CA1045781A - Casting method and a casting mold, particularly for use in the continuous casting of elongated metallic articles - Google Patents
Casting method and a casting mold, particularly for use in the continuous casting of elongated metallic articlesInfo
- Publication number
- CA1045781A CA1045781A CA222,761A CA222761A CA1045781A CA 1045781 A CA1045781 A CA 1045781A CA 222761 A CA222761 A CA 222761A CA 1045781 A CA1045781 A CA 1045781A
- Authority
- CA
- Canada
- Prior art keywords
- passage
- casting
- air
- mold
- cooling
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/04—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
- B22D11/049—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds for direct chill casting, e.g. electromagnetic casting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/12—Accessories for subsequent treating or working cast stock in situ
- B22D11/124—Accessories for subsequent treating or working cast stock in situ for cooling
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Continuous Casting (AREA)
- Inorganic Fibers (AREA)
- Casting Devices For Molds (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
- Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
A casting method is disclosed which is particularly well-suited for the continuous casting of elongated metallic articles such as bars, bands and wires. The method involves admitting a quantity of molten metal into an upstream portion of a passage. This portion of the passage has a configuration which it is desired to obtain for the cast metal. The surface layers of the molten metal are solidi-fied by contact with the walls defining the upstream portion of the passage so that there is formed a metallic element having the config-uration of the upstream portion of the passage. The metallic ele-ment is advanced into a downstream portion of the passage where it is further cooled by direct contact with an air-water mixture which flows countercurrent to the direction of motion of the metallic ele-ment. Thereafter, the now fully solidified metallic element exits from the passage. The air-water mixture is formed near the exit of the passage by forcing water into the passage. This causes an under-pressure to develop in the passage as a result of which air is as-pirated into the passage thereby yielding an air-water mixture. The air-water mixture may, after direct cooling of the metallic element, be used for cooling the wall defining the upstream portion of the passage by conduction through this wall. The cooling of the metallic element in countercurrent flow permits a relatively slow cooling rate to be obtained whereby the danger of crack formation is reduced.
A casting mold is also disclosed and includes a chamber for accom-modating water under pressure. The chamber communicates with a casting passage near the end of the latter so that the injection of water into the passage causes an underpressure to develop which, in turn, causes air to be drawn into the passage. In this manner, an air-water mixture may be formed which flows towards the upstream end of the passage.
A casting method is disclosed which is particularly well-suited for the continuous casting of elongated metallic articles such as bars, bands and wires. The method involves admitting a quantity of molten metal into an upstream portion of a passage. This portion of the passage has a configuration which it is desired to obtain for the cast metal. The surface layers of the molten metal are solidi-fied by contact with the walls defining the upstream portion of the passage so that there is formed a metallic element having the config-uration of the upstream portion of the passage. The metallic ele-ment is advanced into a downstream portion of the passage where it is further cooled by direct contact with an air-water mixture which flows countercurrent to the direction of motion of the metallic ele-ment. Thereafter, the now fully solidified metallic element exits from the passage. The air-water mixture is formed near the exit of the passage by forcing water into the passage. This causes an under-pressure to develop in the passage as a result of which air is as-pirated into the passage thereby yielding an air-water mixture. The air-water mixture may, after direct cooling of the metallic element, be used for cooling the wall defining the upstream portion of the passage by conduction through this wall. The cooling of the metallic element in countercurrent flow permits a relatively slow cooling rate to be obtained whereby the danger of crack formation is reduced.
A casting mold is also disclosed and includes a chamber for accom-modating water under pressure. The chamber communicates with a casting passage near the end of the latter so that the injection of water into the passage causes an underpressure to develop which, in turn, causes air to be drawn into the passage. In this manner, an air-water mixture may be formed which flows towards the upstream end of the passage.
Description
~ 5 7 ~ 1 The invention relates generally to a method of casting and a mold for casting. Of particular lnterest to the invention is the casting of eLengated metallic articles, e.g., bars and wiresO
Methods and molds for the co~pleteLy continuous casting of metallic strands, that is, elongated metalLic articles, are kn~w~.
One type of mold which has become known ~or the continuous casting of metaLlic strands is a contlnuous passage mold which is a type o-f mold wherein molten metal is continuously admitted into one end o~
a cas~ing passage and a soLidiied strand is corltinuousLy withdrawn - .
from the oth~er end of the passageO Molds o~ this type may be water-cooled and generally include a ~haping portion in which the surface of the molten metaL is indirectly cooled by the cooling medium. The indirect cooling of the surface o the molten ~etal causes the sur- -face thereof to solidify by virtue o which there is fonmed a metal-lic element~ The latter is conveyed from the shaping portion of the casting passage to a downstream portion of the passage wherein it is directly cooled, within the mbLd, with the aid of an air-water mixtureO This completes ~he sol~dff~cation and ~he resuLting s~rand is then withdrawn from~he ~oldO
In the known molds and methods of the type outlined above, a rapid cobling of the metallic element or strand to the temperature of the cooling water occur~. As a P-lesult of th~s rapid cooling, there exists ~he danger that severe internal stresses wilL be set up in the strand. Where the casting opera~ion invol~es aLloys, there then arises the posslbility tha~ these in~ernal stresses will cause tearing or cracking of the strand in longitudinal direction thereof. Moreover, the conventionaL rapid cooling of the strand gi~es rise to the danger that, in the subæeque~t working or shap-ing operations to which the strand is subjected, lob~s or projec-tions will be ormed on the strand.
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It is thus clear that improvements in the state of the art are desirabLe~
AccordingLy, it is a general object of thQ invention to provide a novel casting me~hod and a novel casting mold.
Another object of the lnvention is to provide a casting method and a casting moLd which enable in~ernal stresses in a cast article to be minimized.
A ~urther object of the invention is to provide a casting method and a casting moLd which enabLe ~earing or cracking o a cast articLe to be positively avoidcd.
An additionaL objeot of the invention is to provide a casting method and a castLng moLd which make it posslble to avoid the disadvantages arising from the conventional rapid cooling used heretofore~
These objectsg and others which wiLl become apparent as the description proceeds, are achieved in accordance with the in-vention. According to one aspect of the invention there is provid-ed a casting method which is particularly weLl-suited for use in the continuous casting of eLongated metaLlic artlcles such as bars, bands, wires and the like, and especiaLly thin bands, that is, bands of small cross sec~ion. The mtehod comprises admit~ing molt-en material into a passage having an upstream portion of predeter-mined configurati~n and solidifying a surface Layer of the molten m~terial in the upstream portinn of the passage so as to obtain an at least partially solidif~ed element having substantially the pre-de~enmined configuration of the upstream portion of the passage.
The element is advanced into a downstream portion o the passage.
In the downstream portion of the passage~ the element is directly cooLed by contacting it with a cooling medium which flows counter-current to the direction of advancement o~ the element along the ~ 1~4passage .
It wiLl be appreciated that the cooling of ~he element in countercurrent flow enabLes a sL~wer cooling rate than heretofore to be obtained.
In accordance wi~h one c~ncept of the invention, ~he solid~
ification of a sur~ace layer of ~he moLten material may be efected by indirectly cooling the surface layer with the cooling med~um which directly cooLs the at lea~t partially solidiied elemen~ in countercurrent flow.
An advantageous embodiment of the invention provides for the co~ling medium to comprise a gas-liquld mixture and~ preferably, an air-water mix~ureO Favora~ly, the gas-liquid mixture is formed in the region of a downstream end of the d~wnstream portion of the passage, that is, the portion o the passage wherein ~he at least partially solidif~ed element is directly cooled by the cooling m~d-ium. It is further preferred for the gas-liquid mixture to be form-ed immediately adjacen~ the surface of~~he at least partially solid-i~ied elementO The formation of the gas-liquid mixture advantage-ously involve~ aspirating a gas~ e.gO, air, into the passage and forming a liquid spray~ e.g.~ water spray, in the aspirated gas.
Temperature regulation may, in whole or in part, be effect-ed by controLling the quantity or rate of admisslon into the pass-age o~ the gaseous component of ~he gas-liquid mixture, the liquid component of the latter or both the gaseous and l~quid components of the gas-liquid mixtureO On the other hand~ it is aLso possible to sffect temperature regulationJ in whole:~or in part, by control-ling the rate of admission of molten material into the passage~
In accordance with another aspect of ~he invention there is provided a casting mold which is particularly well-suited for use in the continuous cas~ing of elongated metallic articles such ~6~4S781 as hars, bands, wires and the like, and especially thin bands. The mold comprises wall means which defines a passage having an upstream portion o predetermined configuration for the solidification of a surface layer of molten material by contact with the wall means so as to form an at least partially solidified element having substan-tially the configuration of the upstream portion of the passage. The passage also has a downstream portion for further cooling oE an ele-ment advanced therein from the upstream portion thereof by direct contact with a coolant. The admitting means is provided for admit-ting a cooling medium into the passage in the region of a downstreamend of the downstream portion thereo. In this manner, it becomes possible to permit the further cooling of an element advanced into the downstream portion of the passage from the upstream portion thereof to occur by countercurrent motion of the cooling medium and the advancing element.
A plate, for instance, a cover plate, may be arranged up-stream of the passage so as to extend across the latter. This plate may then be provided with an opening for the admission of molten ma-terial into the passage. The plate may, for example, be composed of the product sold under the TM "Marinite", a fireproof sheet made of asbestos fiber,diatomaceous silica and an inorganic binder.
In accordance with the invention, it is of advantage for the wall means which defines the passage to comprise metal of good thermal conductivity.
According to one embodiment of the invention, the means for admitting a cooling medium into the passage includes a chamber arranged for communication with the passage in the region o a downstream end of the downstream portion thereof. The chamber is constructed in such a manner that it is able to accommodate a liquid e.g., water, at a pressure in excess o atmospheric pressure. With such an arrangement, a cooling medium in the form of a mixture in-' .
~ S 7~3~cluding a spray of a liquid in a gas may be obtained.
Thus, a pressure reduction may be produced in the passage One possibility for achieving this is ~o make use of the liquid ac-commod~ed in the chamber to produce a Venturi ef~ect which then causes a lowering of the pressure in the passage. On the other hand, it is possible to cause a pressure reduction in the passage by using a suitable pump for ~his purpose. I~ is fur~her possible to lower ~he pressure in the passage by producing a Venturi e-ffect and com bining this with the action of a pump. Regardless, as a resuLt of the pressure reduction in the passage, a gas, e.g., air, may be as-pirated into the passage, ~or e~ample, through the outlet end of the latterO The aspirated gas may then convey along with it Liquid from the chamber when it flows past the location at which the cham-ber communicates with the passage. In this manner, the liquid may become admixed with the gas in the form of a spray thereby yielding ~-a cooling medium which is in the form of a gas-liquid mixtureO
~ conduit which communicates with the passage ups~ream of the d~wnstream end of the d~wnstream portion thereof may be provided in the wall meansO By means of such an arrangement~ the cooLing medium flowing in upstrPam direction of the passage and whi~h ~ools the at least partialLy soLidified molten material by direct contact may flow into the wall means via the conduitO This cooling mediu~
may then be used ~or effecti~g solidi$ication of a surface layer of molten materlal acc~mmodated in ~he upstream portion of the pass-age by the conduction of heat through the waLl means~ ~hat is, this cooling medium may then be used for indirect cooling of the molten material accommodated in ~he upstream portion of the passage. It is particularly favorabl2 here for tha wall means, or a~ least the part thereof Located in the region of the upstream portion of the passagQ, ~o be composed o~ metal having good thermal conductivity.
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The novel features which are considered a~ characteristic for the invention are set forth in particular in the appended claims.
The invention itseLf7 howeverg both as to its con~truction and its method of operation, together with additional objects and advantages thereof, will be best understood f~m the follawing description of specific;embodiments when read in connection with the accompanying drawingO
The single FIGUR~ ~epresents a verticaL cross section through one form of a casting mold accoxding to the inventi~n which LO may be used for car~ying out a method in accordance with the i~ven ~io~.
As indicated previously, of particular interest to the invention are a method and a mold for the fully continuous casting of me~allic strands or elonga~ed ~etallic articles, especially thin bands. Moreover, the invention is particularly interested in those cases wherein casting is carried out in continuous passage, water-cooled molds having an indi~ectly cooled shaping portion and where-i~ the strand is directly cooled wi~hin the mold with thP ai~ of an air-water mlxture~ Accordingly, the following description wiLl be 2Q primarily with reference to ~he concepts just outlined.
A continuous passage mold may be defined as a mold having a passage exten~ing therethrough and which is so constructed th~
molten material may be continuously introduced in~o one end of the passage while a solidified strand may be continuously withdrawn f~om the other end of the passage.
In a method of the type just outlined, the invention pro~ ;
vides, according to one of i~s aspects, for the air-water mixture which serves to cool ~he ~trand or band within the mold to be con-veyed countercurrent to the direction of motion of the strand and to be produced immedlately adjacent the ~urface of ~he strand at ~457~
the end of the direct cooling zone. In this manner, it becomes possible to regulate the temperature which the stand has upon leav-ing the mold and to maintain the temperature of the strand upon its exit from the mold at an arbitrarily high value. Thus, the strand may be removed from the mold with a relatively high temperature and the formation of tears or cracks when using alloys susceptible to tearing or cracking may thereby be avoided. Moreover, semi-Einish-ed products having definite characteristics as regards, for instance, the formation of lobes or projections on and the hardenability and freedom from stress of cast, shaped plates, may be manufactured from the thus produced strand.
The temperature regulation which it is intended to achieve in accordance with the invention may be carried out in various ways.
For instance, this may be accomplished by con~rolling the rate of casting or by appropriately varying the quantiti~s of cooling air and/or cooling water which are used.
Referring not to the single FIGURE of the drawing, it is pointed out that the particular mold illustrated therein is intend-ed for use in the casting of thin bands. However, this is not to be construed as limiting the invention since it is possible to also cast thicker forms of articles, thicker profiled articles, etc., in the same manner. Moreover, instead of casting in a horizontal di-rection as illustrated in the drawing, it is possible, i~ desired, to cast in a vertical direction.
With the above consideration in mind, it may now be pointed out that the reference numeral 1 indicates a plate such as a cover plate. The plate 1 may, for example, be composed of "Marinite".
The plate 1 is provided with an inlet opening 2 for molten metal which is conveyed through the plate 1 in a direction indicated by the arrow 3, that is, from left to right as seen in the drawing.
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suitable Eeeding means is provided for continuously conveying the molt~n metal through the inlet opening 2 of the pLate lo The feed-ing means has not, however, been iLlustrated since it does not foxm part of the invention per se and is well-known in the artO
After passing ~hrou~h ~he inle~ opening 2 of the plate 1, the m~lten metal enters a mold 4. The latter ls composed o~ metal having good thermal conductivityO
In the mold 4~ the moLten metaL first passes into an in-direct cooling zone the extent of wh~h is ind~cated by the double-headed arrow 5. Su~icient molten metaL is introduced so that ~hemol~en metal contacts a wall portion 6 of the mold 4 in the indirect cooLing zone 5O The wall portion 6 of the mold 4 is cooled by an air-water mixture which wiLL be discussed more fully below. It is sufficient here to point out that a cooling air-water mixture fLows into a chamber 11 of the mold 4 via a conduit ~r conduits provided in the wall of the mold 4. In the illustrated embodimentg a con~
duit through which the air-water!m~xture ~lows into the chamber 11 communicates with the la~er a~ one end thereof and with the inter-ior of the mold 4, that is, the passage through which the molten metal is eonveyed, at ~he other end thereof. In the present in-stance, a conduit through which the air-water mix~u~e flows into the chamber 11 communicates with the interior of the moLd 4 in the approximat~ region of the downstream end of the indirect cooling zone 5O The flow of the air-water mixture into the chamber 11 is indicated by arrows. Suitable means is provided for removing the air-water mLxture from the chamber 11 which, however, has no~ been illustrated for the sake of claxity and because ~uch means is well-kn~wn. The means for rem~ving the air-water mixture from the cham- -~ber 11 may, for instance, comprise a pump for sucking ~he air-wa~er ~:
mixture out of the chamber 11.
~ g _ 1 ~ 4 ~ ~ 8 ~
In a~ly event, the air-water mixture flGwing into the cham-ber 11 cools the wall portion 6 of the moLd 4 by conduction of heat.
Accordingly, this air-water mixture indîrectly cools the molten met-al in the indirect cooling zone 5 by conduction through the waLl : :
portion 60 Therefore, by virtu~ of the contact between ~he surface of the molten metal and the wall portion 6, a thin m~tal crust is formed at the surface of the molten metal.
The partially solidiied molten me~al leaves the indirectcooling zone S and enters a direct cooLing zone the extent of which is indicated by the double-headed arrow lOo In the direct cooling zone 10~ the partially solidified moLten metal is further cooled but now by direct contact wlth an air-water mixtureO In accordance with the invention, the air-water mixture which c0019 the at least partially solidified molten metal in ~he direct cooling zone lO
flows in a direction which is opposite to the casting direction.
In other words, the air-water mixture which cools the at least par-tially solidified moLten metaL in the direct cooling zone 10 flows through the latter in a direction which is countercurrent to the direction of motinn through the moLd 4 of the metal being solidi-fied, that is~ the air-water mixture ~lows through the direct cool-in~ zone 10 from right to left as seen in the drawing. In the il-lustrated embodiment, the arrangement ris such that the air-water mixture which cools the at least partially solidified mo~ten metal in the direct cooling zone 10 subsequently cools the wall portion 6 of the mold 4 and, concomitantly, indirectLy cools the molten ~etal in the indirect cooling zone 5.
In the direct co~ling zone lO; ~he solidlflca~ion which has begun in the ~ndirect cooling zone 5 proceeds furtherO The solidified moLten me~al may finally be withdrawn from the mold 4.
This is indicated by the reference numeral 12 which identifies the ~ 45'7~
band produced in the mold 4.
With reerence now to the form~tion of the cooling air-water mixture, it m~y be seen that the mold 4 is provided with a chamber 9O The chamber 9 is arranged to accommodate cooling water at an overpressure, that is, at a pressure grea~er than atmospheric pressure. SuitabLe means is provided for m~intaining the water in the chamber 9 at an overpressure9 Such means may, ~or instance, comprise pump means, and since means for maintaining the water in the chamber 9 at an overpressur~ is weLl-known7 ~his has not been illustrated in order to simplify an understanding of the invention.
The interior of the chamber 9 communica~es with the passage through which the metal being solidified is conveyed via a conduit or con-duits 8. It will be seen that the conduits 8 open into the passage in the region of the downstream end of the direct cooLing zone 10.
An underpressure, that is, a pressure less than atmospher-ic pressure, is produced in the direct cooling zone 10~ This may be achie~ed in various ways. Thus, it is possible to use the water accommodated in the chamber 9 at an overpressure to produce a Ven turi effect which causes a reductlon in pressure in the direct cool-ing zone 10. On the other hand, pump means may be utilized for Low~ering the pressure in the direct cooling æone 10, for instance, the same pump means as is used or withdrawing the air-water mixture from the chamber lL9 A further possibility resides in that the water accommodated in the chamber 9 is used to provide a Venturi effect and that this effect is co~bined with the ac~ion of suita~Le pump means to cause a l~wering of the pressure in the direct cool-ing zone lOo In any event, air is sucked lnto the direct cooling zone 10 throtgh the outlet end of the mold 4 ~y virtue of the pressure 30 reduction in the direct cooling ~one 10. This is indicated by the ~ 4~'~8~
arrows 7O It will be clear that the air drawn into the direct cool-ing zone 10 10ws in a directi~n which is countercurrent to the di-rection of motinn through ~he mold 4 of the me~al being solidified.
The thus-aspirated air flows by the conduits 8 and, in so doin~s~
draws along with it, via the conduits 8, some of the water accommo-dated in the chamber g as indicated by the arrows, The water drawn out of the chamber 9 becomes finely divided in thP asplrated ~lr, that is, becomes admixed with the aspirated air in the form of a spray. Accordingly, an air-water mixture is formed which flows countercurrent to the direction of motion th~ough the mold ~ of the metaL being s~lidified and which, in the direct cooling zone 10, directly contacts and cools the metal being solidifiedO
Subsequent to directly cooling the metal being solidified, the air-water mixture fLows into the chamber 11 via the conduits provided for this purposeO In so doing, it passes by ~nd c~ntacts the wall portion 6 of the mold 4 thereby removing heat from the wall portion 6. This~ in turn, permi~s heat to be transferred from the molten metal in the indirect cooLing zone 5 to the wall portion ~ so that the air-water mixt~re is efective for indirectly cooling the molten metal in the indirect cooling zone 5 It may be ment.ioned here that suitable means may be pro-vided for regulating the quantity of air aspirated into the direct cooling zone 10 through the outlet end of the mold 4. Simil~rly, suitable means may be provided for regulating the quantity of water withdrawn from the chamber 9~ Such means may, for example, comprise valve meansO Since means for regulating the quan~ities of air and water are known, these have not been illustrated so as to enable a be~er understanding of the invention ~o be achievedO The pro~
vision of regulati~g means for the air and water admitted into the direct ~ooling zone 10 makes it possible to efectively regulate ~ ~ 5 ~ 8 ~
the temperature of the soLidified mDlten m~tal upon it~ exit from the moLd 4O Thus, either the quantity of air or the quantity of water admltted into the direct cooling zo~e 10, or both such quanti-ties, may be regulated to achieve the desired temperature of the solidified molten metal when this is withdrawn from the mold 4. o course, it is possibLe instead to provide temperature ~egulation by controlling the rate of admlssion of molten metal into the mold 4.
It is further pvssible, for the purpose of temperature reguLation, to controL the rate of admission of molten metaL into the mold 4 and to additionaLly regula~e the quan~ity of air and/or water ad-mitted into the direct coollng zone lOo It will be appreciated that ~he invention has provided a method and a mold which enable the rate of cooling during a cas~ing operation to be controlled ln such a manner tha~ tearing or crack ing of the cas~ ar~icle m~y be reliably avoided.
It will be understood that each of the elements described ab w e, or two or more together, may aLso find a useful appLication in other types of methods and molds differing from the type describ-ed ab~ve.
While the invenfion has been iLlustrated and described as embodied in a method and a mold for the continuous casting of metallic strands, it is not intended to be limited to the detaiLs sh~wn since various modificati~ns and structural changes may be made without departing in any way from the spirit of the present invention.
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Methods and molds for the co~pleteLy continuous casting of metallic strands, that is, elongated metalLic articles, are kn~w~.
One type of mold which has become known ~or the continuous casting of metaLlic strands is a contlnuous passage mold which is a type o-f mold wherein molten metal is continuously admitted into one end o~
a cas~ing passage and a soLidiied strand is corltinuousLy withdrawn - .
from the oth~er end of the passageO Molds o~ this type may be water-cooled and generally include a ~haping portion in which the surface of the molten metaL is indirectly cooled by the cooling medium. The indirect cooling of the surface o the molten ~etal causes the sur- -face thereof to solidify by virtue o which there is fonmed a metal-lic element~ The latter is conveyed from the shaping portion of the casting passage to a downstream portion of the passage wherein it is directly cooled, within the mbLd, with the aid of an air-water mixtureO This completes ~he sol~dff~cation and ~he resuLting s~rand is then withdrawn from~he ~oldO
In the known molds and methods of the type outlined above, a rapid cobling of the metallic element or strand to the temperature of the cooling water occur~. As a P-lesult of th~s rapid cooling, there exists ~he danger that severe internal stresses wilL be set up in the strand. Where the casting opera~ion invol~es aLloys, there then arises the posslbility tha~ these in~ernal stresses will cause tearing or cracking of the strand in longitudinal direction thereof. Moreover, the conventionaL rapid cooling of the strand gi~es rise to the danger that, in the subæeque~t working or shap-ing operations to which the strand is subjected, lob~s or projec-tions will be ormed on the strand.
~ ~ .
.
- -. . - . . :
`
~4~8~
It is thus clear that improvements in the state of the art are desirabLe~
AccordingLy, it is a general object of thQ invention to provide a novel casting me~hod and a novel casting mold.
Another object of the lnvention is to provide a casting method and a casting moLd which enable in~ernal stresses in a cast article to be minimized.
A ~urther object of the invention is to provide a casting method and a casting moLd which enabLe ~earing or cracking o a cast articLe to be positively avoidcd.
An additionaL objeot of the invention is to provide a casting method and a castLng moLd which make it posslble to avoid the disadvantages arising from the conventional rapid cooling used heretofore~
These objectsg and others which wiLl become apparent as the description proceeds, are achieved in accordance with the in-vention. According to one aspect of the invention there is provid-ed a casting method which is particularly weLl-suited for use in the continuous casting of eLongated metaLlic artlcles such as bars, bands, wires and the like, and especiaLly thin bands, that is, bands of small cross sec~ion. The mtehod comprises admit~ing molt-en material into a passage having an upstream portion of predeter-mined configurati~n and solidifying a surface Layer of the molten m~terial in the upstream portinn of the passage so as to obtain an at least partially solidif~ed element having substantially the pre-de~enmined configuration of the upstream portion of the passage.
The element is advanced into a downstream portion o the passage.
In the downstream portion of the passage~ the element is directly cooLed by contacting it with a cooling medium which flows counter-current to the direction of advancement o~ the element along the ~ 1~4passage .
It wiLl be appreciated that the cooling of ~he element in countercurrent flow enabLes a sL~wer cooling rate than heretofore to be obtained.
In accordance wi~h one c~ncept of the invention, ~he solid~
ification of a sur~ace layer of ~he moLten material may be efected by indirectly cooling the surface layer with the cooling med~um which directly cooLs the at lea~t partially solidiied elemen~ in countercurrent flow.
An advantageous embodiment of the invention provides for the co~ling medium to comprise a gas-liquld mixture and~ preferably, an air-water mix~ureO Favora~ly, the gas-liquid mixture is formed in the region of a downstream end of the d~wnstream portion of the passage, that is, the portion o the passage wherein ~he at least partially solidif~ed element is directly cooled by the cooling m~d-ium. It is further preferred for the gas-liquid mixture to be form-ed immediately adjacen~ the surface of~~he at least partially solid-i~ied elementO The formation of the gas-liquid mixture advantage-ously involve~ aspirating a gas~ e.gO, air, into the passage and forming a liquid spray~ e.g.~ water spray, in the aspirated gas.
Temperature regulation may, in whole or in part, be effect-ed by controLling the quantity or rate of admisslon into the pass-age o~ the gaseous component of ~he gas-liquid mixture, the liquid component of the latter or both the gaseous and l~quid components of the gas-liquid mixtureO On the other hand~ it is aLso possible to sffect temperature regulationJ in whole:~or in part, by control-ling the rate of admission of molten material into the passage~
In accordance with another aspect of ~he invention there is provided a casting mold which is particularly well-suited for use in the continuous cas~ing of elongated metallic articles such ~6~4S781 as hars, bands, wires and the like, and especially thin bands. The mold comprises wall means which defines a passage having an upstream portion o predetermined configuration for the solidification of a surface layer of molten material by contact with the wall means so as to form an at least partially solidified element having substan-tially the configuration of the upstream portion of the passage. The passage also has a downstream portion for further cooling oE an ele-ment advanced therein from the upstream portion thereof by direct contact with a coolant. The admitting means is provided for admit-ting a cooling medium into the passage in the region of a downstreamend of the downstream portion thereo. In this manner, it becomes possible to permit the further cooling of an element advanced into the downstream portion of the passage from the upstream portion thereof to occur by countercurrent motion of the cooling medium and the advancing element.
A plate, for instance, a cover plate, may be arranged up-stream of the passage so as to extend across the latter. This plate may then be provided with an opening for the admission of molten ma-terial into the passage. The plate may, for example, be composed of the product sold under the TM "Marinite", a fireproof sheet made of asbestos fiber,diatomaceous silica and an inorganic binder.
In accordance with the invention, it is of advantage for the wall means which defines the passage to comprise metal of good thermal conductivity.
According to one embodiment of the invention, the means for admitting a cooling medium into the passage includes a chamber arranged for communication with the passage in the region o a downstream end of the downstream portion thereof. The chamber is constructed in such a manner that it is able to accommodate a liquid e.g., water, at a pressure in excess o atmospheric pressure. With such an arrangement, a cooling medium in the form of a mixture in-' .
~ S 7~3~cluding a spray of a liquid in a gas may be obtained.
Thus, a pressure reduction may be produced in the passage One possibility for achieving this is ~o make use of the liquid ac-commod~ed in the chamber to produce a Venturi ef~ect which then causes a lowering of the pressure in the passage. On the other hand, it is possible to cause a pressure reduction in the passage by using a suitable pump for ~his purpose. I~ is fur~her possible to lower ~he pressure in the passage by producing a Venturi e-ffect and com bining this with the action of a pump. Regardless, as a resuLt of the pressure reduction in the passage, a gas, e.g., air, may be as-pirated into the passage, ~or e~ample, through the outlet end of the latterO The aspirated gas may then convey along with it Liquid from the chamber when it flows past the location at which the cham-ber communicates with the passage. In this manner, the liquid may become admixed with the gas in the form of a spray thereby yielding ~-a cooling medium which is in the form of a gas-liquid mixtureO
~ conduit which communicates with the passage ups~ream of the d~wnstream end of the d~wnstream portion thereof may be provided in the wall meansO By means of such an arrangement~ the cooLing medium flowing in upstrPam direction of the passage and whi~h ~ools the at least partialLy soLidified molten material by direct contact may flow into the wall means via the conduitO This cooling mediu~
may then be used ~or effecti~g solidi$ication of a surface layer of molten materlal acc~mmodated in ~he upstream portion of the pass-age by the conduction of heat through the waLl means~ ~hat is, this cooling medium may then be used for indirect cooling of the molten material accommodated in ~he upstream portion of the passage. It is particularly favorabl2 here for tha wall means, or a~ least the part thereof Located in the region of the upstream portion of the passagQ, ~o be composed o~ metal having good thermal conductivity.
- 6 ~
~ ~S 7 8 ~
The novel features which are considered a~ characteristic for the invention are set forth in particular in the appended claims.
The invention itseLf7 howeverg both as to its con~truction and its method of operation, together with additional objects and advantages thereof, will be best understood f~m the follawing description of specific;embodiments when read in connection with the accompanying drawingO
The single FIGUR~ ~epresents a verticaL cross section through one form of a casting mold accoxding to the inventi~n which LO may be used for car~ying out a method in accordance with the i~ven ~io~.
As indicated previously, of particular interest to the invention are a method and a mold for the fully continuous casting of me~allic strands or elonga~ed ~etallic articles, especially thin bands. Moreover, the invention is particularly interested in those cases wherein casting is carried out in continuous passage, water-cooled molds having an indi~ectly cooled shaping portion and where-i~ the strand is directly cooled wi~hin the mold with thP ai~ of an air-water mlxture~ Accordingly, the following description wiLl be 2Q primarily with reference to ~he concepts just outlined.
A continuous passage mold may be defined as a mold having a passage exten~ing therethrough and which is so constructed th~
molten material may be continuously introduced in~o one end of the passage while a solidified strand may be continuously withdrawn f~om the other end of the passage.
In a method of the type just outlined, the invention pro~ ;
vides, according to one of i~s aspects, for the air-water mixture which serves to cool ~he ~trand or band within the mold to be con-veyed countercurrent to the direction of motion of the strand and to be produced immedlately adjacent the ~urface of ~he strand at ~457~
the end of the direct cooling zone. In this manner, it becomes possible to regulate the temperature which the stand has upon leav-ing the mold and to maintain the temperature of the strand upon its exit from the mold at an arbitrarily high value. Thus, the strand may be removed from the mold with a relatively high temperature and the formation of tears or cracks when using alloys susceptible to tearing or cracking may thereby be avoided. Moreover, semi-Einish-ed products having definite characteristics as regards, for instance, the formation of lobes or projections on and the hardenability and freedom from stress of cast, shaped plates, may be manufactured from the thus produced strand.
The temperature regulation which it is intended to achieve in accordance with the invention may be carried out in various ways.
For instance, this may be accomplished by con~rolling the rate of casting or by appropriately varying the quantiti~s of cooling air and/or cooling water which are used.
Referring not to the single FIGURE of the drawing, it is pointed out that the particular mold illustrated therein is intend-ed for use in the casting of thin bands. However, this is not to be construed as limiting the invention since it is possible to also cast thicker forms of articles, thicker profiled articles, etc., in the same manner. Moreover, instead of casting in a horizontal di-rection as illustrated in the drawing, it is possible, i~ desired, to cast in a vertical direction.
With the above consideration in mind, it may now be pointed out that the reference numeral 1 indicates a plate such as a cover plate. The plate 1 may, for example, be composed of "Marinite".
The plate 1 is provided with an inlet opening 2 for molten metal which is conveyed through the plate 1 in a direction indicated by the arrow 3, that is, from left to right as seen in the drawing.
A
, ~ 45~8~
suitable Eeeding means is provided for continuously conveying the molt~n metal through the inlet opening 2 of the pLate lo The feed-ing means has not, however, been iLlustrated since it does not foxm part of the invention per se and is well-known in the artO
After passing ~hrou~h ~he inle~ opening 2 of the plate 1, the m~lten metal enters a mold 4. The latter ls composed o~ metal having good thermal conductivityO
In the mold 4~ the moLten metaL first passes into an in-direct cooling zone the extent of wh~h is ind~cated by the double-headed arrow 5. Su~icient molten metaL is introduced so that ~hemol~en metal contacts a wall portion 6 of the mold 4 in the indirect cooLing zone 5O The wall portion 6 of the mold 4 is cooled by an air-water mixture which wiLL be discussed more fully below. It is sufficient here to point out that a cooling air-water mixture fLows into a chamber 11 of the mold 4 via a conduit ~r conduits provided in the wall of the mold 4. In the illustrated embodimentg a con~
duit through which the air-water!m~xture ~lows into the chamber 11 communicates with the la~er a~ one end thereof and with the inter-ior of the mold 4, that is, the passage through which the molten metal is eonveyed, at ~he other end thereof. In the present in-stance, a conduit through which the air-water mix~u~e flows into the chamber 11 communicates with the interior of the moLd 4 in the approximat~ region of the downstream end of the indirect cooling zone 5O The flow of the air-water mixture into the chamber 11 is indicated by arrows. Suitable means is provided for removing the air-water mLxture from the chamber 11 which, however, has no~ been illustrated for the sake of claxity and because ~uch means is well-kn~wn. The means for rem~ving the air-water mixture from the cham- -~ber 11 may, for instance, comprise a pump for sucking ~he air-wa~er ~:
mixture out of the chamber 11.
~ g _ 1 ~ 4 ~ ~ 8 ~
In a~ly event, the air-water mixture flGwing into the cham-ber 11 cools the wall portion 6 of the moLd 4 by conduction of heat.
Accordingly, this air-water mixture indîrectly cools the molten met-al in the indirect cooling zone 5 by conduction through the waLl : :
portion 60 Therefore, by virtu~ of the contact between ~he surface of the molten metal and the wall portion 6, a thin m~tal crust is formed at the surface of the molten metal.
The partially solidiied molten me~al leaves the indirectcooling zone S and enters a direct cooLing zone the extent of which is indicated by the double-headed arrow lOo In the direct cooling zone 10~ the partially solidified moLten metal is further cooled but now by direct contact wlth an air-water mixtureO In accordance with the invention, the air-water mixture which c0019 the at least partially solidified molten metal in ~he direct cooling zone lO
flows in a direction which is opposite to the casting direction.
In other words, the air-water mixture which cools the at least par-tially solidified moLten metaL in the direct cooling zone 10 flows through the latter in a direction which is countercurrent to the direction of motinn through the moLd 4 of the metal being solidi-fied, that is~ the air-water mixture ~lows through the direct cool-in~ zone 10 from right to left as seen in the drawing. In the il-lustrated embodiment, the arrangement ris such that the air-water mixture which cools the at least partially solidified mo~ten metal in the direct cooling zone 10 subsequently cools the wall portion 6 of the mold 4 and, concomitantly, indirectLy cools the molten ~etal in the indirect cooling zone 5.
In the direct co~ling zone lO; ~he solidlflca~ion which has begun in the ~ndirect cooling zone 5 proceeds furtherO The solidified moLten me~al may finally be withdrawn from the mold 4.
This is indicated by the reference numeral 12 which identifies the ~ 45'7~
band produced in the mold 4.
With reerence now to the form~tion of the cooling air-water mixture, it m~y be seen that the mold 4 is provided with a chamber 9O The chamber 9 is arranged to accommodate cooling water at an overpressure, that is, at a pressure grea~er than atmospheric pressure. SuitabLe means is provided for m~intaining the water in the chamber 9 at an overpressure9 Such means may, ~or instance, comprise pump means, and since means for maintaining the water in the chamber 9 at an overpressur~ is weLl-known7 ~his has not been illustrated in order to simplify an understanding of the invention.
The interior of the chamber 9 communica~es with the passage through which the metal being solidified is conveyed via a conduit or con-duits 8. It will be seen that the conduits 8 open into the passage in the region of the downstream end of the direct cooLing zone 10.
An underpressure, that is, a pressure less than atmospher-ic pressure, is produced in the direct cooling zone 10~ This may be achie~ed in various ways. Thus, it is possible to use the water accommodated in the chamber 9 at an overpressure to produce a Ven turi effect which causes a reductlon in pressure in the direct cool-ing zone 10. On the other hand, pump means may be utilized for Low~ering the pressure in the direct cooling æone 10, for instance, the same pump means as is used or withdrawing the air-water mixture from the chamber lL9 A further possibility resides in that the water accommodated in the chamber 9 is used to provide a Venturi effect and that this effect is co~bined with the ac~ion of suita~Le pump means to cause a l~wering of the pressure in the direct cool-ing zone lOo In any event, air is sucked lnto the direct cooling zone 10 throtgh the outlet end of the mold 4 ~y virtue of the pressure 30 reduction in the direct cooling ~one 10. This is indicated by the ~ 4~'~8~
arrows 7O It will be clear that the air drawn into the direct cool-ing zone 10 10ws in a directi~n which is countercurrent to the di-rection of motinn through ~he mold 4 of the me~al being solidified.
The thus-aspirated air flows by the conduits 8 and, in so doin~s~
draws along with it, via the conduits 8, some of the water accommo-dated in the chamber g as indicated by the arrows, The water drawn out of the chamber 9 becomes finely divided in thP asplrated ~lr, that is, becomes admixed with the aspirated air in the form of a spray. Accordingly, an air-water mixture is formed which flows countercurrent to the direction of motion th~ough the mold ~ of the metaL being s~lidified and which, in the direct cooling zone 10, directly contacts and cools the metal being solidifiedO
Subsequent to directly cooling the metal being solidified, the air-water mixture fLows into the chamber 11 via the conduits provided for this purposeO In so doing, it passes by ~nd c~ntacts the wall portion 6 of the mold 4 thereby removing heat from the wall portion 6. This~ in turn, permi~s heat to be transferred from the molten metal in the indirect cooLing zone 5 to the wall portion ~ so that the air-water mixt~re is efective for indirectly cooling the molten metal in the indirect cooling zone 5 It may be ment.ioned here that suitable means may be pro-vided for regulating the quantity of air aspirated into the direct cooling zone 10 through the outlet end of the mold 4. Simil~rly, suitable means may be provided for regulating the quantity of water withdrawn from the chamber 9~ Such means may, for example, comprise valve meansO Since means for regulating the quan~ities of air and water are known, these have not been illustrated so as to enable a be~er understanding of the invention ~o be achievedO The pro~
vision of regulati~g means for the air and water admitted into the direct ~ooling zone 10 makes it possible to efectively regulate ~ ~ 5 ~ 8 ~
the temperature of the soLidified mDlten m~tal upon it~ exit from the moLd 4O Thus, either the quantity of air or the quantity of water admltted into the direct cooling zo~e 10, or both such quanti-ties, may be regulated to achieve the desired temperature of the solidified molten metal when this is withdrawn from the mold 4. o course, it is possibLe instead to provide temperature ~egulation by controlling the rate of admlssion of molten metal into the mold 4.
It is further pvssible, for the purpose of temperature reguLation, to controL the rate of admission of molten metaL into the mold 4 and to additionaLly regula~e the quan~ity of air and/or water ad-mitted into the direct coollng zone lOo It will be appreciated that ~he invention has provided a method and a mold which enable the rate of cooling during a cas~ing operation to be controlled ln such a manner tha~ tearing or crack ing of the cas~ ar~icle m~y be reliably avoided.
It will be understood that each of the elements described ab w e, or two or more together, may aLso find a useful appLication in other types of methods and molds differing from the type describ-ed ab~ve.
While the invenfion has been iLlustrated and described as embodied in a method and a mold for the continuous casting of metallic strands, it is not intended to be limited to the detaiLs sh~wn since various modificati~ns and structural changes may be made without departing in any way from the spirit of the present invention.
' .. ...
Claims (14)
1. A casting method, particularly for use in the continu-ous casting of elongated metallic articles, comprising admitting molten material into a passage having an upstream end portion of predetermined configuration; solidifying a surface layer of said molten material in said upstream portion of said passage so as to obtain an at least par-tially solidified element having substantially said predetermined configuration; advancing said element into a downstream portion of said passage; and directly cooling said element in said downstream portion of said passage by contacting said element with a cooling medium which flows countercurrent to the direction of advancement of said element along said passage.
2. A method as defined in claim 1, wherein said solidi-fication is effected by indirect cooling of said surface layer with said cooling medium.
3. A method as defined in claim 1, wherein said cooling medium comprises a liquid-gas mixture.
4. A method as defined in claim 3, wherein said mixture comprises water and air.
5. A method as defined in claim 3, wherein said mixture is formed in the region of a downstream end of said downstream por-tion of said passage.
6. A method as defined in claim 3, wherein said mixture is formed immediately adjacent the surface of said element.
7. A method as defined in claim 3, wherein the formation of said mixture comprises aspirating a gas into said passage and forming a liquid spray in the aspirated gas.
8. A method as defined in claim 3, wherein temperature regulation is at least in part effected by controlling the quantity of at least one of the components of said mixture.
9. A method as defined in claim 1, wherein temperature regulation is at least in part effected by controlling the rate of admission of said molten material into said passage.
10. A casting mold, particularly for use in the continu-ous casting of elongated metallic articles, comprising wall means defining a passage having an upstream portion of predetermined configuration for the solidifcation of a surface layer of molten material by contact with said wall means so as to form an at least partially solidified element having substantially said predetermined configuration, said passage also having a downstream portion for further cooling of an element advanced therein from said upstream portion by direct contact with a coolant; and means for admitting a cooling medium into said passage in the region of a downstream end of said downstream portion thereof so as to permit said further cool-ing to occur by countercurrent motion of said cooling medium and an element advanced into said downstream portion of said upstream portion thereof.
11. A mold as defined in claim 10, wherein a plate is arranged upstream of said passage and extends across the latter, said plate having an opening for the admission of molten material into said passage.
12. A mold as defined in claim 11, wherein said plate comprises "Marinite".
13. A mold as defined in claim 10, wherein said admit-ting means comprises a chamber arranged for communication with said passage in the region of said downstream end of said downstream por-tion thereof, said chamber being constructed to accommodate a liquid at a pressure in excess of atmospheric pressure so that a pressure reduction in said passage which causes aspiration of gas into said passage permits liquid from said chamber to be sprayed into said gas to yield a cooling medium in the form of a gas-liquid mixture.
14. A mold as defined in claim 10, said wall means com-prising metal of good thermal conductivity; and wherein a conduit is provided in said wall means, said conduit communicating with said passage upstream of said downstream end of said downstream portion thereof so as to permit said cooling medium to flow into said con-duit and effect solidification of a surface layer of molten material accommodated in said upstream portion of said passage by heat con-duction through said wall means.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE2419684A DE2419684C3 (en) | 1974-04-24 | 1974-04-24 | Method and device for cooling during continuous casting of metal |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1045781A true CA1045781A (en) | 1979-01-09 |
Family
ID=5913748
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA222,761A Expired CA1045781A (en) | 1974-04-24 | 1975-03-21 | Casting method and a casting mold, particularly for use in the continuous casting of elongated metallic articles |
Country Status (13)
| Country | Link |
|---|---|
| JP (1) | JPS5236936B2 (en) |
| AT (1) | AT335094B (en) |
| BE (1) | BE825597A (en) |
| CA (1) | CA1045781A (en) |
| CH (1) | CH591295A5 (en) |
| DE (1) | DE2419684C3 (en) |
| FR (1) | FR2268584B1 (en) |
| GB (1) | GB1501902A (en) |
| IT (1) | IT1030128B (en) |
| LU (1) | LU72338A1 (en) |
| NL (1) | NL7504474A (en) |
| NO (1) | NO140169C (en) |
| SE (1) | SE400913B (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS53103931A (en) * | 1977-02-24 | 1978-09-09 | Takaoka Kogyo Kk | Secondary cooling method in continuous casting of cast iron and its device |
| WO2009115877A1 (en) | 2008-03-19 | 2009-09-24 | Nucor Corporation | Strip casting apparatus with casting roll positioning |
| US20090236068A1 (en) | 2008-03-19 | 2009-09-24 | Nucor Corporation | Strip casting apparatus for rapid set and change of casting rolls |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CH363129A (en) * | 1958-12-11 | 1962-07-15 | Concast Ag | Process for the continuous casting of metal strands and a permanent mold for carrying out the process |
-
1974
- 1974-04-24 DE DE2419684A patent/DE2419684C3/en not_active Expired
-
1975
- 1975-01-30 AT AT68975*#A patent/AT335094B/en not_active IP Right Cessation
- 1975-02-12 IT IT67368/75A patent/IT1030128B/en active
- 1975-02-17 BE BE2054152A patent/BE825597A/en not_active IP Right Cessation
- 1975-02-18 CH CH198875A patent/CH591295A5/xx not_active IP Right Cessation
- 1975-02-18 SE SE7501787A patent/SE400913B/en unknown
- 1975-02-26 FR FR7506053A patent/FR2268584B1/fr not_active Expired
- 1975-02-27 NO NO750666A patent/NO140169C/en unknown
- 1975-03-14 GB GB10852/75A patent/GB1501902A/en not_active Expired
- 1975-03-21 CA CA222,761A patent/CA1045781A/en not_active Expired
- 1975-04-15 NL NL7504474A patent/NL7504474A/en not_active Application Discontinuation
- 1975-04-22 LU LU72338A patent/LU72338A1/xx unknown
- 1975-04-24 JP JP50049213A patent/JPS5236936B2/ja not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| JPS5236936B2 (en) | 1977-09-19 |
| DE2419684B2 (en) | 1980-07-03 |
| JPS50146525A (en) | 1975-11-25 |
| NO140169C (en) | 1979-07-18 |
| FR2268584B1 (en) | 1981-07-24 |
| FR2268584A1 (en) | 1975-11-21 |
| BE825597A (en) | 1975-06-16 |
| DE2419684C3 (en) | 1981-04-23 |
| AT335094B (en) | 1977-02-25 |
| SE400913B (en) | 1978-04-17 |
| IT1030128B (en) | 1979-03-30 |
| NO750666L (en) | 1975-10-27 |
| LU72338A1 (en) | 1975-08-20 |
| CH591295A5 (en) | 1977-09-15 |
| DE2419684A1 (en) | 1975-11-20 |
| GB1501902A (en) | 1978-02-22 |
| NO140169B (en) | 1979-04-09 |
| NL7504474A (en) | 1975-10-28 |
| SE7501787L (en) | 1975-10-27 |
| ATA68975A (en) | 1976-06-15 |
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