BR112019026131B1 - DYNAMIC MOLD SHAPE CONTROL FOR COLD DIRECT CASTING - Google Patents

Abstract

It is a system, apparatus and method for continuous metal casting and, more particularly, a mechanism for controlling the shape of a direct cold casting mold to dynamically control a profile of an ingot cast from the mold during casting. casting process. Embodiments may provide an apparatus for casting material that includes: first and second opposing side walls; first and second end walls extending between the first and second side walls, wherein the first and second side walls are opposed and the first and second end walls are opposite: form a mold cavity of generally rectangular shape. At least one of the first and second opposing side walls may include two or more contact regions, wherein each of the two or more contact regions may be configured to be offset relative to a straight line along the side wall. .

Description

TECHNICAL FIELD

[0001] The present invention relates to a system, apparatus and method for continuous metal casting and, more particularly, to a mechanism for controlling the shape of a direct cold casting mold to dynamically control a profile of a cast ingot from the mold during the casting process.

BACKGROUND

[0002] Metal products can be formed in various ways; however, numerous forming methods first require an ingot, billet, or other casting that can serve as the raw material from which a final metal product can be manufactured, such as through rolling or machining. One method for manufacturing ingots or billets is through a semi-continuous casting process known as direct cold casting, in which a vertically oriented mold cavity is situated above a platform that translates vertically into a casting pit. A starting block may be situated on the platform and form a bottom of the mold cavity, at least initially, to begin the casting process. Molten metal is poured into the mold cavity, whereupon the molten metal cools, typically using a cooling fluid. The platform with the starting block on it can descend into the casting pit at a preset speed to allow the metal to exit the mold cavity and descend with the starting block to solidify. The platform continues to be lowered as more molten metal enters the mold cavity and solid metal exits the mold cavity. This continuous casting process allows metal ingots and billets to be formed according to the profile of the mold cavity and with a length limited only by the depth of the casting pit and the hydraulically driven platform that moves in it.

BRIEF SUMMARY

[0003] The present invention relates to a system, apparatus and method for continuous metal casting and, more particularly, to a mechanism for controlling the shape of a direct cold casting mold to dynamically control a profile of a cast ingot from the mold during the casting process. Embodiments may provide an apparatus for casting material that includes: first and second opposing side walls; first and second end walls extending between the first and second side walls, wherein the first and second side walls are opposed and the first and second end walls are opposite: form a mold cavity of generally rectangular shape. At least one of the first and second opposing side walls may include two or more contact regions, wherein each of the two or more contact regions may be configured to be displaced relative to a straight line between a first end of the at least one of the first and second opposing side walls and a second end of the at least one of the first and second opposing side walls in response to receiving a respective externally applied force from the mold cavity. The respective displacement in a first of the two or more contact regions may be different from a displacement in a second of the two or more contact regions and a respective force in each of the two or more contact regions may change the curvature of at least one of the first and second opposing side walls.

[0004] According to some embodiments, the respective force in the first of the two or more contact regions may include a force in a first direction, wherein the respective force in the second of the two or more contact regions may include a force in a second direction, opposite to the first direction. The respective force in the first of the two or more contact regions may include a force of the first magnitude in a first direction, wherein the respective force in the second of the two or more contact regions may include a force of the second magnitude in the first direction. , with the second magnitude being different from the first magnitude. The first and second opposing side walls may include an inner casting surface and an outer surface. Each of the first and second opposing side walls may further include a flexible bladder disposed along the outer surface, wherein a cooling fluid chamber is defined between each respective opposing side wall and the respective flexible bladder. The casting surface of each of the first and second opposing side walls may include a plurality of orifices in fluid communication with a respective fluid chamber. A baffle may be disposed between a cooling fluid chamber and its side wall, wherein the baffle includes a plurality of flow restricting holes. The plurality of orifices in each of the first and second opposing side walls may be configured to direct cooling fluid from the respective cooling fluid channel toward a molten material as the molten material advances past the casting surfaces of the first and second opposing side walls.

[0005] The first and second opposing side walls and the first and second opposing end walls of the exemplary embodiments may cooperate to define a mold cavity having a shape defined by the opposing side walls and end walls. Examples of embodiments of an apparatus may include: first means for applying a first force to a first of the two or more contact regions; and second means for applying a second force to a second of the two or more contact regions. The first means and the second means can be controlled by a single controller to change the shape of the mold cavity according to one or more properties of the material to be cast. The first means and second means may be configured to change the shape of the mold cavity as the material is melted based on one or more of an alloy of molten material, a temperature of the molten material exiting the mold cavity, a temperature profile of the mold material or a shape of the molten material exiting the mold cavity.

[0006] Embodiments of an apparatus provided herein may include a controller, wherein the displacement of the first contact region and the displacement of the second contact region are carried out in response to at least one of an unexpected softening of the liquid in the cavity of the mold or feedback from an actuator that applies a respective force to one or both of the first contact region and the second contact region. Embodiments may include two or more fixed position members, wherein the two or more fixed position members may be configured to resist movement of the first and second opposing sidewalls in response to a respective force applied to one or more of the two or more contact regions. The first and second opposing side walls may each include an upper portion and a lower portion. The upper portion of the at least one of the first and second opposing side walls may be displaced near the first contact region a first distance relative to the straight line between the first end of the at least one of the first and second opposing side walls. and the second end of at least one of the first and second opposing side walls. The lower portion of the at least one of the first and second opposing side walls may be displaced next to the first contact region a second distance relative to the straight line between the first end of the at least one of the first and second opposing side walls. and the second end of at least one of the first and second opposing side walls, thereby defining a taper between an upper portion of the mold cavity and a lower portion of the mold cavity.

[0007] Embodiments described herein can provide a system for metal casting. The system may include: a controller; a mold including a first side wall, a second side wall opposite the first side wall, a first end wall, and a second end wall opposite the first end wall. The first side wall, second side wall, first end wall and second end wall may cooperate to define a mold cavity having a mold cavity profile. The system may include a first force receiving element of the first side wall located in front of the mold cavity, wherein a first force applied to the first force receiving element may be controlled by the controller and cause a first displacement of the first side wall. on the first force receiving element. A second force receiving element of the first side wall may be located in front of the mold cavity, wherein a second force applied to the second force receiving element may be controlled by the controller and causes a displacement of the first side wall in the second element. receiving force. The first offset may be different from the second offset. The controller may be configured to adjust the first displacement of the first force-receiving element and the second displacement of the second force-receiving element during a casting process using the mold. The controller may adjust the first displacement and the second displacement in response to at least one of the properties of the metal being cast or a profile of the metal exiting the mold.

[0008] According to some embodiments, the first side wall and the second side wall of the mold may each include a plurality of holes for directing cooling fluid along the metal exiting the mold during the casting process. A cooling fluid channel may be defined along the first side wall outside the mold cavity, wherein the cooling fluid channel may be defined between the first side wall and a flexible bladder. The first force and the second force may be configured to be applied to the first force receiving element and the second force receiving element in opposite directions. Each of the first side wall and the second side wall may define therein a respective cooling fluid channel and a plurality of cooling fluid orifices. The system may include a cooling fluid supply, wherein the cooling fluid supply may be configured to supply cooling fluid to each of respective cooling fluid channels to be sprayed through the plurality of orifices toward a material casting exiting the mold cavity at different angles.

[0009] Embodiments described in this document can provide a component of a mold. The component may have a body extending along a defined length between a first end wall and a second end wall; an inner face defining a portion of a mold cavity and extending from the first end wall to the second end wall; and an outer surface opposite the inner face, wherein the outer surface is configured to receive a first force and a second force. The first end wall and the second end wall may be substantially stationary, wherein the component is configured to be moved from a first shape between the first end wall and the second end wall to a second shape between the first end wall. end and the second end wall in response to the application of the first force and the second force, wherein the first force and the second force are different.

[0010] Embodiments may provide a wall of a direct cold casting mold that includes: a longitudinally extending body that extends along a length between a first end and a second end; an inner face defining a portion of a mold cavity and extending from the first end to the second end, wherein a first set of holes and a second set of holes are defined in the wall proximate the inner face; an outer face opposite the inner face; a first fluid chamber disposed near the outer surface; and a second fluid chamber disposed proximate the outer surface, wherein the first fluid chamber is in fluid communication with the first set of orifices and the second fluid chamber is in fluid communication with the second set of orifices. According to some embodiments, the inner face may be configured to be displaced along a geometric axis substantially orthogonal to the inner face in response to receiving a force along the geometric axis applied to the outer surface. The first set of holes may include a set of holes disposed proximate the inner face of the longitudinally extending body and the first set of holes may extend along the longitudinally extending body. The second set of holes may include a set of holes disposed proximate the inner face of the longitudinally extending body and the second set of holes may extend along the longitudinally extending body.

[0011] According to some embodiments, the direct cold casting mold wall may include a first set of fasteners, a second set of fasteners, and a third set of fasteners, wherein each of the First, the second and third sets of fasteners extend longitudinally along the outer surface. The first fluid chamber may be disposed between the first set of fasteners and the second set of fasteners, and the second fluid chamber may be disposed between the second set of fasteners and the third set of fasteners. . The first fluid chamber and the second fluid chamber may extend along the body extending longitudinally on the outer surface, wherein the outer surface of the side wall defines at least one wall of the first fluid chamber and the second fluid chamber. . The first fluid chamber and the second fluid chamber may be bounded on one side by the outer surface of the side wall and bounded in front of the outer surface of the side wall by a flexible membrane.

[0012] The wall of a direct cold casting mold of exemplary embodiments may include a force receiving element, wherein the force receiving element may be attached to the outer surface of the longitudinally extending body and is attached to the surface exterior of the body extending longitudinally through a first subset of at least two of the first set of fasteners, the second set of fasteners, and the third set of fasteners. The force receiving element may be repositionable along the longitudinally extending sets of fasteners using a second subset of at least two of the first set of fasteners, the second set of fasteners, and the third set of fasteners. fixture, where the second subset is different from the first subset. The first fluid chamber may be in fluid communication with the first set of orifices through a defined passage within the side wall. The inner face of the side wall may include a graphite material, wherein the graphite material may be configured to flex congruently with the wall of the direct cold casting mold.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Having thus described the invention in general terms, reference will now be made to the attached drawings, which are not necessarily drawn to scale, and in which:

[0014] Figure 1 illustrates an exemplary embodiment of a direct cold casting mold according to the prior art;

[0015] Figure 2 illustrates an ingot formed by direct cold casting according to the prior art;

[0016] Figure 3 illustrates a top view of a direct cold casting mold having sides with an adjustable curvature profile in accordance with an exemplary embodiment of the present invention;

[0017] Figure 4 illustrates a bottom view of a direct cold casting mold having sides with an adjustable curvature profile in accordance with an exemplary embodiment of the present invention;

[0018] Figure 5 represents a side wall assembly of a direct cold casting mold according to an exemplary embodiment of the present invention;

[0019] Figure 6 represents another view of a side wall assembly of a direct cold casting mold in accordance with an exemplary embodiment of the present invention;

[0020] Figure 7 illustrates a component view of a side wall and force receiving element of a side wall assembly of a direct cold casting mold in a straight configuration in accordance with an exemplary embodiment of the present invention;

[0021] Figure 8 illustrates a view of the rear face of a portion of a side wall assembly of a direct cold casting mold in accordance with an exemplary embodiment of the present invention;

[0022] Figure 9 illustrates the component view of a side wall and a force receiving element of a side wall assembly of a direct cold casting mold in a curved configuration in accordance with an exemplary embodiment of the present invention;

[0023] Figure 10 represents an end of a portion of a sidewall assembly of a direct cooling mold in accordance with an exemplary embodiment of the present invention;

[0024] Figure 11 illustrates a mechanism for distributing force along a side wall of a side wall assembly of a direct cooling mold in accordance with an exemplary embodiment of the present invention;

[0025] Figure 12 illustrates a sectional view of a side wall of a direct cooling mold according to an exemplary embodiment of the present invention;

[0026] Figure 13 illustrates a profile view of a mold wall of a direct cooling mold including an internal casting surface in accordance with an exemplary embodiment of the present invention;

[0027] Figure 14 illustrates a top view of a direct cooling mold with adjustable side walls according to an exemplary embodiment of the present invention;

[0028] Figure 15 illustrates a top view of a direct cooling mold with adjustable side walls according to another exemplary embodiment of the present invention;

[0029] Figure 16 represents a mold frame assembly including a plurality of direct cooling molds in accordance with an exemplary embodiment of the present invention; It is

[0030] Figure 17 illustrates two adjacent sidewall assemblies of adjacent direct cooling mold assemblies in accordance with an exemplary embodiment of the present invention.

DETAILED DESCRIPTION

[0031] Exemplary embodiments of the present invention will now be described in more detail hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. In fact, the invention can be configured in several different ways and should not be interpreted as limited to the embodiments set forth herein; rather, these modalities are provided so that this disclosure satisfies applicable legal requirements. Similar numbers refer to similar elements throughout the report.

[0032] Embodiments of the present invention generally relate to the design of a direct cold casting mold to facilitate a more consistent ingot profile. Direct vertical cold casting is a process used to produce ingots or billets that can have large cross-sections for use in a variety of manufacturing applications. The vertical direct cold casting process begins with a horizontal table containing one or more vertically oriented mold cavities arranged thereon. Each of the mold cavities is initially closed at the bottom with a starter block or starter cap to seal the bottom of the mold cavity. Molten metal is introduced into each mold cavity through a metal distribution system to fill the mold cavities. As the molten metal approaches the bottom of the mold adjacent to the starting block solidifies, the starting block is moved vertically downward along a linear path. Movement of the starting block may be caused by a hydraulically lowered platform to which the starting block is connected. Moving the starter block vertically downward draws solidified metal from the mold cavity while additional molten metal is introduced into the mold cavities. Once started, this process moves in a relatively stable state to a semi-continuous casting process that forms a metal ingot with a profile defined by the mold cavity and a height defined by the depth to which the platform and starting block are moved. .

[0033] During the casting process, the mold itself is cooled to encourage solidification of the metal before the metal exits the mold cavity as the starting block advances downward, and a cooling fluid is introduced to the surface of the mold. metal near the mold exit cavity when the metal is melted to extract heat from the molten metal ingot and to solidify the molten metal within the ingot's now-solidified shell. As the starting block is advanced downward, cooling fluid can be sprayed directly onto the ingot to cool the surface and extract heat from within the ingot core.

[0034] The direct cold casting process allows ingots to be cast in a wide variety of sizes and lengths, as well as different profile shapes. Although circular billet and rectangular billet are the most common, other profile shapes are possible. Circular profile billets benefit from a uniform shape, where the distance from the outer surface around the billet to the core is equivalent around the perimeter. However, rectangular ingots do not have this depth uniformity from surface to core and therefore have additional challenges to consider during the direct cold casting process.

[0035] A direct cold casting mold for producing an ingot with a rectangular profile does not have a perfectly rectangular mold cavity due to deformation of the ingot when it cools after leaving the mold cavity. The portion of the ingot that exits the mold cavity as the platform and starting block descends retains a molten or at least partially molten core within the solidified shell. As the core cools and solidifies, the external profile of the ingot changes so that the profile of the mold cavity, while defining the shape of the final cooled ingot, is not identical in shape or profile to the final cooled ingot.

[0036] Figure 1 is an exemplary embodiment of a conventional direct cold casting mold 100 that would be received within a table or structure of a direct cold casting system. As shown, the mold 100 includes first 110 and second 120 opposing side walls that extend between the first 130 and second 140 end walls of the mold cavity. The first and second opposing side walls 110, 120 and the first and second end walls 130, 140 combine to form the mold cavity 150 which has a generally rectangular profile. The first and second opposing side walls 110, 120 have an arched shape, or at least some degree of curvature to the profile of the wall. This shape allows the casting ingot to have substantially flat opposing sides during a steady-state casting operation of the direct cold casting process. The end walls 130 and 140 may also have a specified shape, which may include a curvature, a series of flat sides arranged in an arched shape, a compound curvature, or a straight side, for example. The "steady state" portion of the casting process, as described herein, is the portion of the casting process after the initial startup phase or initial casting phase and before the end of the casting process or the final casting phase. Steady-state casting occurs when the temperature profile in the portion of the ingot exiting the mold cavity remains constant or nearly constant. Different casting control parameters may be desired at each phase of casting, from the initial phase to the steady state phase to the final phase, based on the type of material being cast.

[0037] Although direct cold casting molds have been designed and developed to generate an ingot with substantially flat sides in its rectangular profile for the ingot portion produced during a steady-state portion of the casting process, the initial casting process cold direct includes challenges that distinguish the initial casting phase process and the initial portion of the ingot formed during the initial casting phase process from the steady-state phase of the casting process and the portion of the ingot formed during the steady-state casting .

[0038] During the initial phase of direct cold casting, high thermal gradients induce thermal stresses that cause deformation of the ingot in ways different from those experienced during the steady-state casting phase. Due to changes in thermal gradients and stresses experienced in the startup phase versus the steady-state casting phase, a constant profile mold cavity results in a non-uniform profile of the cast ingot portion during the startup phase, also known as top and ingot during the steady-state casting phase. Because the portion produced during steady-state casting forms the majority of the ingot, the mold profile can be designed so that the sides and opposing ends of an ingot are substantially flat. This can result in an ingot top formed during the initialization phase without substantially flat sides, as illustrated in the cast ingot cross-section of Figure 2. The illustrated embodiment of Figure 2 represents a basic cross-section of an ingot mold during the process. Of foundry. As illustrated, the molten metal 161 is received within the mold cavity between the mold side walls 110 and 120, wherein the molten metal passes into the solid metal near the well indicated by the dashed line 163. The starting block 157 of the The illustrated position has already descended with the platform 159 in the direction of the arrow 162, and the casting is currently in the steady state phase, with the sides 165 of the ingot 160 being substantially flat. The portion of the ingot 160 produced during the starting phase is shown adjacent to the starting block 157 with a profile that is swollen 170 relative to the desirable flat sides 175 of the steady-state casting phase.

[0039] The deformation of the ingot portion produced during the initialization phase 170 may not be usable depending on the end use of the ingot, so that the portion of the ingot formed during the initialization period may be sacrificial (i.e., cut from ingot and reused/remelted). This sacrificial end top of the ingot can be of substantial size, particularly in direct cold casting molds that have relatively large profiles, and although the top can be remelted so that material is not lost, time lost, reheating Melting costs and labor associated with the lost portion of the ingot and the potential for reduced maximum size of an ingot result in losses in the efficiency of the direct cold casting process. Similar problems may exist at the end of a casting in the formation of the “head” of the ingot or billet, when the casting ceases to be steady state and may require specific control parameters to maximize the usable portion of the ingot and reduce waste.

[0040] Certain embodiments of the present invention include a direct cold casting mold that has flexible opposing side walls that can be dynamically moved during the casting process to eliminate top swelling of conventional direct casting casting molds to reduce waste. and improve the efficiency with which ingots are cast. Direct cold casting molds, as described herein, may include an opposing pair of casting surfaces on the side walls of the mold that are flexible, allowing them to change shape while the mold is casting an ingot. Each of the opposing side walls may include two or more contact parts or force receiving elements, each configured to receive a force that causes the opposing side walls of the mold to dynamically move and change shape during the forming process. foundry. The forces applied to the two or more contact regions may be independent and may include forces in opposite directions, as described below. The contact regions may optionally be repositionable along the length of the opposing sidewalls to allow greater control over the shape of the sidewall resulting from the applied forces.

[0041] Figure 3 illustrates a top view of a direct cold casting mold assembly 200 in accordance with an exemplary embodiment of the present invention. As shown, the mold assembly 200 includes a first and a second opposing side wall assemblies 210, 220 and a first and a second end wall assemblies 230, 240. Each of the opposing side wall assemblies 210, 220 includes a mold cavity side wall 250 which cooperates with the end walls of the end wall assemblies 230 and 240 to form the mold cavity profile which is the shape of the perimeter of the mold cavity.

[0042] Figure 4 illustrates a view of the bottom plates of the mold assembly 200, omitting the sidewall assemblies and the top plates of the mold assembly visible in Figure 3 for ease of understanding. As shown, the bottom plates 212 and 222 of the opposing sidewall assemblies 210 and 220 include a curvature 214 and 224 on the edge facing the mold cavity 250. This curvature provides an opening at the bottom of the mold assembly 200 that is at least least as large as the side walls and end walls of the mold cavity 250 can provide. Although the side walls of the mold assembly 200 may define a curvature less than that of the respective bottom plate 212, 222, the curvature of the respective side walls may not be greater than the curvature 214, 224 of the bottom plates 212, 222 of the wall assemblies. side 210, 220.

[0043] As noted above, the opposing side walls of the exemplary embodiments described herein may include a profile that is dynamically adjustable between two or more curvature profiles. Adjusting the curvature of the opposing side wall may allow an ingot or billet top produced early in the casting process to be produced without swelling or other dimensional or physical attributes that make the top unsatisfactory for the intended purpose of the billet or ingot being cast. Exemplary embodiments described herein allow for near-infinite size optimization of a mold in a given casting pit.

[0044] Figure 5 illustrates one of the pairs of opposing sidewall mounts 210, including a top plate 216, an actuation plate 218, and a bottom plate 212. The bottom plate includes the curvature 214 as described above in relation to Figure 4. Side wall 211 is illustrated in a substantially straight, unbent configuration. Also visible is the fluid conduit block 260 configured to allow cooling fluid to flow through channels arranged behind the side wall 211, as described and illustrated below. The side wall may include a taper from top to bottom, narrowing the opening 250. Although any degree of taper may be utilized, a desirable range may be on the order of one-half degree of taper to three degrees of taper from the top edge of the side wall. 211 to the bottom edge of the side wall. The fluid conduit block 260 may include a fluid flow path for adapting fluid flow from an inlet of the fluid conduit block to one or more fluid chambers of the sidewall assembly 210. The fluid conduit block 260 may optionally include one or more valves for controlling the flow of fluid through the fluid conduit block 260 to one or more fluid chambers of the sidewall assembly 210. The fluid conduit block 260 may optionally include one or more elements filter to filter the fluid as it passes through the fluid conduit block. Additionally, the fluid conduit block 260 may optionally regulate the pressure of the cooling fluid.

[0045] The side wall 211 of exemplary embodiments may be made of a material that is strong but flexible to facilitate bending of the mold wall, as described in more detail below. For example, aluminum can be used, and in particular, 6061-T651 can be selected because of the strength-to-flexibility ratio and corrosion resistance. Aluminum with a T651 treatment is a heat-treated, stress-relieved, and artificially aged solution, which enhances the desirable properties in embodiments of the present application. Casting of molten aluminum can influence the composition of the metal, although the embodiments described herein lose temperature only at the surface of the mold walls, as the cooling mechanisms described below will help maintain a lower temperature at the mold walls and therefore , the temperature and strength of the material used for the mold walls will be maintained more consistently. A-O (annealed) quenching can be used because of the low distance from the casting surface to the water chamber, so the temperature gradient in the mold wall material can be high.

[0046] The pressure of the cooling fluid within the fluid chambers discussed further below may be in a range of about 0 (MPa) 0 psi (pounds per square inch) to about 3.10 MPa (45 psi), and desirably between about 1.37 MPa and 1.034 MPa (2 psi and 15 psi). On the face of the side wall 211, there are a plurality of holes 262 arranged in a position in the side wall near the top of the mold cavity to direct lubricating fluid from the side wall 211 toward the mold cavity. A second set of holes may also be provided as shown at 264, as will be illustrated below. The first set of orifices 262 may be configured to direct a lubricating fluid toward the mold cavity to lubricate the casting surface (i.e., the surface surrounding the mold cavity along which molten metal is solidified) of the wall. side 211 during casting. The casting surface is the portion of the side wall that is in contact with the molten material or facing the molten material and there separated by the lubricating fluid. The casting surface may include a friction-reducing material, such as a coating or an insert, to complement the lubricating properties of the lubricating fluid, such as a graphite material. The casting surface may be coated with a low-friction coating or may receive an insert of low-friction material, such as a graphite insert, which may be replaceable and may not require lubricant.

[0047] An internal casting surface of graphite or other porous material can be used to function as a grease or lubricant reservoir or sponge to distribute the grease or lubricant during the casting process and, potentially, for multiple cast materials. This may allow grease or lubricant to be applied once before casting or possibly once before a sequence of castings. The inner casting surface may be flexible to allow the inner casting surface to flex with the mold wall to create the desired hole profile and resulting casting profile. The graphite or other internal casting surface material may be attached to the mold wall using adhesive or mechanical means, such as shrink fit, fasteners, dovetail or other grooves, for example. The material cross-section of the internal casting surface may be constant or vary along the length or height of the material. For example, the material may be wider near the top of the inner casting surface and narrower near the bottom to account for bending stress. Additionally, the inner casting surface may be attached to the side wall in pieces or have grooves (e.g., vertical grooves) on one side of the material to allow the material to flex more easily and bend with the mold wall. Figure 12, discussed further below, illustrates an exemplary embodiment in which a side wall 211 includes an internal graphite casting surface 271.

[0048] Figure 6 depicts the rear side of the sidewall assembly 210 illustrating the upper actuation plate 218 adjacent to the upper plate 216 and the lower actuation plate 217 adjacent to the lower plate 212. Also visible is the curvature 214 of the plate bottom visible below the rear side of the side wall 211 when the side wall is illustrated in a substantially straight configuration. An end plate 320 secures the upper actuation plate 218 to the lower actuation plate 217 so that they move together in unison through the movement of the actuation mount 330. The actuation mount may be any of a variety of mechanisms. to provide the actuation necessary to achieve the movement described in this document. Movement includes substantially linear movement along arrow 340, wherein actuation plates 217 and 218 are configured to move along a longitudinal axis defined by sidewall assembly 210. Sidewall 211 is attached to the drive mechanism. actuation through the force receiving elements 310. This movement, as described below, transmits a bending force to the side wall 211.

[0049] Figure 7 illustrates the mechanism used to impart a bending motion to the side wall 211 using the actuation plates 217, 218 as actuated by the actuation assembly 330. The actuation assembly may include a linear actuator, a spindle mechanism, ball bearing, a rack and pinion mechanism, hydraulic piston, pneumatic piston, solenoid or similar. While the illustrated embodiment of Figure 6 illustrates a screw mechanism, which can be turned manually, embodiments can generally include an automated actuation assembly to impart movement of the side walls 211. As shown herein, actuation can be accomplished through a generally linear movement and translated through the action plates 217, 218 to cause a bend to be transmitted in the side wall 211. Actuation may be automated through actuator means such as a solenoid, electric motor, hydraulic actuator or the like. Optionally, actuation may be manual, as depicted in Figure 6, including a pivot lever 330 that may be configured to move the drive plates relative to the sidewall assembly by virtue of a helical screw adjustment mechanism.

[0050] Figure 7 shows a portion of the side wall 211 including a force receiving element 310 attached thereto at a point of contact by arms 410 and brackets 420. The force receiving element 310 may be attached to the side wall at one or more points or locations of contact along a height of the side wall 211, the height extending along a geometric axis orthogonal to the image of Figure 7. Figure 8 illustrates a perspective view of the rear of another portion of the side wall 211, including force receiving elements 310 secured by arms 410 and brackets 420 to attachment points 450 that define contact regions for the force receiving elements 310. As shown, a plurality of attachment points 450 are disposed along the along the rear portion of the sidewall 211, so that the force receiving elements 310 can be repositioned along the length of the sidewall 211 as necessary to produce the required contour of the sidewall 211 through an application of force through the sidewall 211 elements. receiving force 310. The attachment points provide a secondary function of securing the flexible bladders that form the cooling fluid channels 460 and 465, as described further below, using attachment elements that can be used to secure the flexible bladders and also attach brackets 420 to side wall 211 as appropriate. In the illustrated embodiment, there are two cooling fluid chambers 460 and 465, with attachment points 450 arranged on both sides of the fluid channels and between the fluid channels. Attachment of the force receiving elements 310 at three locations along the height of the side wall 211 provides an even distribution of forces applied to the force receiving elements 310 in a position along the side wall, from the top of the side wall to the wall background. sidewall, minimizing angular deflection of the sidewall. However, as described further below, forces may be applied distinctly from top to bottom of the force receiving elements to induce a taper as appropriate, according to some exemplary embodiments.

[0051] Although the illustrated embodiments described herein generally depict two fluid chambers (460 and 465), there may be more or fewer fluid chambers based on the desired design configuration. A single fluid chamber may be used in some embodiments to provide cooling fluid flow through the side wall 211. Optionally, more than two fluid chambers may be used, particularly in an embodiment in which different flow rates or pressures may be used. desirable through orifices associated with each of the fluid chambers. Likewise, while three attachment points are shown for each of the force receiving elements 310, embodiments may include fewer or more attachment points. According to some embodiments, the force receiving elements may be attached to the side wall in only a single location, while in other embodiments the force receiving elements may be attached to the side wall in two, three, or more locations.

[0052] Returning to Figure 7 and with reference to Figure 6, each of the actuation plates 217, 218 includes an angular slot in which a respective end of the force receiving elements 310 is disposed. This angled groove is represented by the dashed line 440 of Figure 7. The upper plate 216 and the lower plate 212 also include grooves in which the respective ends of the force receiving elements 310 are received. These slots are perpendicular to the line along which the side wall extends and are represented by the dashed line 430 of Figure 7. Figure 8 illustrates the end portion 314 of the force receiving elements 310 which are received in the slots 440 of the plates. of actuation, while the end portion 312 of the force receiving elements 310 is received in a respective top plate 216 or bottom plate 212 in the slot 430. The end portions 312, 314 of the force receiving elements 310 may include bearings or reduced friction surfaces in order to transmit forces between the slots 430, 440 and the force receiving elements 310 as described herein, while reducing the frictional forces involved at the interface between the force receiving elements 310 and the slots 430, 440.

[0053] According to the illustrated embodiment of Figure 7, as the actuation plates 217, 218 are advanced simultaneously by the actuation assembly 320 in the direction of arrow 445, the slot 440 also moves in the direction of arrow 445 with the actuation plates. acting relative to the receiving members 310. The force receiving element 310 is held fixed in the y axis (shown in Figures 7 and 9) by virtue of the force receiving element being received in the slots 430 of the upper and lower plate, restricting the movement or displacement of force receiving members only along the geometric x axis. When the force receiving element is moved along the slot 440 as the actuating plate is moved, the force receiving element 310 is displaced along the x axis in the slot 430 of the upper and lower plate. With the ends of the side wall 211 held substantially fixed with respect to the x axis, movement of the force receiving member 310 along the slot 430 results in a displacement of the force receiving member 310 from its original position and a bend is transmitted to the side wall 211 as shown in Figure 9 based on the displacement of the force receiving element, which may be exaggerated for ease of understanding. The forces between the actuating plates 217, 218 and the force receiving element 310 and the lower plates 216 and 212 and the force receiving element 310 are transmitted between the slots 440 and 430, respectively, and the support surfaces of the force receiving element 312, 314 shown in Figure 8. This allows for a smooth transition as the profile of the sidewall 211 is changed during the casting process. This bend in the sidewall 211 allows the profile of the mold cavity to be dynamically adjusted during casting to reduce swelling of the top of the ingot during the startup phase of the casting.

[0054] Although the embodiment described and illustrated above includes actuation plates 217, 218 that move simultaneously and in synchronization, exemplary embodiments described herein may provide an actuation mechanism that allows the upper actuation plate 218 to be moved independently of the lower actuation plate 217. Disconnecting the fixed relationship between the upper actuation plate 218 and the lower actuation plate 217 allows a curvature in the sidewall 211 to be different between the top and bottom of the sidewall, such as a tapered opening of a wider curve at the top of the sidewall 211 to a narrower curve at the bottom of the sidewall. By disconnecting the fixed relationship between the upper actuation plate 218 and the lower actuation plate 217, the displacement of the force receiving element 310 may be different from the top of the force receiving element to the lower force receiving element. This additional degree of freedom can allow better control over the profile of the cast ingot from the mold, allowing different offsets along the x-axis between the top of a sidewall and the bottom of the sidewall. Separate actuation may include any of the mechanisms described above duplicated for upper and lower actuation plates, or use a single actuation mechanism with a fit allowed between the actuation mechanism and one or both of the upper 218 and lower 217 actuation plates. Such an adjustment mechanism may be a mechanism that allows a length to be changed between the actuation mechanism and one or both actuation plates, thereby allowing a displacement to be transmitted between the upper actuation plate and the lower actuation plate.

[0055] Furthermore, while the illustrated embodiment of Figures 3 to 9 depict actuation plates that engage each of the force receiving elements, according to some embodiments, multiple actuation plates may be used for each of the actuation plates. upper and lower actuation to decouple the displacement of the force receiving elements. As will be described below, other mechanisms can be used to displace the force-receiving limbs, and these mechanisms can also displace the force-receiving limbs independently of each other. According to one embodiment, by implementing actuation plates as in Figures 3 to 9, multiple actuation plates may be used, with each actuation plate engaging one or more force receiving elements, and each actuation plate may be independently actuable to provide different displacements in each force-receiving member as necessary to achieve the desired sidewall profile during casting.

[0056] In response to a curve introduced into the side wall 211 of the mold cavity through the displacement of the force receiving elements 310 along the x axis shown in Figures 7 and 9, the ends of the side wall tend to pull toward to the middle of the side wall 211 when the wall is made of a material such as a metal that may be flexible but resists elastic stretching. To accommodate this, the ends of the sidewall 211 may be maintained in an arrangement that allows some degree of movement between different curvatures of the sidewall 211 introduced by the mechanism described above. Figure 10 illustrates such an arrangement, with the side wall 211 held between an end plate 480 and the fluid conduit block 260. The end plate 480 may be secured at the top and bottom to a respective top plate 216 and bottom plate. 212, keeping the end plate 480 in a fixed position relative to the end plate assembly 210. When the side wall 211 is moved between a straight profile and a curved profile, the ends of the side wall 211 may slide relative to the end plate 480 and to the fluid conduit block 260, allowing the necessary freedom of the ends of the side wall 211 to prevent unnecessary stresses on the folded middle portion of the side wall 211 between the two opposing ends. A force may be applied to the fluid conduit block 260 in the direction of the end plate 480 to capture the side wall 211 between the end plate 480 and the fluid conduit block 260. However, the fluid conduit block may be fixed to the side wall 211 and move together with the side wall through the relatively small sliding movement of the side wall 211 during bending of the side wall. The end plate 480 may optionally be part of the end wall assembly, such that the end wall assembly is attached to the side wall assembly through the top plate 216 and the bottom plate 212 to form the mold cavity.

[0057] The illustrated embodiment of Figures 7 to 9 represent mechanisms by which a force is applied to the side wall 211 of the mold cavity to introduce a curvature in the side wall. These forces can be substantial, and the interface between the force receiving elements 310 and the side wall 211 can experience relatively high stresses. To reduce or mitigate these stresses, a force distribution mechanism can be used to more evenly distribute the forces between the force receiving members 310 and the side wall 211. Figure 11 illustrates an exemplary embodiment of a force distribution member of bogie 411 that can help mitigate stress concentration along sidewall 211. As shown, bogie 411 rigidly connects pivot points 421 to force receiving member 310, while being fixedly hinged to the force receiving member 310 and to the side wall 211 through the attachment points 420. This arrangement promotes the distribution of force from the force receiving element 310 along a portion of the side wall 211 extended by the truck 411.

[0058] Also illustrated in Figure 11 is a fixed position element 520, as described in more detail below, but which remains at a fixed point within the sidewall assembly 210 and applies a resistive force against the sidewall 211 when the elements receiving force 310 displace the side wall forming a curved side wall. The fixed position element 520 may be fixed only at the pivot point 521, so that the location of the fixed position element 520 remains constant during deformation of the side wall 211. However, according to some embodiments, the fixed position element 520 fixed position member 520 can rotate about the axis 521 in order to better distribute forces along the side wall 211. As shown, the fixed position member 520 is pivotable about the axis 521 and includes arms 522 that are articulated pivoted to the fixed position block 525 at pivot points 523. The fixed position block 525 distributes forces from the pivot point 521 to the arms 522. The arms 522 distribute forces to the attachment points 524. In this way, forces between the pivot point 521 and the side wall 211 are distributed along the wall at the attachment points 524 to reduce any stress concentrations along the wall that may decrease the likelihood of failure.

[0059] During the casting process, when material exits the mold cavity in response to the starting block 157 advancing downward, as shown in Figure 2, cooling of the material exiting the mold cavity is necessary to properly form the ingot 160. This cooling is accelerated by the use of cooling fluid or cooling fluid sprayed from holes near the bottom of the side wall 211 in the direction of the material exiting the mold cavity. Figure 12 illustrates a cross-sectional view of a side wall 211 including cooling fluid chambers 460 and 465 formed by flexible bladder 462. Also shown is a fluid chamber 261 formed on the rear side of the side wall 211 and separated from the cooling chambers. fluid 460 and 465. The flexible bladder 462 may be made of a silicone rubber with a nylon reinforcement. Silicone withstands high temperatures, especially in short bursts, and sluffs molten aluminum with relative ease. The nylon reinforcement can prevent the flexible bladder 462 from stretching, which can create pressure variations and weaken the flexible bladder. The fluid chamber 261 is configured to transport lubricating fluid along the length of the side wall 211 and is in communication with the plurality of orifices 262 (of which a cross section of one is shown in Figure 12), which supplies lubricating fluid. to the face of the side wall 211. Lubricating fluid can be supplied to the fluid chamber 261 at a relatively high pressure and release into the mold at a more uniform and lower pressure. Lubricating fluid exits orifice 262 flowing generally downward along the casting surface of sidewall 211, rather than spraying outward from the sidewall to provide a layer of lubrication between the casting and sidewall 211. Each of the The plurality of orifices 262 for supplying lubricating fluid to the face of the sidewall 211 may be configured to allow the lubricating fluid to flow substantially uniformly across the length of the sidewall 211 using as many or as few lubricating fluid orifices as deemed suitable for the purpose. mold size and material to be cast. According to some embodiments, the holes may be round and spaced along the side wall 211, while in other embodiments, the holes may be elongated slits that extend along the side wall 211. In an embodiment wherein the holes are slits elongated, the slots may be fed from the fluid chamber 261 along paths to the elongated slots disposed in the side wall 211. This may allow the elongated slots to provide a “curtain” of lubricating fluid across the side wall as the lubricating fluid comes out of the holes.

[0060] As described above, the mold walls, including the illustrated side wall 211 and the end walls, may include an internal casting material, such as graphite. Figure 12 illustrates such an example, including an internal graphite casting material on the inner surface of the illustrated mold wall. This material can be adhered to the side wall 211 of the mold or mechanically fixed by any means available. The illustrated internal molding material 271 extends over only a portion of the height of the side wall 211, but may extend the entire height of the wall. Additionally, the inner casting material may include holes therethrough to allow lubricant from the holes 262 through the inner casting material or, alternatively, the lubricant from the holes 262 may provide lubricant to the porous inner casting material which can then distribute the lubricant along the face of the internal casting material due to the porous nature of the material.

[0061] Figure 13 illustrates an exemplary embodiment of an internal casting material 271 attached to the face of a mold wall 211. As shown, the internal casting material 271 includes a relatively thicker taper 272 near the top of the wall of the mold and a thinner thickness 273 near the bottom of the mold wall 211. The exemplary embodiment of Figure 13 includes an internal casting material that extends from a location near the bottom of the mold wall 211 to the top of the mold wall . A lip 274 is incorporated into the side wall 211 upon which the inner casting material 271 rests. This may allow the inner casting material 271 to be inserted from an upper part of the mold and may reduce dependence on adhesive fastening means. or mechanical between the inner casting material 271 and the mold wall 211, as the lip 274 can support the inner casting material 271 and prevents movement of the inner casting material in a downward direction as the material is melted through the mold.

[0062] As noted above, embodiments may include any number of cooling fluid chambers, wherein each cooling fluid chamber may feed one or more sets of orifices to supply cooling fluid to the casting as it exits the mold. . As shown in Figure 12, coolant chambers 460 and 465 may be configured to transport coolant to two sets of coolant ports 264 and 266. The sidewall assembly may include baffles disposed between the coolant chambers. 460, 465 and the side wall 211, wherein baffle holes may be sized and spaced to regulate fluid flow and pressure through holes 264 and 266. As shown in the embodiment of Figure 12, a first set of baffle holes 263 can regulate the flow of cooling fluid through the fluid passage 270 in the side wall 211 to a first set of holes 266. A second set of baffle holes 269 can regulate the flow of cooling fluid through the second set of holes 264. The use of a baffle plate 268 with orifices 263, 269 arranged therein may regulate fluid flow and pressure, but may also allow fluid to flow from orifices 264, 266 in a laminar flow pattern along paths 265 and 267 based, at least in part, on the length of the fluid channel between the baffle plate 268 orifices 263 and 269 and orifices 266 and 264, respectively. While both orifices 264 and 266 are visible in the sectional view of Figure 12, along with the fluid flow paths for each, it is appreciated that both orifices and the associated fluid flow paths may not be visible in a cross-sectional view. physical section. The sectional view of Figure 12 is provided for illustration and ease of understanding. While holes 264, 266 are illustrated as round, embodiments may include holes 264, 266 that are elongated along side wall 211. This may allow a different cooling fluid flow pattern from the holes to cool the casting when it comes out of the mold.

[0063] According to an exemplary embodiment, a baffle plate between fluid flow chambers 460, 465 and orifices 263, 269 may have vertically arranged slit-shaped openings to reduce back pressure in the fluid chambers. This can allow less restrictive fluid flow into the holes. However, embodiments may include flow restrictors disposed near the cooling ports 265, 267 to promote uniform fluid flow between the ports. Between the baffle plate and the restrictor, a consistent and uniform flow of fluid can be achieved through orifices 265, 267.

[0064] In accordance with the illustrated embodiment, the fluid chamber 465 may be in fluid communication with the cooling orifices 264, which may be disposed at an angle to the side wall 211. In the depicted embodiment, the cooling orifices 265 are arranged at an angle of forty-five degrees relative to the side wall 211, as shown by arrow 265, indicating the direction of fluid exiting the first plurality of cooling holes 264. The second plurality of cooling holes 266 may be arranged to direct the cooling fluid at a different angle, as shown by arrow 267, which is illustrated at an angle of twenty-two degrees relative to the side wall 211. However, the second plurality of cooling holes may be in fluid communication with the cooling fluid chamber 460 instead of the chamber 465. In order to supply cooling fluid from the cooling fluid chamber 460 to the plurality of orifices 266, a channel 270 may be machined or otherwise formed in the rear face of the wall side 211, below the substrate 280 on which the cooling channels are supported. A channel 270 may be present for each of the second set of cooling holes 266 or, alternatively, the channels 270 may exist at a plurality of locations along the length of the sidewall 211 in cooperation with a channel closer to the second set of cooling holes. cooling holes 266 extending longitudinally along the side wall 211 in a manifold arrangement.

[0065] In accordance with the illustrated embodiment, the flow of cooling fluid through each of the first plurality of orifices 264 and the second plurality of orifices 266 may be fed independently by a respective cooling fluid chamber 460, 465. This This configuration allows a cooling profile to be generated according to the type of material being melted with the appropriate flow rates and spray patterns from the respective set of cooling holes. The fluid conduit block described above in relation to Figure 10 may include separate valves for controlling the flow of cooling fluid to each of the cooling fluid chambers 460, 465. Separately controlled valves may allow independent flow regulation through of the chambers and, therefore, through the respective holes with which the chambers are in fluid communication. Optionally, cooling fluid temperatures can be controlled separately to provide even more control over the cooling of the material exiting the mold. To achieve this, the fluid conduit block may receive cooling fluid from two separate sources through two separate inlets and control flow from the separate inlets independently through each of the cooling fluid chambers 460, 465.

[0066] Furthermore, while arrows 265 and 267 represent a general direction of cooling fluid exiting ports 264, 266, respectively, spray patterns and fluid flow rates can be designed in accordance with a spray pattern preferred based on the cooling requirements of the material being melted. The cooling fluid can also be selected based on the cooling requirements of a specific material being melted. Such cooling fluid may include, for example, water, ethylene glycol, propylene glycol, Organic Acid Technology (OAT) cooling fluid, or other fluid suitable for removing heat from the casting. The angle of the cooling ports 264 and 266 may also be set to a specific angle of impact on the casting, which may be at an angle to encourage laminar flow at the port exit and turbulent casting cooling fluid flow as per cooling occurs in contact with the casting. The flow angle of the cooling ports 264 and 266 may be in the range of about 0 degrees (directed downward, substantially parallel to the side of the casting exiting the mold) to about 90 degrees (directed perpendicular to the side of the casting part that exits the mold towards the casting). This angle can be established based on the characteristics of the material to be cast in the mold, for example.

[0067] According to some embodiments, the fluid conduit block 260, as shown in Figures 5 and 6, may be configured to control the flow and pressure of fluid along the fluid channels in communication with the orifices 264, 266, in accordance with the established cooling needs of the material being melted through the use of one or more valves, which may be disposed within the fluid conduit block 260. In an embodiment wherein the fluid conduit block 260 includes a valve for each refrigeration fluid chamber, the fluid conduit block can be configured to independently control flow and pressure throughout chambers 460 and 465 as needed. Fluid flow levels and pressures can be established based on an alloy composition, temperature of the material being melted, speed at which the material is being melted (i.e., speed at which the starting block descends into the melt pit). casting) or other properties that affect the casting process. The fluid channels, as described further below, may be flexible so that bending of the side wall 211 does not affect or adversely impact the integrity of the fluid channels.

[0068] Each of the fluid chambers 460 and 465 may be defined by a flexible bladder 462, such as a heat-resistant silicone or similar material. Although a separate flexible bladder may be used to define each cooling fluid chamber, in accordance with the illustrated embodiment, a single flexible bladder 462 is used to define both cooling fluid chambers 460, 465, wherein the flexible band of the Bladder can be captured between the fastening elements 450 and their corresponding fastening holes within the side wall 211. The baffle plate 261 can also be captured between the flexible bladder tissue and the side wall 211 using the same fastening elements. The flexible bladder fabric may also be adhered to the baffle plate 261 using a high temperature adhesive or sealant. Optionally, the flexible bladder material may be fiber-reinforced, multi-material, or geometrically layered to improve the service life of the chambers 460, 465. The bladders may be flexible to accommodate bending of the sidewall 211, yet strong enough to allow a Fluid pressure is applied to the fluid within the chambers to facilitate the appropriate flow rate and spray pattern from the orifices 264, 266.

[0069] In addition to providing cooling fluid to the orifices 264, 266, the cooling fluid chambers 465 and 466 provide a cooling effect on the side wall 211 itself. The cooling fluid chambers 465 and 466 are arranged in a manner which facilitates the extraction of heat from the rear face of the sidewall 211 into the cooling fluid. This sidewall cooling effect further reduces the temperature of the sidewall 211 near the lubricating fluid channel 261 to prevent overheating of the lubricating fluid, which can result in evaporation or premature burning of the lubricating fluid. Cooling the sidewall 211 using the cooling fluid chambers 460 and 465 further reduces the likelihood and degree to which the lubricating fluid burns or evaporates as it flows along the sidewall 211 with the molten material.

[0070] Exemplary embodiments have been described and illustrated herein as incorporating flexible side walls of a direct cold casting mold with fixed profile end walls. However, embodiments described herein with respect to side walls may optionally include end wall assemblies with constructions similar to the side walls described herein. End walls that are long enough to result in swelling of the molten material during an initialization phase of the casting process or that require profile correction may be configured to be flexible in the same or a similar manner as described herein with relative to the side walls. The flexibility of end walls can further reduce swelling of the top of the ingot during the start-up phase and can decrease waste while increasing the efficiency and output of a direct-cooled casting casting mold.

[0071] The exemplary embodiments described and illustrated above include a plurality of force-applying members that, in response to a received force, induce a bend in a side wall (or end wall) of a mold. Figure 14 illustrates a representation of a sidewall assembly 500 of a mold simplified for ease of understanding. As shown, the contour of a top plate 505 includes a side wall 511 disposed in a curved position. The illustrated curved position is achieved by displacing the force receiving elements 510 through forces applied to force the receiving elements 510 in the direction of arrow 515. Embodiments described herein may optionally include fixed position elements that resist movement of the side wall. 511. Figure 14 depicts fixed position elements 520, which can be securely attached to the top plate 505 and the bottom plate (not shown) of the sidewall assembly 500. The fixed position elements 520, which are also depicted in Figure 6, can be configured to ensure that the appropriate curvature shape is achieved in response to the force applied to the force receiving elements 510. In this way, the fixed position elements 520 can limit the maximum deformation of the side wall or end wall in a specific position along the wall.

[0072] The forces applied to the force receiving elements 510 can be different across a side wall. For example, as shown in Figure 14, the three force receiving elements 510 may be configured to be displaced by a predefined amount from a straight configuration. This displacement will define the curvature transmitted to the side wall 511. To achieve the desired curvature, the force applied to the average force receiving element 510 may be different from those adjacent to it. For example, applying an equal force to each force-receiving element 510 may result in an arc with maximum displacement in the middle of the curve of the sidewall 511, where the intermediate force-receiving element is. However, the desired curvature of the wall may not include a maximum degree of curvature near the center of the wall 511 and may actually include a relatively straight section along the three force receiving elements. In such an embodiment, the displacement for each of the force receiving elements may be equal, while the average force receiving element 510 may actually apply a force to the side wall 511 in a direction opposite to the arrow 515, opposing the curvature. of wall 511 to achieve a flatter curve in the middle of the side wall. As such, the displacement of the force receiving elements 510 may be critical to establishing the shape of the sidewall curve, while forces are applied as necessary to achieve the desired displacement.

[0073] Adjusting the curvature of a side wall or end wall of a direct cooling mold during the casting process can be controlled using a plurality of different methods. For example, a melt may have a casting profile that determines parameters regarding casting speed (e.g., liquid melt flow rate and starting block descent speed), the temperature of the liquid melt entering the mold cavity, the flow/pressure rate of the cooling fluid through the cooling holes, the flow/pressure rate of the lubricating fluid through the lubricating holes, and a curvature profile for the material at each stage of the casting process. The curvature profile can be adjusted from a first position during the initial casting phase, to another curvature profile during the steady state phase, to another curvature profile during the final phase, and any number of curvature profiles in between these phases ( for example, a constant dynamic change between different phases). In such an embodiment, a controller may dictate the shape of the curvature of the side walls and/or end walls throughout the casting process in response to the casting phase. Feedback on the properties of the material being melted may not be necessary in such an embodiment.

[0074] According to some embodiments, the curvature profile of the mold walls can be determined based on a closed-loop feedback system. A controller can receive temperature information (e.g., of the liquid casting material, the material exiting the mold, mold temperature, etc.), casting speed (e.g., the speed of the block descent and starting platform) , dimensional information (e.g., dimensions of the casting as it exits the mold cavity or at a predefined distance below the exit from the mold cavity), stress and/or strain feedback, or other information related to the casting process, and use this information to establish the appropriate curvature profile of the wall. A plurality of sensors may be dispersed around the exit of the mold cavity, such as thermal sensors for detecting the temperature of the casting exiting the mold or distance sensors configured to measure the dimensions of the casting exiting the mold. These sensors can provide feedback to the controller to determine the appropriate curvature profile given data regarding the casting exiting the mold cavity.

[0075] Although exemplary embodiments described herein can be implemented to reduce or control the top expansion of a casting, exemplary embodiments can optionally be implemented to prevent or mitigate the castings from becoming trapped within the mold. For example, top winding and excessively hot casting conditions of a casting such as an ingot during the casting process can cause an interference fit of the casting within the mold, whereby the mold walls (side walls , end walls, or both) become engaged by the casting in a manner that prevents the casting 160 from leaving the mold assembly 200 when the starting block 157 descends into the casting pit. These conditions that lead to interference between the mold and casting can lead to catastrophic failures such as mold leakage if not quickly corrected or mitigated. During the steady-state portion of the casting process, several factors can contribute to a casting hanging in the mold, such as inadequate lubrication, abnormal cooling, or the like. During the end of the casting process, the casting may undergo "reduced head shrinkage" and the flexible mold walls of exemplary embodiments may be controlled to accommodate this shrinkage. During movement of the mold side walls, a binding condition may occur where the casting becomes stuck or hangs in the mold. In each of these cases, although the causes may be different, a casting can become stuck in the mold, which can lead to catastrophic failure if not mitigated quickly.

[0076] Exemplary embodiments described herein may provide feedback from the mold to a controller, indicating when a condition arises in which the casting is stuck or hanging in the mold. Feedback to the controller may include one or both of the two detected changes. A first change that occurs in the casting process when the casting is suspended within the mold is that the flow of casting fluid decreases as the movement of the starting block continues down the casting pit. Casting fluid flow is controlled by the size of the control pin and spout orifice based on metal level feedback, so if the fluid flow increases while the starting block continues to descend, it is an indication that the casting may be stuck in the mold. The level of molten metal in the mold can be maintained at a constant or nearly constant level during casting by feeding the level in the mold back to a valve, such as a control pin on a fluid flow tube, to adjust the flow accordingly. with the fluid level in the mold. If this fluid flow control unexpectedly needs to reduce fluid flow to maintain level, it may be a symptom of a casting stuck in the mold cavity.

[0077] Likewise, if the flow of casting fluid from a first mold cavity among a plurality of mold cavities is different and slower than the remaining cavities, this may be an indication of a stuck casting. A second change that can occur during casting that may be indicative of a casting stuck in a mold is the resistance or feedback experienced by the actuation mechanism that provides a bend in the side walls of the mold. The side walls of the mold can be held in a predetermined position by the drive mechanism, and when the casting is stuck or hangs in the mold, a force can be applied by the casting to the mold walls. In the case of an electrical actuation mechanism, the actuation mechanism may experience an increase or spike in amperage current or current in the actuation mechanism, indicating a resistive force opposing the actuation mechanism. This peak may be indicative of the suspension of a casting in the mold. In the case of a hydraulic drive mechanism, a pressure spike or current draw in a hydraulic pump can similarly be indicative of a casting being hung in the mold.

[0078] Yet another mechanism for detecting a casting stuck in the mold may be through a weight or force on the starting block 157 and platform 159 (as shown in Figure 2). During casting, the weight of the casting will increase as the starting block descends into the casting pit due to the increase in material flowing in and out of the mold cavity. If the weight decreases at any time during casting, it is an indication that the starting block can no longer support the total weight of the casting. This may be an indication of a casting stuck in the mold. The decrease in weight on the starting block can be detected by a force measuring transducer or other sensor on the starting block or platform. However, the reduced weight in the starting block can also be detected through the mechanism that lowers the platform and starting block. For example, a hydraulic system used to lower the platform and starting block may control platform lowering by controlling fluid flow from a chamber. In response to an unexpected change in flow or flow pressure, a system controller may determine that the weight on the starting block has decreased.

[0079] In response to the indication that a casting is hanging in the mold, whether through an unexpected slowdown in the flow of casting fluid or a spike or increase in hydraulic pressure or electrical current from the actuating mechanism, the The controller may adjust the shape of the mold walls, such as the side walls, in an effort to cause the casting to loosen or separate from the mold, allowing lubricant to reach between the casting and the mold walls. This shape change can be caused by the controller that drives the shape drive mechanism to encourage the casting to descend from the mold cavity along with the starting block into the casting pit.

[0080] The actuation mechanism for inducing the appropriate curvature profile is described and illustrated above to include a pair of actuation plates and an actuation mechanism for moving the actuation plates. However, other mechanisms may be employed to provide forces to force receiving elements to impart a curvature to the side walls or end walls of a mold. Figure 15 illustrates such an exemplary embodiment including the sidewall assembly arrangement 500 of Figure 14. The force receiving elements 510 of Figure 15 are connected to actuators 530 that can push or pull the force receiving elements along the axis. geometric X (for example, in the direction of arrow 515 or opposite to it). The exemplary embodiment of Figure 15 may include actuators 530 that are linear actuators for pushing/pulling force receiving elements 510. The actuators may optionally include rotational actuators that rotate a gear such as a pinion gear in a rack gear to transmit a force to force the receiving member 510, or a ball screw or helical gear that is rotated to transmit a force on the force receiving member 510. As noted above, the actuators 530 may be capable of independently controlling the displacement of the receiving elements of force 510 individually or in subassemblies.

[0081] In an exemplary embodiment in which the actuators 530 function as described in relation to Figure 15, multiple molds suspended within the same mold structure can benefit from equal and opposite forces applied by the actuators 530. Figure 16 illustrates a plurality of mold assemblies 540 disposed within the mold frame assembly 545. The mold assemblies 540 may be attached to the mold frame assembly 545 in any conventional manner to support the mold assemblies within the frame as the frame assembly mold transitions between a substantially vertical position in which the mold assemblies are positioned at the end, to a substantially horizontal position in which the mold assemblies are suspended during casting using the mold cavities 550. As shown, the three mold assemblies illustrated 540 include two pairs of adjacent sidewall assemblies 560. During casting, each of the mold assemblies is ideally at the same stage of the casting phase at the same time, due to a uniform material being cast in each of the mold cavities. 550 and to a common platform on which the three starting blocks for the molds are descending simultaneously. As such, the curvature profile of the side walls of each mold must be the same. The adjacent sidewall assemblies 560 would then be providing equal and opposite forces to their respective sidewalls.

[0082] Figure 17 illustrates an exemplary embodiment of a pair of adjacent sidewall assemblies 560 from a pair of adjacent mold assemblies. In such an embodiment, the benefits of equal and opposite applied forces can be achieved. In the embodiment of Figure 17, actuators 530 may be disposed between the pair of adjacent sidewall mounts 560 and configured to apply forces that are equal and opposite to a pair of opposing force receiving elements 510. In this manner, the actuators remain in a neutral force condition, regardless of the force applied to the force receiving elements 510. This allows the support structures supporting these actuators to be less substantial and not require a reinforcing superstructure to prevent the mold assemblies from bending based 17 illustrates shared actuators 530, exemplary embodiments may include individual actuators for each force receiving element 510 of each side wall assembly, but may allow coupling between corresponding actuators of the wall assemblies. sidewalls 560. This allows the sidewall assemblies to cooperate to be force neutral while still producing the required curvature profile in the sidewall. Sidewall assemblies that do not have an adjacent sidewall assembly may require increased structural support relative to sidewall assemblies that are adjacent to other sidewall assemblies. The augmented structural support can be modular and removable, while the coupling of adjacent actuators can be interchangeable to allow molds to be placed within a structure without regard to their order and to allow coupling between any pair of adjacent sidewall assemblies and reinforcement of any adjacent sidewall assemblies.

[0083] The dynamically adjustable side walls of the exemplary embodiments described herein can be used to establish the profile of the casting as it exits the mold cavity and cools. However, according to some embodiments, dynamically adjustable side walls may optionally be used to assist in aligning the starting block with the mold cavity. Alignment of the starting block with the mold cavity is important to ensure that no casting fluid leaks out at the beginning of the casting process. Although a mold structure may be moved to align with a starting block through, for example, electrical, pneumatic, or hydraulic actuator means, embodiments described herein may use the dynamic flexibility of the mold sidewalls to align the mold cavity. mold to the starting block. The starting block 157 may be positioned on a platform 159. The interface between the starting block 157 and the platform 159 may be a low-friction interface, such as through the use of a lubricating material (e.g., grease, oil, graphite , etc.) or using an air cushion with air fed through the platform to between the platform 159 and the starting block 157. One or more alignment features may extend below the mold cavity to be used as guides to guide the starting block 157 for fitting into the mold cavity. Prior to casting, when the platform is raised to engage the starting block 157 with the mold cavity, or when the mold is engaged with the starting block, the side walls of the mold cavity can be adjusted to open the mold cavity. Opening the mold cavity using dynamically adjusted side walls can provide a larger area in which the starting block 157 can be received, helping to facilitate alignment.

[0084] Bringing the starting block 157 into engagement with the mold cavity can be aided by the alignment features of the mold, and once the starting block 157 is within the mold cavity, the dynamically adjusted side walls can be adjusted to a smaller opening to provide adequate clearance with the starting head for the start of casting. In the event that the starting block is not properly aligned or centered within the mold cavity, adjusting the side walls of the mold cavity may move the starting block so that it is centered within the mold cavity. The reduced friction surface between the starting block 157 and the platform 159 can facilitate this movement. Through this mechanism, alignment between the starting block 157 and the mold cavity can be more easily achieved.

[0085] Many modifications and other embodiments of the inventions set forth herein will come to mind to those skilled in the art to which these inventions belong having the benefit of the teachings set forth in the foregoing descriptions and associated drawings. Therefore, it will be understood that the inventions will not be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are used in this document, they are used only in a generic and descriptive sense and not for the purpose of limitation.

Claims (20)

1. Apparatus for casting material characterized by the fact that it comprises: first (110, 210) and second (120, 220) opposing side walls; and first (130, 230) and second (140, 240) end walls extending between the first (110, 210) and second (120, 220) side walls, wherein the first (110, 210) and second (120, 220) opposing side walls and the first (130, 230) and second (140, 240) opposing end walls form a mold cavity (150, 250) in rectangular shape; and two or more force receiving elements (310); wherein at least one of the first (110, 210) and second (120, 220) opposing side walls comprises two or more contact regions, each of the two or more force receiving elements (310) connected to at least one at least one of the first (110, 210) and second (210, 220) opposing side walls in a respective contact region at two or more pivoting attachment points (450), wherein each of the two or more contact regions is configured to be displaced relative to a straight line between a first end of the at least one of the first (110, 210) and second (120, 220) opposing side walls and a second end of the at least one of the first (110, 210) and second (120, 220) opposing side walls in response to receiving a respective force applied to the two or more force receiving elements (310) externally of the mold cavity (150, 250), wherein the respective displacement in a first of the two or more regions of contact with respect to the straight line is different from a displacement in a second of the two or more regions of contact with respect to the straight line, in which the force applied to the respective force receiving element (310) is distributed across of the two or more pivoting attachment points (450) and wherein a respective force in each of the two or more contact regions alters a curvature of the at least one of the first (110, 210) and second (120, 220) side walls between the first and second ends of the at least one first (110, 210) and second (120, 220) opposing side walls. 2. Apparatus according to claim 1, characterized by the fact that the respective force applied to a respective force receiving element (310) in the first of the two or more contact regions comprises a force in a first direction, in that the respective force applied to a respective force receiving element (310) in the second of the two or more contact regions comprises a force in a second direction, opposite to the first direction. 3. Apparatus according to claim 1, characterized by the fact that the respective force applied to a respective force receiving element (310) in the first of the two or more contact regions comprises a force of a first magnitude in a first direction, wherein the respective force applied to a respective force receiving element (310) in the second of the two or more contact regions comprises a force of a second magnitude in the first direction, wherein the second magnitude is different from the first magnitude. 4. Apparatus according to claim 1, characterized by the fact that it comprises two or more fixed position members, wherein the two or more fixed position members are configured to resist movement of at least one of the first (110, 210) and second (120, 220) opposing side walls in response to a respective force applied to one or more of the two or more contact regions. 5. Apparatus according to claim 1, characterized in that the first (110, 210) and second (120, 220) opposing side walls each comprise an upper portion and a lower portion, wherein the upper portion of at least one of the first (110, 210) and second (120, 220) opposing side walls is displaced near the first contact region by a first distance relative to the straight line between the first end of the at least one of the first ( 110, 210) and second (120, 220) opposing side walls and the second end of the at least one first (110, 210) and second (120, 220) opposing side walls and the lower portion of at least one of the first (110 , 210) and second (120, 220) opposing side walls is displaced near the first contact region a second distance relative to the straight line between the first end of at least one of the first (110, 210) and second (120, 220 ) opposing side walls and the second end of the at least one first (110, 210) and second (120, 220) opposing side walls, thereby defining a taper between an upper portion of the mold cavity (150, 250) and a lower portion of the mold cavity (150, 250). 6. Apparatus according to claim 1, characterized in that the mold cavity (150, 250) defines an opening in a top of the mold cavity (150, 250) in which molten metal is received, and a opening in the bottom of the mold cavity (150, 250) from which at least partially solidified metal exits, wherein a first and second side casting surface tapers from one end near the top of the mold cavity (150, 250) to an end near the bottom of the mold cavity (150, 250) such that the opening at the bottom of the mold cavity (150, 250) is larger than the opening at the top of the mold cavity (150, 250 ). 7. System for metal casting characterized by the fact that it comprises: a controller; a mold as described in claim 1, comprising: a first side wall (110, 210); a second side wall (120, 220) opposite the first side wall (110, 210); a first end wall (130, 230); and a second end wall (140, 240) opposite the first end wall (130, 230), wherein the first side wall (110, 210), the second side wall (120, 220), the first end wall (130, 230) and the second end wall (140, 240) cooperate to define a mold cavity (150, 250) having a mold cavity profile (150, 250); a first force receiving element (310) connected at two or more pivoting attachment points (450) to the first side wall (110, 210) located opposite the mold cavity (150, 250), wherein a first force applied to the first force receiving element (310) distributed by the two or more pivoting attachment points (450) of the first force receiving element (310) is controlled by the controller and causes a first displacement of the first side wall (110, 210) in the first force receiving element (310); and a second force receiving member (310) attached at two or more pivot attachment points (450) to the first side wall (110, 210) located opposite the mold cavity (150, 250), wherein a second force is applied to the second force receiving element distributed through the two or more fastening elements (450) of the second force receiving element (310) is controlled by the controller and causes a second displacement of the first side wall (110, 210) in the second element force receiving element (310) and wherein the first displacement is different from the second displacement, wherein the first force receiving element (310) and the second force receiving element (310) are spaced apart along a length of the first side wall (110, 210) between the first end wall (130, 230) and the second end wall (140, 240). 8. System according to claim 7, characterized by the fact that the controller is configured to adjust the first displacement of the first force receiving element (310) and the second displacement of the second force receiving element (310) during a casting process using the mold. 9. System according to claim 8, characterized in that the controller adjusts the first displacement and the second displacement in response to at least one of a property of the metal to be cast or a profile of the metal leaving the mold. 10. System according to claim 7, characterized in that the first side wall (110, 210) and the second side wall (120, 220) of the mold comprise a first plurality of holes (262) and a second plurality of holes (262), wherein the first plurality of orifices (262) provides cooling fluid at a first angle relative to the metal exiting the mold during a casting process and the second plurality of orifices (262) provides cooling fluid at a second angle in relation to the metal leaving the mold during the casting process, where the first angle and the second angle are different. 11. System according to claim 10, characterized by the fact that a first cooling fluid channel is defined along the first side wall (110, 210) outside the mold cavity (150, 250), wherein the first cooling fluid channel is defined between the first side wall (110, 210) and a flexible bladder (462), wherein a second cooling fluid channel is defined along the first side wall (110, 210) outside the mold cavity (150, 250), wherein the second cooling fluid channel is defined between the first side wall (110, 210) and the flexible bladder (462), wherein the first cooling fluid channel provides cooling fluid cooling fluid for the first plurality of orifices (262) and the second fluid channel provides cooling fluid for the second plurality of orifices (262). 12. The wall of a direct cold casting mold according to claim 1, the wall being characterized by the fact that it comprises: a body extending longitudinally along a length between a first end and a second end; two or more force receiving elements (310) attached to the longitudinally extending body at two or more contact regions offset laterally from each other along the length of the longitudinally extending body, each force receiving element (310) attached to a respective contact region at two or more pivoting attachment points (450), wherein a force applied to the respective force receiving element (310) is distributed through the two or more pivoting attachment points (450) and displaces the respective contact region in relation to a straight line between the first end and the second end; an inner face defining a portion of a mold cavity (150, 250) and extending from the vicinity of the first end to the vicinity of the second end, wherein a first set of holes (262) and a second set of holes (262) ) are formed through the longitudinally extending body close to the inner face of the longitudinally extending body; an outer surface opposite the inner face; a first fluid chamber (465) disposed near the outer surface; and a second fluid chamber (465) disposed near the outer surface; wherein the first fluid chamber (465) is in fluid communication with the first set of orifices (262) and the second fluid chamber (465) is in fluid communication with the second set of orifices (262), wherein the first set of holes (262) and the second set of holes (262) are each arranged to supply cooling fluid to a portion of a casting as it exits the mold. 13. Wall of a direct cold casting mold according to claim 12, characterized in that the internal face is configured to be displaced along a geometric axis orthogonal to the internal face in response to receiving a force at the along the geometric axis applied to the external surface. 14. Wall of a direct cold casting mold according to claim 13, characterized in that the first set of holes (262) comprises a set of holes (262) formed through the body extending longitudinally proximate to the inner face of the longitudinally extending body and the first set of holes (262) extending along the longitudinally extending body, wherein the second set of holes (262) comprises a set of holes (262) formed through the body extending longitudinally near the inner face of the longitudinally extending body and the second set of holes (262) extending along the longitudinally extending body. 15. Wall of a direct cold casting mold according to claim 14, characterized in that the first set of holes (262) provides cooling fluid to the cast part as it exits the mold at a first angle relative to the cast part, and the second set of orifices (262) provides cooling fluid to the cast part as it exits the mold at a second angle relative to the cast part, wherein the first angle is different from the second angle. 16. Wall of a direct cold casting mold according to claim 14, characterized in that it further comprises a first set of fastening elements, a second set of fastening elements, and a third set of fastening elements , wherein each of the first set of fasteners, the second set of fasteners, and the third set of fasteners extends longitudinally along the outer surface where the first fluid chamber (465) is disposed between the first set of fasteners and the second set of fasteners, and the second fluid chamber (465) is disposed between the second set of fasteners and the third set of fasteners. 17. Wall of a direct cold casting mold according to claim 12, characterized in that the first fluid chamber (465) and the second fluid chamber (465) extend along the extending body longitudinally over the outer surface, wherein the outer surface of the direct cold casting mold wall defines at least one wall of the first fluid chamber (465) and the second fluid chamber (465). 18. Wall of a direct cold casting mold according to claim 17, characterized in that the first fluid chamber (465) and the second fluid chamber (465) are delimited on one side by the outer surface of the direct cold casting mold wall and bounded opposite the outer surface of the direct cold casting mold wall by a flexible membrane. 19. Wall of a direct cold casting mold, according to claim 12, characterized by the fact that the two or more force receiving elements (310) are repositionable along the longitudinally extending body. 20. The wall of a direct cold casting mold according to claim 12, wherein the inner face comprises a graphite insert material, wherein the graphite insert material is configured to flex in congruence with the body that extends longitudinally.