles within the above range facilitates keeping the joint thickness f at not wider than 0.5 mm or more preferaby 0.1 mm.
But the arrangement of the ceramic tiles is not limited to the one described above. For example, a smaller piece of ceramic 6f may be affixed to the inner wall of the continuous-caster mold 1 as shown in Fig. 8. The portion of this ceramic piece 6f in the proximity of the molten metal surface 8 is thicker than the lower part whose thickness is progressively decreased downward. When the thickness of the inner lining is varied, it is preferable to change it in three or more steps.
The thicker portion that comes in contact with the molten metal 5 near the surface 8 thereof permits solidification of the molten metal to start at a point 9 below the surface 8. A mold that thus permits the molten "metal to solidify below the surface thereof can be directly connected to the tundish.
A clearance g can be provided between the ceramic tile and the inner wall 2 in the proximity of the molten metal surface as shown in Fig. 8, thereby permitting effective heat insulation and facilitating the solidification of liquid steel below the surface level thereof.
Figs. 9 and show equipment arrangements including the continuous-caster mold of the type desc:ribed above. The molten metal 5 fed into a tundish 12 through a long nozzle 13 is then poured into a continuous-caster mold 1 through a sliding nozzle 14 provided in the bottom wall of the tundish 12.
An arrangement shown in Fig. 9 has a widthadjustable mold 1 suited for use, for example, in slab casting. Because the tundish 12 and the mold 1 are directly connected, the top of the mold 1 is not left open as in the conventional practices but closed with a cover 15. It is possible to slide the walls of the mold 1 in the direction 0367p:mmb 18 of the arrows in which the narrow mold faces la are positioned perpendicular to the cover 15. Highly lubricating ceramics 6 provided in the upper portion of the mold 1 assure a smooth slide of the mold 1 with respect to the cover The arrangement shown in Fig. 9 has a fixed-width continuous-caster mold 1 suited for use, for example, in bloom casting. The mold 1 and tundish 12 are connected with a large or equal-sized opening to pour the molten metal to assure smooth casting without nozzle clogging and other hitches.
When the solidifying shell 7 is thus formed without exposing the molten metal 5 to the atmosphere, the problem of oxidation at the molten metal surface is completely solved. By choosing an appropriate opening of the sliding nozzle 14, the static pressure of the molten metal 5 in the continuous-caster mold 1 is controlled to eliminate the risk of breakouts and other defects. It is also possible to control the molten metal static pressure by applying an upward driving force to the stream of molten metal flowing through the sliding nozzle 14 by means of a magnetic coil provided around the sliding nozzle 14.
S"In the conventional continuous casting process, by contrast, the molten metal is poured through the nozzle in the bottom of the tundish 12 into the copper-lined mold 1 wherein it is cooled and solidified. Accordingly, solidification of the molten metal begins at the molten 'metal surface and powders are used to lubricate the interface between the copfer lining and the solidifying shell. And these factors lead to various serious quality and operational problems, such as the entrapment of powders and aluminum-oxide-type inclusions, pinholes and blowholes due to the entrapment of sealing argon gas from the detachable immersion nozzle and air, and nozzle clogging.
To avoid these problems, it is necessary not to use mold powders, not to start solidification of the molten metal at the surface level, to use a continuous caster 0367p:mmb 19 having a vertical section of 2.5 m or longer to promote the flotation of inclusions, and to use a large diameter pouring tube in place of a common immersion nozzle. Such drastic improvements can be effectively achieved by directly connecting the tundish and mold.
Direct connection of the tundish and mold simplifies the casting operation and permits fully automatic casting and great labour saving because it reduced many difficult controls such as those of the pouring rate, molten metal surface and powder addition. The use of a large-diameter pouring tube in place of an immersion nozzle prevents conventional defects due to the formation of inclusions by the powder and slag in the mold. The large opening between the tundish and mold prevents nozzle clogging, permits casting at low temperatures, and greatly cuts down refractories consumption and production costs through the improvement of segregation and the use of lower-temperature molten metal. Direction connection of the tundish and mold permits providing a vertical section to a curved continuous caster, as a consequence of which the caster functions like a curved caster with a vertical section. As described above, this invention provides many beneficial effects.
[Example 1] S. Continuous casting was performed using a continuous caster mold 1 of the type shown in Fig. 2 that had ceramic tiles 6b and 6d affixed to the front side of the inner wall 2 thereof. The thickness of the ceramic tiles 6b and 6d was adjusted so that intense cooling in the upper part (indicated by curve in Fig. subdued cooling in the upper part (indicated by curve in Fig. 3) and uniform cooling (indicated by curve in Fig. 3) could be achieved. For the purpose of comparison, continuous casting was also performed using a conventional mold without a ceramic lining. The cooling pattern in the compared example was an S-shaped curve (indicated by curve in Fig. 3).
By pouring liquid plain carbon steel, which had a temperature of 1540°C in the tundish, into the individual 0367p:mmb 20 molds, sections (slabs and blooms) were cast at a speed of 0.6 to 1.2 m per minute. The obtained results are shown .n Table 1. Using the temperature of the copper lining determined by thermocouples, simulation was made by the finite element method. Then, the point uf molten metal solidification 9 was found to be 50 to 80 mm below the molten metal surface 8.
Table 1 In the mold used in this example, an opening of 1 to 2 mm was left between the front side of the mold inner wall 2 and the upper ceramic tile 6b in order to suppress the transfer of heat from the molten metal to the inner wall. The asterisks in Table 1 indicate the provision of the opening. Provision of this opening permits attaining a great heat-insulating effect and achieving solidification of the molten metal below the surface level even when the thickness of the ceramic tiles 6b is reduced. With the mold used in this example, the ceramic blocks 6a were not mounted on top of the inner wall 2.
In the operation according to this invention shown in Table 1, continuous casting was achieved without sprinkling mold powders on the molten metal surface, and solidification of the molten metal started below the surface level.
I Bleeding marks decreased even without mold oscillation, and even with peritectic steels. But high-speed casting can be achieved if mold oscillation is employed.
Castings having good surface quality were also obtained when molten metal was poured into the continuous-caster mold 1 from the tundish 12 directly connected thereto as shown in Fig,, 9 Kept out of contact with the atmosphere, the molten metal flowing down from the tundish 12 is as clean as when it was poured into the tundish 12, with its internal structure free from entrapped oxides.
[Example 2] Continuous casting was performed using a continuouscaster mold 1 of the type shown in Fig. 2 that had a BN ceramic block 6a pressed and fastened to the top of f "^a I 0c1, js.
Table 1-1 DTmbdiITents of This Invention Comrpared Conventional Molds Description a b c d X Y Size of Mold Frame 290 sq. 250 x 980 250 sq. 250 x 980 250 x 980 290 sq.
Size of Ceramics Piece 40 x 80 .150 x 300 100 x 200 150 x 300 Thickness of Ceramics Piece at Different Parts of Mo~ld Height (inn) Top End Upper P~i-t *15 *15 *15 *20 Ni-Cr plated Ni-Cr plated Middle Part 7 10 9 Lower Pa-rt 10 7 8 7 II Type of Cast Steel Al-Si-K L Al-K Al-Si-K Peritectic Prtci Prtci steel steel steel (C)=0109% Al-Si-K Al-Si-K Al-Si-K Mold oscillation Applied Applied Not applied Not applied A'pplied Applied Casting Speed (rr/min) 0.6 1.2 0.7 1.0 1.2 0.9 Cooling Pattern Upper Upper Upper part. part Uniform part -uvcoln S-recoig intense suibdued cooling siWhdued S-uvcoln Screcoig 1codling cooling cooling Table 1-2 Description nTbx'diments off This invention Comp~ared Conventional Molds a b c d X Y Mold Powder IN.ot used Not used Not used Not used Used Used Mold Superheating 15 16 17 15 14 Temrperature 0
C)
Evaluation Surface Cord ition Good Good Good Fine bleeding Many bleeding Many bleeding marks at marks irarks corners Oscillation Mark None None None None Pronounced Pronounced overall x x 0367p:mmb 23 the mold 1 by a clamp 10. The tiles 6b and 6d affixed to the front side of the inner wall 2 were of BN ceramics.
Sections were continuously cast by pouring molten metal having a composition of plain carbon steel into the mold 1 as in Example 1. The obtained results zre shown in Table 2. Using the temperature of the copper lining determined by thermocouples, simulation was made by the finite element methor. Then, the point of molten metal solidification 9 was found to be 40 to 70 mm below the molten metal surface 8.
Table 2 The mold used in this example had a 120 mm thick heatinsulating BN block 6a on top thereof. A combination of a heat-insulating zone surrounded by the ceramic blocks and a cooling zone line with ceramic tiles 6b to 6d kept the molten meilal in the upper part of the mold molten, with solidification of the molten metal allowed to start below the molten mstal surface 8 in the cooling zone.
[Fxample 3] Methods of affixing pieces of ceramics (hereinafter called ceramic tiles for simplicity) to the inner wall of the continuous-caster mold will be described in the S..following.
With the continuous-caster molds according to this invention, organic adhesives of epoxy, silicone and phenol resins, which permit bonding at ordinary temperature and have high buffer capacities to absorb thermal stress, are used. But they can not withstand temperatures higher than 260 0 C. Also, their heat conductivities are lower than those of inorganic adhesives. While one side of the mold is exposed to high temperature (of molten me.il), the other side thereof is kept at ordinary temperature (by cooling water), Under such condition, the temperature gradient in the bonding layer becomes steep and exceeds 260*C on the high temperature side, Therefore, adhesives of the above type have conventionally found to be unsuitable for use in the bonding of ceramic tiles to the continuous-caster molds, as the adhesive strength drops at the interface on the high Z T': I T a Table 2-I 1 1~ Description Embodiments of This Invention Compared Conventional Molds Size of Mold Frame (mm) 290 sq. 250 x 980 250 sq. 250 x 980 250 x 980 290 sq.
Size of Ceramics Piece 150 x 300 150 x 300 (rn) x 150 x 00 100 x 200 100 x 200 Thickness of Ceramics Piece at Different Parts of Mold Height (mm) Top End 120 120 120 120 None None Upper Part 15 15 15 20 Ni-Cr plated Ni-Cr plated Middle Part 9 7 7 10 Lower Part 8 10 10 7 Type of Cast Steel Al-Si-K L(C)Al-K Al-Si-k Peritectic Peritectic Peritectic steel steel steel (C)=0.10 (C)=0.09 (C1=0.10 Al-Si-K Al-Si-K Al-Si-K Mold Oscillation Applied Applied Not applied Not applied Applied Applied Casting Speed (m/min) 0.6 1.2 0.7 0.8 1.2 0.9 Cooling Pattern Uniform cooling Upper part intense cooling Upper part intense cooling Upper part sibdued cooling S-curve cooling S-curve cooling
IC-
f o ~7fZ Table 2-2 Description .Dpbodirnents of This Invention Con-pared Conventional Molds E G H X Y Mo~ld Pouder Not used Not used Not used Not used dse'd Used Mold Superheating 1618 15 16 1 Temperature 0 C) .41 Evaluation Surface Condition~ Good Good Good Fine bleeding many bleeding Many bleeding Imarks at marks marks corners Oscillation mark None None None None Pronounced Pronounced overall x
©QXX
0367,:mmb 26 temperature side where the temperature exceeds 260 0 C. As such, adhesives of the above type have conventionally been unsuitable for use in the bonding of ceramic tiles to the continuous-caster mold.
In this example, therefore, metal powder was added to the organic adhesives. This addition improved heat conductivity, made the temperature gradient gentler, and brought the temperature of the bonding layer into the tolerable temperature range, thereby maintaining the original adhesive strength and enhancing the heat extraction characteristic.
Powder of such high-heat conductivity metals as gold, silver, copper, aluminum and iron is suited for addition.
The higher the heat conductivity, the greater will be the improving effect. The amount of powder added affects heat conductivity, adhesive strength and the efficiency of kneading. When the amount of addition exceeds 60 percent, heat conductivity increases but adhesive strength drops.
When the amount is smaller than 10 percent, heat extraction becomes insufficient to raise the temperature to such a level as to lower the strength of organic adhesives.
iTherefore, the amount of metal powder added to the adhesives Sused on the continuous-caster mold should be kept between *and 60 percent by volume. Because the bonding layer is approximately 50 un thick, the added powder must consist of spherical particles having a mean diameter of 10 pm, with a maximum diameter of 30 pm. Still the shape of the metal powder particles is not limited to spherical, but may also be flaky and fibrous.
This type of organic adhesives with added metal powders can be used in bonding ceramic tiles to the metal wall of larger molds too because the conventional need of applying pressure or heat is avoided. When molten metal is poured, a temperature difference arises between both sides because the ceramic tiles are in contact with the molten metal and the metal plate with cooling water. But the organic adhesives with high buffer capacities absorb the strain and stress due T77 0367p:mmb 27 to the difference in the coefficient of linear expansion between the metal plate and ceramic tiles. Therefore, the ceramic tiles do not crack or come off even when the mold is used repeatedly. As the organic adhesives absorb the expansion of the metal powders mixed therein, internal cracking can be prevented as well. The improved heat conductivity resulting from the addition of the metal powders permit extracting greater amounts of heat and, therefore, form a sufficiently thick, stable solidifying shell.
As described above, the addition of metal powders to organic adhesives used in the bonding of ceramic tiles to the inner wall of the mold has made it possible to use them under conventionally difficult conditions involving heavy thermal loads by taking advantage of the heat extraction achieved by the metal powders while absorbing thermal 'stresses by mean? of the buffer characteristics of the •organic substances. Also, the elastic buffer capacity characteristic of the organic substances absorbs the thermal expansion of the metal powders that can lead to the breaking of the bonded joint. By solving such contradictory technical problems, it has now become possible to provide a lining of ceramic tiles to a continuous-caster mold.
A thermal analysis was carried out using a mold with an inner wall to which ceramic tiles were bonded with a silicone resin adhesive with 33 percent by volume of a metal powder (copper powder added thereto). As shown in Fig. the same adhesive without the metal powder (the compared examples indicated by dotted line) was unusable becausj adequate heat extraction through the mold was unattaiiable.
In the example in which the adhesive resin with the auded metal powder was used (indicated by the solid line), by contrast, as much heat was extracted as was substantially comparable to the amount of heat extracted through the conventional molds without the lining of ceramic tiles (such as a conventional copper-lined mold indicated by the dot-dash line).
0367p:mmb 28 Table 3 shows the results obtained in continuously casting bloons and slabs through the molds lined with ceramic tiles bonded with adhesives with added metals.
Table 3 As is obvious from Table 3, the molds according to this invention shown under I to K gave rise to no surface defects, oscillation marks and spalling of tiles.
[Example 4] Another preferred embodiment in which ceramic tiles are affixed to the inner wall of the mold by another method will be described in the following. This method assures more uniform extraction of greater amounts of heat than in the embodiment using adhesives mixed with metal powders. This method also eliminates the difficulty of obtaining a homogeneous mixture when large quantities of metal powder are added to an adhesive even after much stirring and mixing.
.T This method bonds ceramic tiles to the front side of the inner wall of the mold with an organic adhesive, with a metal2 wire netting interposed between the tile and the inner wall.
The metal wire netting interposed between the copper lining and ceramic tiles are of gold, silver, copper, aluminum or iron, or alloys containing two or more of them, having wire diameters of 10 pm to 70 pm. The wire netting may be made up of vertical wires alone, horizontal wires alone, or both of them. The adhesive may contain powder of the same metal of which the wire netting is made.
In place of interposing the wire netting, surface irregularities may be provided on the ceramic tile side of the copper mold lining. Then, the ceramic tiles and copper plate are bonded together with an organic adhesive, with the projecting portion of the irregularly shaped copper plate held in contact with or in the vicinity of the ceramic tiles. Or otherwise, wire netting or metal powder of the type mentioned before may be provided in the openings left by the surface irregularities of thp copper lining.
Figs. 11 and 12 are schematic cross sections of the p. p p a 0 0 '1 4 p o* a oo *0c *a Table 3-1 Description Embodiments of This Invention Compared Conventional Molds Description I J K X Y Size of Mold Frame 290 sq. 250 x 980 250 x 980 250 x 980 290 sq.
Size of Ceramics Piece (im) 150 x 300 150 x 300 150 x 300 Thickness of Ceramics Piece at Different Parts of Mold Height (mm) Top End 120 120 120 None None Upper Part 15 15 20 Ni-Cr plated Ni-Cr plated Middle Part 12 7 10 Lower Part 12 7 Ceramics Bonding Conditions Addition of Metal Powder 33% 25% Kind of Adhesive Organic Organic Organic adhesive adhesive adhesive Type of Cast Steel Al-Si-K L(C)Al-K Peritectic Peritectic Peritectic steel steel steel (C)=0.10 (C)=0.09 (C)=0.09 Al-Si-K Al-Si-K Al-Si-K Mold Oscillation Applied Applied Not applied Applied Applied Casting Speed (m/min) 0.6 1.2 0.8 1.2 0.9 Mold Powder Not used Not used Not used Used Used Table 3-2 Description Emboxdirents of Thi;§ Invention f Conpared Conventional Molds I J K x Mold Superheating Temperature 0 C) 12 13 13 14 Evaluation SraeCondition Good Goodxoo Many bleeding Many bleeding SurfceParks rnirks Oscilation Mark None None None Pronounced Pronounced Peeling None None None Overall 0~ x x 0367p: pmmb 31 continuous caster molds of the type just described.
In Fig. 11, ceramic tiles 30 having a width and a length of 30 to 300 mm are placed over a metal wire netting 23 attached to the inner wall 2 that has a cooling water passage 4 therein, with the openings left therebetween filled with an organic adhesive 25. In Fig. 12, surface irregularities 26 are provided, in place of the metal wire netting, on the surface of the mold inner wall that come in contact with the ceramic tiles 30. With the projecting portion of the irregularly shaped mold wall kept in point contact, as indicated by reference numeral 27 at the left, or in plane contact, as indicated by reference numeral 28 at the right, with the. ceramic tiles 30, the openings left between the inner wall 2 and ceramic tiles 30 are filled with an organic adhesive 'Metal powders, 10 to 60 percent in quantity, may be added to the organic adhesives used with the preferred :embodiments shown in Figs. 11 and 12.
Table 4 shows the performance of various types of bonding layers formed with organic adhesives evaluated under the molten metal loads applied in simulation tests (see also Figs. 13 and 14).
Table 4 A compared example designated as type e in Table 4 consists of an organic adhesive alone. The bonding layer formed on the continuous-caster mold is exposed to high temperatures (of liquid steel) on one side and kept at ordinary temperature (by cooling water) on the other. Under such conditions, the temperature gradient in the bonding layer becomes very steep, as a result of which the interface temperature on the higher temperature side will exceed the tolerable limit of 260°C. Therefore, the adhesive of type e should not be used where the temperature exceeds the tolerable limit.
Type f is an organic adhesiv- with a metal powder added, which keeps the temperature of the bonding layer within the tolerable limit by making the temperature 7 *0
S
Table 4 (Adhesive: Organic silicone resin based) Cross- Plnr Heat Extraction disieHomogeneity Remarks Description Sectional* Appearan~e -(Improvment Adhesive of Bonded (Bonded Layer) of Mold layer ConductiviyLye A Fig. 13(A) Fig. 14(A) Thickness: 70 irn Cross-sectional area ratio of metal po% 3er 78 B Fig. 13 IFig. 14 Thickness: 70 im Fmin~xhrents 0 Cross-sectional area retio of metal powder 50 oThsC Fig. 13 Fig. 14(C) Thickness: 70 iM of Tis ©0 Cross-sectional area ratio of metal powder 81 Invention D Fig. 13 Fig. 14(D) Thickness: 70 pmn Cross-sectional area ratio of metal powder 58 f Fig. 13(f) Fig. 14 Thickness: 50 200 p'm 0 Ins Cross-sectional area ratio of netal power 33 Comnpared e Fig. 13(e) Fig. 14(e) Thickness: 30 150 U'm Conventional x x Cross-sectional area ratio Mold of metal powder 0 0367p:mmb 33 gradient therein gently through the enhancement of heat conductivity. This results in remarkably increased adhesive strength and heat extraction efficiency. But gas bubbles are likely to form during mixing. The gas bubbles inhibit heat extraction and uniform mixing of the metal powder.
Therefore, the adhesive and metal powder must be mixed thoroughly.
Type A in Table 4 has a heat transfer surface at higher temperature (on the ceramic tiles side) and a heat transfer surface at lower temperature (on the water-cooled copper lining side) that are kept in direct contact with metal wire that has good heat conductivity. Therefore, type A exhibits high heat conductivity and a good heat extraction characteristic. Because the temperature of the peripheral bonding layer is lowered, stable adhesive strength is obtained. The following paragraphs describe the characteristics of type A compared with those of type f. In the bonding layer of type f formed with an organic adhesive mixed with metal powder, heat conductivity can be enhanced by increasing the mixing ratio of the metal powder. But addition of the metal powder should not be continued when kneading becomes difficult and too many gas bubbles are formed. Con':aining many heat transfer interfaces and gas bubbles that Inwer heat conductivity, the bonding layer of type f transfers less heat than those of type A to D as shown in Fig. By contrast, type A permits good heat transfer because the higher and lower temperature sides are directly connected by the metal wire that has high thermal conductivity. Type B also produces good results analogous to those of type A. f££ective heat extraction is achieved by means of the surface irregularities formed on the inner wall of the mold, in place of interposing the metal wire, with the projecting portion thereof held in contact with or in the vicinity of the heat transfer surface on the higher temperature side.
Types C and D, which are combinations of the preferred o>5 LU} n ^b ~y\t 0367p:mmb 34 embodiments described above, also provide as satisfactory results as type A.
The bonding layer of type A is formed by first making holes of 80 pm diameter in a metal frame at intervals of 100 pm, with 70 pm diamet-er wires stretched in one direction. To the wired metal frame mounted on the inner wall of the mold are bonded ceramic tiles with an organic adhesive by applying a given pressure. Finishing is applied when the adhesive has thoroughly solidified. By this method, a bonding layer having a uniform high heat conductivity can be easily obtained. In addition to the one-way wired embodiment just described, a two-way wired variation can be made also, though not as easily as the one-way wired embodiment, by forming a net-like pattern with wires stretched at right angles with each other. The net-like grooves in type B can be easily made by machining.
With the preferred embodiments of types A, B, C and D, the ratio of the cross-sectional area occupied by the added metal (to be more specific, the ratio of the area the added metal occupies in the vertical cross section of the bonding layer) can be varied as shown in the planar configurations of the bonding layer in Table 4. Then, satisfactory adhesive strength can be obtained by thus attaining a higher metal density in the upper portion and a lower metal density in the lower portion and by increasing the bonding area of the adhesive within the temperature limit tolerable by the adhesive.
Figs. 16 and show the relationships among the index of shear stress index of heat conductivity and the cross-sectional area occupied by the added metal of types f and A to D shown in Table 4. Obviously, the preferred embodiments of this invention exhibit much higher shear stress and heat coniuctivity.
The percentage cross-sectional area occupied by the added metal should be kept between 25 and 85 percent. The higher the percentage cross-sectional area occupied by Lhe added metal, the higher the heat conductivity. Then, the
I
."0d 0367p:mmb 35 temperature of the bonding layer drops to enhance the soundness of the bonding layer. On the other hand, however, adhesive strength decreases as a result of a decrease in the bonded area. In Figs. 16 and the upper limits of the percentage cross-sectional area occupied b. the added metal are indicated by hatching. The upper limits are those tolerable for satisfactory bonding.
When the percentage drops, by contrast, heat conductivity is reduced to cause the temperature of the bonding layer to exceed the upper limit of the temperatures tolerable by the adhesive. Then, the likelihood of the ceramic tiles and adhesive spalling due to zeterioration under high temperatures increases. Therefore, the percentage should preferably be kept between 85 and 39.3 percent with the metal wire type (types A and C) and between 68.5 and 25.0 percent with the grooved type (types B and SD). Good heat extraction and adhesive strength are obtained when the percentage is between 78.5 and 39.3 percent with type between 55 and 25 percent with type B between and 39.3 percent with type C, and between 68.5 and 25.0 percent with type D.
6 In the preferred embodiments just described, the higher temperature heat transfer surface of the ceramic tiles on the molten metal side and the lower temperature heat transfer surface on the copper mold lining side are brought ~*into direct contact by means of the metal having good thermal conductivity, thereby forming a bonding layer that assures the transfer of heat at high temperatures. Because, in addition, the metal portion and adhesive are handled individually, the viscosity of the adhesive remains undamaged. As the metal occupies a greater portion of the bonding layer, heat conductivity can be increased without lowering the adhesive strength of the bonded joint.
[Example In this preferred embodiment, the thickness of the ceramic lining is varied both in the withdrawing direction of the casting and along the width of the mold.
0367p:mmb 36 Table 5 shows the results of bloom and slab casting achieved by varying the thickness of the ceramic lining as described above.
As i- obvious from Table 5, the castings made by the use of the molds according to this invention were free from surface defects, oscillation marks and impression at the corners. This was due to the fact that a substantially uniform cooling capacity was secured across the width of the mold by controlling the thickness of the lining in that direction. By contrast, the aforementioned surface defects occurred on the castings made for the purpose of comparison, using conventional molds. This was due to the nonuniform cooling capacity across the width of the mold, which resulted from the higher cooling capacity in the proximity of the ends of the mold width than in the middle.
[Example 6] The ceramic lining of this preferred embodiment is curved in the upper portion thereof.
Table 6 shows the results of bloom and slab casting achieved by varying the radius of curvature of the curved portion of the ceramic lining.
Table 6 *As is obvious from Table 6, the castings made by use of the molds according to this invention were free from surface defects, oscillation marks and breakouts. This was due to the component of the withdrawing force in the direction of the radius of curvature of the curved portion acts in such a manner as to separate the solidifying shell from the inner surface of the mold, thereby decreasing the friction therebetween. By contrast, pronounced oscillation marks occurred on the castings made for the purpose of comparisor, using conventional molds without the curved portion that reduces unwanted friction.
[Example 7] The inner surface of the mold described hereunder is tapered in the direction in which the casting is withdrawn.
4 t o• Table 5-1 Description Size of Mole Embodiments of This inve cion M N Compared Conventional Molds 4 Frame (nm) 290 sq. 250 x 910 250 x 980 250 x 980 250 x 980 250 x 980 Size of Ceramics Piece 100 x 200 P150 x 300 150 x 300 150 x 300 150 x 300 Thickness of Ceramics Piece at Different Parts of Mold Height (mn) Top End 120 120 120 120 Upper Part 15 15 20 15 Ni-Cr plated Ni-Cr plated Middle Part 9 7 10 7 Lower Part 8 10 7 10 Thickness of Ceramics Piece at Different Parts of Mold Width (rm) Middle The same The same The same The same The same The -ame as above as above as above as above as above as abcve At and near Above Above Above Above The same The san.e the end 0.5 mit 1.0 rnm 1.5 un 1.0 mm as above as above (Corner)
I
Type of Cast Steel Al-Si-K L AI-K Peritectic L Al-R Peritectic L A1-K steel steel (C)=0.10 (C)=0.09 Al-Si-K Al-Si-K Mold Oscillation Applied Applied Applied Not applied Applied Applied I
A
Table 5-2 Description L Dnbxdimeints of This Invention Compared Conventional Molds Casting Speed (nrVmin) 0.6 N. 1.0 0.8 1.2 Mold Powder Not used Not used Not used Not used Used Used Mold Superheating 16 18 16 15 14 18 Tenperature BEa2uation Surface Condition Good Cccxi Good Good Many bleeding Bleeding marks marks at corners at corners Oscillation Mark None None None None Present Present Impression at None None None None Present Present Corner End overall Q x x e Table 6-1 Description Embodiments of This Invention Compared Conventional Molds P 0 R S X 2 Y2 Size of Mold Frame (mm) 290 sq. 250 x 980 250 x 980 250 sq. 250 x 980 250 x 980 290 sq.
Size of Ceramics Pie Ceramics Pi 150 x 300 150 x 300 150 x 300 150 x 300 150 x 300 Thickness of Ceramics Piece at Different Parts of Mold Height (irm) Mai n Thickness 150 15 150 15 150 15 120 11 150 at Top End InnerRadiusof R 100 R 80 R 80 R =30 R 300 Curvature Upper Part 15 15 15 15 15 Ni-Cr plated Ni-Cr plated Middle Part 7 7 7 7 7 i" Lower Part 10 10 10 10 10 Type of Cast Steel Al-Si-K L(C)Al-K L(C)Al-K Al-Si-K L(C)Al-K Al-Si-K Al-Si-K Mold Oscillation Applied Applied Not applied Not applied Not applied Applied Applied Casting Speed (m/min) 1.1 1.4 1.4 1.2 1.2 1.6 1.4 Cooling Pattern Upper Upper Upper Upper Upper S-curve S-curve part part part part part cooling cooling intense intense fntense intense intense cooling cooling cooling cooling cooling a. a
I
4.
Table 6-2 Descrpt~onEmbodime~nts of This Invention Canrpared Conventional Molds P Q R S 2Y Mold Powder Not used Not used Not used Not used Not used Not used Not used Mold Superheating 15 17 16 15 15 18 16 Temperature (OC) Evaluation Surface Condition Good Good Good Good Good Good Poillatio Oscillation Mark None None None None None None mark Breakout None None None None None Occurred Possibility is strong overall 0 0 0 0 0 x x 0367p:mmb 41 Table 7 shows the results of bloom and slab casting achieved by using a mold whose inner surface narrows downward and one whose inner surface flares downward.
As is obvious from Table 7, the molds according to this invention (designated by T and U) proved to exhibit a longer service life without causing breakouts. This was due to the fact that air gap formation between the inner surface of the mold and the solidifying shell is prevented by controlling the thickness of the lining and adjusting the taper of the inner surface of the mold according to the deformation (creeping and bulging) of the solidifying shell under the static pressure of the molten metal. By contrast, breakouts occurred on the castings made for the purpose of comparison, using conventional powdered molds. The occurrence of breakouts was due to the air gaps formed between the inner surface of the mold and the solidifying shell where uniform .distribution of the mold powder and, therefore, adequate heat extraction were not attained.
a a a *o *O 42 Table 7 9
S
S S
S
S S 9 Embodiments of Campared Description This Invention Conventional Molds T U X 3
Y
3 Size of Mold Frame 290 sq. 250 x 980 250 x 980 290 sq.
(mm) Size of Ceramics 150 x 300 150 x 300 Piece (rmn) Thickness of Ceramics Piece at Different Parts of Mold Height (mm) Upper Part 15 15 Ni-Cr plated Ni-Cr plated Middle Part 7 7 Lower Part 10 10 Type of Cast Steel Al-Si-K L(C)Al-K Peritectic Peritectic steel steel (C)=0.09 (C)=0.09 Al-Si-K Al-Si-K Mold Oscillation Applied Not applied Applied Applied Casting Speed (m/min) 0.6 1.2 1.2 0.9 Cooling Pattern Upper Upper S-curve S-curve part part cooling cooling intense intense cooling cooling 'Taper .Index -0.3 +0.5 +3.0 Thickness of Fusion 1.0 Zone (nrn) Mold Powder Not used Not used Used Used Mold Superheating 13 19 18 Temperature Evaluation Mold Wear Index 0.8 0.9 1.1 Breakout None None Sometimes Sanometimes Overall x x
Q
'S
J
A

Claims (18)

  1. 2. A continuous-caster mold comprising: a water-cooled inner mold wall of copper or a copper alloy; and a lining of pieces of a nitride ceramic material taken from the group consisting of boron nitride and silicon nitride, formed on the inner wall and having resistance to abrasive wear, heat and thermal shock, and heat conductivity and having a lubricating property, said lining having an inner surface exposed to and defining the shape of metal being cast, the thickness of the lining being varied in the direction in which the cast metal is withdrawn from the mold for preventing formation of air gaps between the inner surface of mold and the solidifying shell of the metal being cast and the variation in thickness and the thermal S.conductivity of said nitride ceramic material together causing cooling of the cast metal according to the desired cooling pattern.
  2. 3. A continuous-caster mold according to claim 1 or 2, in which the lining in the proximity of the molten metal surface has sufficient thickness to prevent escape of heat from the molten metal in the vicinity of the surface to thereby cause the solidification of the molten metal to start at a point lower than the molten metal surface.
  3. 4. A continuous-caster mold according to claim 1 or 2, in which a heat-insulating clearance is provided between the inner mold wall and the inner lining in the proximity of the molten metal surface to prevent escape of heat from the molten metal in the vicinity of the surface to thereby cause the solidification of the molten metal to start at a point lower than the molten metal surface. A continuous-caster mold according to claim 1 or 2, in which the upper portion of the mold has a block-like 0367p:mmb 44 heat-insulating layer thereon to prevent escape of heat from the molten metal in the vicinity of the surface to thereby cause the solidification of the molten metal to start at a point lower than the molten metal surface.
  4. 6. A continuous-caster mold according to claim 1 or 2, in which the mold has a rectangular cross section and the thickness of the inner lining is larger in the proximity of the ends of each side of the rectangle than in the middle thereof.
  5. 7. A continuous-caster mold according to claim 6, in which the thickness of the inner lining in the proximity of the ends of each side of the rectangle is larger by 0.3 to mm than in the middle thereof.
  6. 8. A continuous-caster mold according to claim 1 or 2, in .which the inner surface of the upper part of the mold is curved around the entire periphery thereof, the arc of the curved portion extends downwardly and outwardly in the withdrawing direction, the angle defined by the top and bottom ends of the arc does not exceed 90 degrees and the starting point of molten metal solidification is at the level of the curved portion. S9. A continuous-caster mold according to claim 8, in which the radius of curvature of the curve is between 30 and S300 mm. A continuous-caster mold according to claim 1 or 2, in which the inner lining is formed by pieces of ceramic bonded "I to the inner mold wall wAth an organic adhesive mixed with a metal powder or metal fibers.
  7. 11. A continuous-caster mold according to claim 1 or 2, in which the inner lining is formed by pieces of ceramic bonded to the inner mold wall with an organic adhesive, with metal wire netting interposed between the inner mold wall and the ceramics pieces.
  8. 12. A continuous-caster mold according to claim 1 or 2, i which the inner lining is formed of pieces of ceramic bonded to the inner mold wall with an organic adhesive, the inner mold wall having surface irregularities therein including 0367 p:mmb 45 projecting portions, the ceramic pieces being held in contact with the projecting portions.
  9. 13. A continuous-caster mold. according to claim 1 or 2, in which the inner lining is formed of pieces of ceramic bonded to the inner mold wall with an organic adhesive, the inner mold wall having surface irregularities therein including projecting portions, the ceramic pieces being held in the vicinity of the projecting portions.
  10. 14. A continuous-caster mold according to claim 1 or 2, in which the inner lining is formed by pieces of ceramic that are bonded to the inner mold wall in an irregular pattern. A continuous casting process which comprises using a mold having a water-cooled inner wall of copper or a copper alloy covered with a lining of pieces of a nitride ceramic taken from the group consisting of boron nitride and silicon nitride and having resistance to abrasive wear, heat and thermal shock, and heat conductivity and having a lubricating property, the thickness of the lining varying in the direction in which the cast metal is withdrawn from the mold, solidifying the molten metal by extracting heat therefrom, and withdrawing the solidifying metal smoothly under the effect of the solid lubrication provided by said nitride ceramic.
  11. 16. A continuous casting process which comprises the steps of: preparing a mold having a water-cooled inner wall ot copper or a copper alloy covered with a lining consisting of pieces of a nitride ceramic material taken from the group consisting of boron nitride and silicon nitride having resistance to abrasive wear, heat and thermal shock, and hicat conductivity, and having a lubricating property, the thickness of the lining varying in the casting direction with the thickness being larger in the proximity of the molten metal surface in the mold than elsewhere so that solidification of the molten metal starts below the molten metal surface; pouring the molten metal into the mold from above; and causing thesolidifying shell of the molten metal to 0367p:mmb 46 form and grow by extracting heat from the molten metal though the inner lining and water-cooled inner mold wall.
  12. 17. A continuous casting process according to claim 16, in which solidification of the molten metal is started at a point at least 30 mm below the molten metal surface.
  13. 18. A continuous casting process according to claim 16, in which the variation in the thickness of the inner lining is such as, at the thermal conductivity of said nitride ceramic, to cause the metal being cast to be cooled according to the desired cooling pattern while preventing the formation of air gaps between the inner surface of the mold and the solidifying shell.
  14. 19. A continuous cating process according to claim 15 or 16, in which the mold has a rectangular cross section and the inner lining has a larger thickness in the proximity of the ends of each side of the mold than in the middle thereof. A continuous casting process according to claim 19, in which a mold whose inner surface of the upper part is curved around the entire periphery thereof is used, the arc of the curved portion extending downwardly and inwardly in the withdrawing direction, the angle defined by the top and bottom ends of the arc not exceeding 90 degrees, the starting point of molten metal solidification being at a level in the curved portion, whereby the friction between the inner surface of the mold and the solidifying shell is reduced by the component of the withdrawing force that acts in the direetion of the radius of curvature.
  15. 21. A continuous casting process according to claim 15 or S"16, in which the mold inner wall is tapered according to the amount of creep deformation of the solidifying shell due to i" the molten metal static pressure which the molten metal exerts on the solidifying shell, for reducing the friction between the inner surface of the mold anu the solidifying shell.
  16. 22. A continuous casting process according to claim 21, in which the taper index with respect to the line extending in the withdrawing direction is kept between -2.0 and +1.8. 0367p:mmb 47
  17. 23. A continuous casting process according to claim 15 or 16, in which solid lubrication is provided between the inner surface of the mold and the solidifying shell by taking advantage of the lubricating property of the ceramics inner lining.
  18. 24. A continuous casting process according to claim 23, in which casting is performed without oscillating the mold. A continuous casing process according to claim 16, further comprising connecting a tundish to the mold by a pouring tube of a heat insullating material, covering the top opening of the mold to prevent exposure of the molten metal therein to the atmosphere, and pouring the molten metal from the tundish into the mold through the pouring tube. DATED this 26th day of June, 1992. NIPPON STEEL CORPORATION By Its Patent Attorneys DAVIES COLLISON CAVE C o C
AU61287/90A 1990-03-30 1990-08-23 Continuous caster mold and continuous casting process Ceased AU635311B2 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
JP2-83530 1990-03-30
JP8353090A JPH03285741A (en) 1990-03-30 1990-03-30 Ceramic mold for continuous casting
JP17028990A JPH0459153A (en) 1990-06-29 1990-06-29 Mold for continuous casting
JP2-170289 1990-06-29

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AU6128790A AU6128790A (en) 1991-10-03
AU635311B2 true AU635311B2 (en) 1993-03-18

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GB9621427D0 (en) * 1996-10-15 1996-12-04 Davy Distington Ltd Continuous casting mould
EP1870182B1 (en) * 2005-04-11 2016-10-19 Hitachi Metals, Ltd. Process for the casting of molten alloy
US8056611B2 (en) * 2008-10-06 2011-11-15 Alcoa Inc. Process and apparatus for direct chill casting
US9925591B2 (en) * 2014-08-21 2018-03-27 Molyworks Materials Corp. Mixing cold hearth metallurgical system and process for producing metals and metal alloys
CN113102708B (en) * 2019-10-31 2022-08-23 杭州富通电线电缆有限公司 Continuous casting crystallizer for manufacturing copper rod
CN110981172A (en) * 2019-12-21 2020-04-10 张忠恕 Epitaxial process quartz weldment assembly and processing process thereof
CN115110018B (en) * 2022-06-22 2023-11-10 武汉钢铁有限公司 Preparation method of coating for crystallizer copper plate

Citations (1)

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Publication number Priority date Publication date Assignee Title
AU212833B2 (en) * 1956-02-07 1956-08-09 American Smelting And Refining Company Continuous metal casting process

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Publication number Priority date Publication date Assignee Title
JPS5813445A (en) * 1981-07-17 1983-01-25 Hitachi Zosen Corp Copper plate of mold for continuous casting installation
JPS59153550A (en) * 1983-02-23 1984-09-01 Kawasaki Steel Corp Mold for continuous casting
JPH0616921B2 (en) * 1985-11-12 1994-03-09 住友電気工業株式会社 Mold for continuous casting

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AU212833B2 (en) * 1956-02-07 1956-08-09 American Smelting And Refining Company Continuous metal casting process

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CA2023826A1 (en) 1991-10-01
EP0448773A3 (en) 1993-03-17
DE69029467T2 (en) 1997-07-10
EP0448773A2 (en) 1991-10-02
AU6128790A (en) 1991-10-03
DE69029467D1 (en) 1997-01-30

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