CA1090982A - Method of and apparatus for continuously forming a flexible elongate metallic member - Google Patents

Method of and apparatus for continuously forming a flexible elongate metallic member

Info

Publication number
CA1090982A
CA1090982A CA278,635A CA278635A CA1090982A CA 1090982 A CA1090982 A CA 1090982A CA 278635 A CA278635 A CA 278635A CA 1090982 A CA1090982 A CA 1090982A
Authority
CA
Canada
Prior art keywords
tube
molten metal
column
metal
flexible elongate
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
Application number
CA278,635A
Other languages
French (fr)
Inventor
Frederick Irish
David A. Taylor
Peter Gregory
Alan J. Bangay
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Balfour Beatty PLC
Original Assignee
BICC PLC
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by BICC PLC filed Critical BICC PLC
Application granted granted Critical
Publication of CA1090982A publication Critical patent/CA1090982A/en
Expired legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/01Continuous casting of metals, i.e. casting in indefinite lengths without moulds, e.g. on molten surfaces
    • B22D11/015Continuous casting of metals, i.e. casting in indefinite lengths without moulds, e.g. on molten surfaces using magnetic field for conformation, i.e. the metal is not in contact with a mould
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/14Plants for continuous casting
    • B22D11/145Plants for continuous casting for upward casting

Landscapes

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

Abstract

ABSTRACT
A flexible elongate metal member, e.g. a rod or wire, is continu-ously formed by causing molten metal contained in an upstanding tube to be ejected out of the open upper end of the tube whilst, at the same time, establishing about said upper end an alternating electromagnetic field which sets up forces such as to cause the ejected metal to be compressed inwardly to form a column of molten metal which protrudes from the tube. The column of molten metal is cooled to such an extent that at least an upper end part of the column is in a substantially solid state and, whilst molten metal is fed into a lower part of the tube, the substantially solidified part of the column of metal is withdrawn upwardly in the form of a continuous flexible elongate metal member.

Description

10'~)98Z

This invention relates to forming a flexible elongate member of metal, the term "metal" as used in this specification being employed in its broadest sense to include any metal or metal alloy that can exist in rod or wire form.
S It is an object of the present invention to provide an improved method of forming as a continuous process from molten metal a flexible elongate metal member.
According to the invention the method comprises causing molten metal contained in an upstanding, preferably substantially vertical, tube to ejected out of the open upper end of the tube whilst, at the same`time, establishing about said open upper end an alternating electromagnetic field which sets up forces such as to cause the ejected molten metal to be compressed inwardly to form a column of molten metal which protrudes from the open upper end of the tube; cooling said column of molten metal to such an extent that at least an upper end part of the column is in a substantially solid state; and, whilst feeding molten metal into a lower part of the tube, withdrawing the substantially solidified part of the column of metal upwardly in the for~ of a continuous flexible elongate metal member.
The alternating electromagnetic field established about the open upper end of the tube induces eddy currents in the molten metal being ejected out of the upper part of the tube and the interaction between these eddy currents and the electromagnetic field causes an electrodynamic force to be set up, which force has the effect of causing the metal to compress ~~ inwardly and form a column of metal that protrudes from the open upper end of the tube. The forces set up by the alternating electromagnetic field may be such that, as compared with the internal cross-sectional area of the tube, ~0~0~38f the cross-sectional area of the column of molten metal is reduced to an extent that the flexible elongate metal member that is continuously withdrawn upwardy from the tube is in rod or wire form and requires no further change in cross-sectionai shape and/or reduction in cross-sectional size. Alternatively, the flexible elongate member that is withdrawn upwardly from the tube may be in rod or other form of a shape and size suitable for rolling down to rod form of smaller diameter or for drawing down into wire.
Preferably molten metal is caused to be ejected out of the open upper end of the tube by controlled continuous feeding of molten metal into a lower part of the tube and preferably the molten metal is fed into the tube from a container of molten metal which is connected to but remote from the tube and which constitutes, in effect, the other limb of a U-tube. Molten metal may be fed at a controlled rate into the container from a source of supply, for instance a holding furnace. Preferably the surface area of the molten metal in the container is substantially greater than the cross-sectional area of the tube. Molten,metal may be continuously fed from the container into the lower end of the tube under controlled fluid pressure, e.g. air pressure, that is greater than atmospheric pressure.
Cooling of the column of metal to suchan extent that --at least an upper end part of the column is in a substantially solid state may be effected by any convenient means but, preferably, initial cooling of the column and withdrawal of the column upwards from the alternating electromagnetic field at the upper open end of the tube is effected by means of a cold dummy member which is brought into contact with the upper end of the column to cause the upper end to solidify and bond to the dummy member and to which is connected a flexible line to haul-off means. The linear speed of withdrawal of the flexible elongate member so formed, having regard to the rate of cooling of the upper part of the column, will be such that there is no risk that fracture of the column will occur in the ~ vicinity of the solidified or partially solidified part of the _ column.
Preferably, on emerging from the alternating electromagnetic field, the solidified upper part of the column of metal and the succeeding flexible elongate metal member are subjected to a cooling medium, fo~ example cold air or water sprays.
The haul-off means may consist of or constitute a part of a take-up device or it may serve to feed the flexible elongate member to, or it may constltute a part of, treatment or processing apparatus. The flexible elongate member may pass directly to the haul-off means or, in travelling to the haul-off means, pass through reducing rolls or other reducing means and/or it may pass part way around one or more than one guide roller. Where the cross-sectional area of the flexible elongate member is reduced as it travels towards the haul-off means, the haul-off means, and if a rotatably driven guide roller or rotatably driven guide rollers is or are present the or each guide roller, will each be driven at such a rotational speed that the linear speed of the flexible elongate member emerging from the upper end of the tube is substantially constant.
The invention also includes apparatus for use in the method of forming a flexible elongate total member, which apparatus comprises at least one upstanding, preferably substantially vertical, tube open at its upper end and 1090~8Z

connected at or near its lower end to a source of molten metal; means, surrounding the open upper end of the tube, for establishing an alternating electromagnetic field about said open upper end, which means will set up forces that will cause molten metal being ejected from said open upper end to be compressed inwardly to form a column of molten metal protruding ~ from said upper end; means for cooling at least an upper end part of the-column of molten metal; and means for withdrawing upwardly a substantially solidified part of said column of metal.
Preferably for initially cooling at least an upper end part of the column of metal and for withdrawing the column upwards a dummy member is provided which is of a shape and size suitable for bringing into contact with the upper end of a column of molten metal protruding from the upper open end of the or each tube and which is connected by a flexible line to haul-off means.
Preferably, the source of molten metal is a container of molten metal remote from the tube or tubes and the lower end of the or each upstanding tube is connected to an outlet in the lower part of the container by a pipe, the or each tube, associated pipe and container, in effect, constituting a U-tube.
The means for establishing an alternating electromagnetic field about the open upper end of the or each tube preferably comprises an annular electromagnetic inductor which can be positioned around the open upper end of the tube.
Preferably the cooling means for the column of metal comprises a chamber housing cold air or water sprays.
The method and apparatus of the present invention are especially suitable for use in forming rod or wire of - copper or copper alloy and of aluminium or aluminium alloy.
The invention provides several important advantages that are not present in conventional methods of forming a flexible elongate member in which a stream of molten metal is arranged to flow downwardly from an outlet. in a lower part of a container of molten metal. Firstly, the upstanding tube from which the column of metal is drawn upwardly can be spaced a substantial distance from the container or other source of supply of molten metal with the result that cooling of metal, e.g. by cooling water, is much safer than is the case when cooling water is positioned below a container holding a large quantity of molten metal. Secondly, should the column of metal being withdrawn upwardly from the tube fracture for any reason or should the source of power to the means establishing the alternating electromagnetic field fail, little or no molten or semi-molten metal will spill over the upper end of the upstanding tube so that there is negligible risk to personnel.
Thirdly, since the upstanding tube can be spaced a substantial distance from the container or other source of supply of molten metal, a single container or other source can be employed to feed molten metal to two or more upstanding tubes, upward withdrawal of a column of metal from each tube being independently controlled. Fourthly, the flexible elongate metallic member can be directed to a take-up device or process or treatment apparatus by passing the flexible member around appropriate guide pulleys supported above the ground with a consequential saving in floor space.
The invention is further illustrated by adescription, by way of example, of the preferred method of and apparatus for use in forming two flexible rods of copper with reference to the accompanying diagrammatic drawings, in which:-Figure 1 is a diagrammatic representation of theapparatus, and Figure 2 is a diagrammatic representation, on a larger scale, of the preferred method of initially cooling and withdrawing the rod.
Referring to the drawings, the apparatus comprises a container 1 which contains molten copper C fed into the container from a holding furnace 2. The container 1 is surrounded by thermal insulation 3 and the copper in the container is main~ained in the molten state at a temperature of about 1150C by electrical heating coils 4. Two substantially vertical tubes 6, positioned remote from the container 1, are fed with molten copper from the container through pipes 7, one end of each of which is connected to a lower part of the container 1 and the other end of each of which is connected to the lower end of one of the tubes 6. The pipes 7 are surrounded by thermal insulation 8 and are heated by heating coils 9.
The upper open end of each vertical tube 6 is surrounded by an annular electromagnetic inductor 11, the upper part of the inducto~ being housed in the lower part of a water cooling chamber 12. A guide pulley 14 is positioned above each cooling chamber 12.
Each tube 6 has a bore of circular cross-section and of a cross-sectional area of 100 sq. mm. The internal cross-sectional area of the main body of the container 1 is 1.0 sq. m.
At the start of operations, the level of molten copper C in the container 1 is such that the level of molten ', copper in each of the tubes 6 is just below the upper open end of the tube. A predetermined quantity of molten copper C is now introduced into the container 1 from the holding furnace 2to form in the container 1 a sufficient head of molten copper 109098'~

to cause molten copper to be ejected from the open upper end of each tube 6 (Figure 2). At the same time, an alternating current having a frequency of 500 kHz is caused to .flow through each of the inductors 11 to establish an electromagntic field about the open upper end of the associated tube 6 which sets up forces such as to cause the ejected copper to be compressed inwardly to form a column 20 of molten copper which protrudes from the open end of the tube (Figure 2). With the column 20 of copper protruding from each tube held in this position, a cold dummy member 15, attached to a flexible line (not shown) connected to a haul-off device (not shown), is lowered into contact with the upper end of the column 20 to cause the upper . end part of the column to solidify and bond to the dummy member at 21. When a firm bond has been obtained, the haul-off device is brought into operation to draw th-e dummy member 15 and solidified part of the column 20 upwardly whilst, at the same time, molten copper is introduced from the holding furnace into the container 1, the rate of feed of molten copper into the container 1 and t.he speed of upward withdrawal of each of the haul-off devices being such that a continuous flexible copper rod 22 is drawn upwardly from each tube 6 through the cooling chamber 12, where the rod is cooled by water sprays, and over the pulley 14, without fracture of the column 2~--of molten copper protruding from the tube.

;

Claims (21)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:-
1. A method of forming as a continuous process from molten metal a flexible elongate metal member which comprises causing molten metal contained in an upstanding tube to be ejected out of the open upper end of the tube whilst, at the same time, establishing about said open upper end an alternating electromagnetic field which sets up forces such as to cause the ejected metal to be compressed inwardly to form a column of molten metal which protrudes from theopen upper end of the tube; cooling said column of molten metal to such an extent that at least an upper end part of the column is in a substantially solid state; and, whilst feeding molten metal into a lower part of the tube, withdrawing the substantially solidified part of the column of metal upwardly in the form of a continuous flexible elongate metal member.
2. A method of forming as a continuous process from molten metal a flexible elongate metal member which comprises causing molten metal contained in an upstanding tube to be ejected out of the open upper end of the tube whilst, at the same time, establishing about said open upper end an alternating electromagnetic field which sets up forces such as to cause the ejected metal to be compressed inwardly to form a column of molten metal which protrudes from the open upper end of the tube; bringing a cold dummy member, which is connected to a flexible line extending to haul-off means, into contact with the upper end of the column; cooling said column of molten metal to such an extent that at least an upper end part of the column is in a substantially solid state and bonds to the dummy member; and, whilst feeding molten metal into a lower part of the tube, operating the haul-off means to withdraw upwardly the dummy member with the substantially solidified part of the column of metal bonded thereto to form a continuous flexible elongate metal member.
3. A method as claimed in Claim 1 or 2, wherein, on emerging from the alternating electromagnetic field, the substantially solidified upper end part of the column and the succeeding flexible elongate metal member are subjected to a cooling medium.
4. A method as claimed in Claim 1, wherein molten metal is caused to be ejected out of the open end of the tube by controlled continuous feeding of molten metal into a lower part of the tube.
5. A method as claimed in Claim 4, wherein molten metal is fed into the tube from a container of molten metal which is connected to but remote from the tube and which constitutes, in effect, the other limb of a U-tube.
6. A method as claimed in Claim 4, wherein molten metal is fed from-a container into the lower end of the tube under controlled fluid pressure that is greater than atmospheric pressure.
7. A method as claimed in Claim 5 or 6, wherein the surface area of the molten metal in the container is substantially greater than the cross-sectional area of the tube.
8. A method as claimed in Claim 1 or 2, wherein the flexible elongate metal member is in rod or wire form.
9. A method as claimed in Claim 1, wherein the flexible elongate metal member being withdrawn upwardly from the tube is of a shape and size suitable for rolling down to rod form of smaller diameter or for drawing down into wire and wherein, in travelling from the tube to haul-off means, the cross-sectional area of the flexible elongate member is substantially reduced to that of rod or wire form.
10. A method as claimed in Claim 9, wherein the haul-off means, and if a rotatably driven guide roller or rotatably driven guide rollers is or are present the or each guide roller, are each driven at such a rotational speed that the linear speed of the flexible elongate member emerging from the upper end of the tube is substantially constant.
11. A method as claimed in Claim 1 or 2 wherein the tube is substantially vertical.
12. A method as claimed in Claim 1 or 2 wherein the metal is copper or copper alloy.
13. A method as claimed in Claim 1 or 2 wherein the metal is aluminium or aluminium alloy.
14. Apparatus for use in forming a flexible elongate metal member comprising at least one upstanding tube open at its upper end and connected at or near its lower end to a source of molten metal; means, surrounding the open upper end of the tube, for establishing an alternating electromagnetic field about said open upper end, which means will set up forces that will cause molten metal being ejected from said open upper end to be compressed inwardly to form a column of molten metal protruding from said open upper end; means for cooling at least an upper end part of the column of molten metal; and means for withdrawing upwardly a substantially solidified part of said column of metal.
15. Apparatus as claimed in Claim 14, wherein, for initially cooling at least an upper end part of a column of metal and for withdrawing the column upwardly, a dummy member is provided which is of a shape and size suitable for bringing into contact with the upper end of a column of molten metal protruding from the open upper end of the or each tube and which is connected by a flexible line to haul-off means.
16. Apparatus as claimed in Claim 14, wherein the source of molten metal is a container of molten metal remote from the tube or tubes and the lower end of the or each upstanding tube is connected to an outlet in the lower part of the container by a pipe, the or each tube, associated pipe and container, in effect, constituting a U-tube.
17. Apparatus as claimed in Claim 16, wherein at least two upstanding tubes are connected to outlets in the lower part of the container and separate means is associated with each tube for withdrawing upwardly a solidified part of the column of metal, said withdrawal means each being independently controllable.
18. Apparatus as claimed in Claim 16, wherein means is associated with the continer of molten metal for feeding molten metal at a controlled rate into the container from a holding furnace or other source of supply.
19. Apparatus as claimed in Claim 14, 15 or 16, wherein the cooling means for the column of metal protruding from the or each tube comprises a chamber housing cold air.
20. Apparatus as claimed in Claim 14, 15 or 16, wherein the cooling means for the column of metal protruding from the or each tube comprises a chamber housing water sprays.
21. Apparatus as claimed in Claim 14, 15 or 16, wherein the means for establishing an alternating electromagnetic field about the open upper end of the or each tube comprises an annular electromagnetic inductor positioned around the open upper end of the tube.
CA278,635A 1976-05-19 1977-05-17 Method of and apparatus for continuously forming a flexible elongate metallic member Expired CA1090982A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB20743/76 1976-05-19
GB2074376A GB1580433A (en) 1976-05-19 1976-05-19 Method of and apparatus for continuously forming and apparatus for continuoulsy forming a flexible elongate member

Publications (1)

Publication Number Publication Date
CA1090982A true CA1090982A (en) 1980-12-09

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ID=10150923

Family Applications (1)

Application Number Title Priority Date Filing Date
CA278,635A Expired CA1090982A (en) 1976-05-19 1977-05-17 Method of and apparatus for continuously forming a flexible elongate metallic member

Country Status (3)

Country Link
AU (1) AU2522577A (en)
CA (1) CA1090982A (en)
GB (1) GB1580433A (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113198991A (en) * 2021-05-13 2021-08-03 江西泰和百盛实业有限公司 Method for manufacturing small-size copper rod based on up-drawing method

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP5794259B2 (en) * 2013-07-30 2015-10-14 トヨタ自動車株式会社 Pull-up type continuous casting apparatus and pull-up type continuous casting method

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113198991A (en) * 2021-05-13 2021-08-03 江西泰和百盛实业有限公司 Method for manufacturing small-size copper rod based on up-drawing method

Also Published As

Publication number Publication date
AU2522577A (en) 1978-11-23
GB1580433A (en) 1980-12-03

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