CA1238763A - Direct chill metal casting apparatus and technique - Google Patents

Direct chill metal casting apparatus and technique

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Publication number
CA1238763A
CA1238763A CA000426155A CA426155A CA1238763A CA 1238763 A CA1238763 A CA 1238763A CA 000426155 A CA000426155 A CA 000426155A CA 426155 A CA426155 A CA 426155A CA 1238763 A CA1238763 A CA 1238763A
Authority
CA
Canada
Prior art keywords
cavity
fluid
wall section
overhang
molten metal
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
CA000426155A
Other languages
French (fr)
Inventor
Frank E. Wagstaff
William G. Wagstaff
Richard J. Collins
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.)
Wagstaff Engineering Inc
Original Assignee
Wagstaff Engineering Inc
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Filing date
Publication date
Application filed by Wagstaff Engineering Inc filed Critical Wagstaff Engineering Inc
Application granted granted Critical
Publication of CA1238763A publication Critical patent/CA1238763A/en
Expired legal-status Critical Current

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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
    • B22D11/04Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
    • B22D11/049Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds for direct chill casting, e.g. electromagnetic casting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/04Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
    • B22D11/0401Moulds provided with a feed head
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/07Lubricating the moulds
    • 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
    • B22D11/08Accessories for starting the casting procedure

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Sampling And Sample Adjustment (AREA)
  • External Artificial Organs (AREA)

Abstract

DIRECT CHILL METAL CASTING APPARATUS AND TECHNIQUE

ABSTRACT OF THE DISCLOSURE
In the direct chill casting of a metal, a mass of the molten metal is introduced into the top of an open bottomed mold cavity having a support telescoped therein, the molten metal mass is chilled, and the mold and support are reciprocated in relation to one another axially of the cavity to form the chilled mass into an elongated body of the metal. According to the invention, a stream of pressurized gas is delivered to a point outside of the cavity, the gas is discharged into the cavity at a point on the periphery thereof, and means are interposed between the point of delivery and the point of dishcarge, externally of the cavity, to convert the stream of gas into an annulus of fluid that extends about the metallic mass at the periphery of the cavity.

Description

Z~8~7~

1 ¦DIRECT CHILL METAL CASTING APPARATUS AND TECHNIQUE
2 1
3 ¦ABSTRACT OF THE DISCLOSURE i l .~ . _
4 ¦ ~In the direct chill casting of a metal, a nass of the
5 ~olten metal is introduced into the top of an open bottomed mold
6 ¦ cavity having a support telescoped therein, the molten metal mass
7 ¦ is chilled, and the mold and support: are reciprocated in rela~ion
8 ¦ to one another axially of the cavity to fo~m the chilled mass into
9-¦ an elongated body of the metal~ According to the invention, a
10 ¦ stream of pressurized gas is delivered to a point outside of the
11 ¦ cavity, the gas is discharged lnto the cavity a a point on the
12 ¦ periphery thereof, and means are interposed between the point of
13 ¦ delivery and the point of dishcarge, externally of the cavity, to
14 ¦ convert the stream of gas into an annulus of fluid that extends
15 ¦ about the metallic mass at the periphery of the cavity.
16 1
17 ¦ THE INVENTION IN GENERAL
lB ¦ This invention relates to ~he direct chill casting of l9 1 metals such as aluminum.
20 ¦ When casting a metal in this fashion, a mass of the molten 21 ¦ metal is introduced into the top of an open bottomed mold cavity 22 ¦ having a support telescoped therein, the molten metal mass is 23 ¦ chilled, and the mold and support are reciprocated in relation 24 Ito one another axially of the cavity to form the chilled mass into 25 ¦an elongated body of the metal. Normally, the molten metal is 26 ¦introduced into the top of the cavity through an opening having 27 la smaller diameter than the peripheral wall of the cavity, and 28 ¦the molten metal ~;play~ into a metallic mass the meniscus of which 29 ¦ tends to contact the peripheral wall of the cavity in the plane 30 ¦ o maximum divergence of the metal. Moreover, the metallic mass 1238~

normally assumes a divergent-convergent cross-sectional outline, the intermediate continuum of which between the planes of maxi-mum divergence and minimum convergence thereof, has a peripheral outline corresponding generally to the peripheral outline of the cavity at the wall thereof. Meanwhile, there is a pocket of relatively metal-free space formed between the meniscus of the metal and the top corner of the cavity at the overhang thereof about the opening.
In USP 4,157,728, a stream of pressurized air is delivered to the top of this pocket, to pressurize the same, and the mold operator is instructed to llse the pressurization of the pocket itself, internally of the cavity, as a means for genera-ting a sleeve-like annulus of gas which, given certain idealized conditions in the pocket, will tend to flow downwardly about the metallic mass at the periphery of the cavity. According to the invention, however, a stream of pressurized gas is delivered to a point outside of the cavity, the gas is discharged into the cavity at a point on the periphery thereof, and means are inter-posed between the point of delivery and the point of discharge, externally of the cavity, to convert the stream of gas into an annulus of fluid that extends about the metallic mass at the periphery of the cavity. In this way, it is now possible for the mold designer to build in the conditions for generating and maintaining the ~nnulus and they no longer must be left to the skill of the mold operator.
According to one aspect of the present invention there is provided in the process of direct chill casting a metal in an open ended mold cavity having a support telescoped in the discharge end thereof and an opening at the other end thereof whose diameter is smaller than the peripheral wall of the cavity so that the inner peripheral edge of said other end opening forms an overhang relatively over the wall, the steps of:

~.~f23~ 3 continuously filliny said other end opening of the cavity with molten metal so that the mass of molten metal splays about the inner peripheral edge of the other end opening and forms a body of molten metal in the cavity whose cross-section has a diver-gent/convergent outline between the ends thereof, the interme-diate continuum of which between the planes of maximum divergence and minimum convergence thereof, has a peripheral outline corres-ponding generally to the outline of the cavity at the peripheral wall thereof, circumposing graphite or graphite-like wall de-fining means about the molten metal body in the peripheral wall of the cavity at a level below the overhang adapted to that the intermediate continuum is surrounded by a solid but fluid per-meable wall section of said means, simultaneously forcing a lubricating oil and an additional fluid medium selected from the group consisting of a highly heat vaporizable llquid medium and a gaseous medium, through the fluid permeable wall section so that the oil and additional fluid medium discharge into the cavity at points on the inner peripheral surface of the wall section opposite the intermediate continuum, and simultaneously chilling the molten metal body from points below the interme-diate continuum and reciprocating the mold and support in rela-tion to one another endwise of the cavi-ty to elongate the body, the wall of the cavity co-termi.nating with the overhang at the aforesaid other end of the cavity so that the part of the molten metal body directly adjacent the overhang is surrounded by a closed corner of the cavity, and the fluid thus discharged about the intermediate continuum forming an annulus of fluid tending to flow relatively away from the closed corner of the cavity toward the discharge end thereof.
According to another aspect of the present invention - 2a -3~3 1'S3 there .is provided apparatus for direct chill casting a metal comprising: means defining an open ended mold cavity having a discharge end adapted to have a support telescoped therein, and having an opening at the opposing end thereof whose diameter is smaller than the peripheral wall of the cavity so that the inner peripheral edge of said opposing end opening forms an overhang relatively over the peripheral wall, whereby when said opposing end of the cavity is continuously filled with molten metal, the mass of molten metal splays about the inner peripheral edge of the opposing end opening and forms a body of molten metal in the cavity whose cross-section has a divergent/convergent outline between the ends thereof, the intermediate continuum of which between the planes of maximum divergence and minimum con-vergence thereof, has a peripheral outline corresponding gener-ally to the outline of the cavity at the peripheral wall thereof, means for chilling the molten metal body from points below the intermediate continuum, graphite or graphite-like wall defining means disposed in the peripheral wall of the cavity at a level below the overhang for surrounding the intermediate con-tinuum of the molten metal body by a solid but fluid permeable wall :
section, and fluid delivery means for simultaneously forcing a lubricating oil and an additional fluid medium selected from the group consisting of a highly heat vaporizable liquid medium and a gaseous medium~ through the fluid permeable wall section so that the oil and additional fluid medium discharge into the cavity at points on the inner peripheral surface of the wall section opposite the intermediate continuum, while the molten metal body is chilled and the mold and support are reci-procated in relation to one another endwise of the cavity to elongate the body, the wall of the cavity co-terminating with - 2b -~3~ 3 the overhang at the aforesaid other end of the cavity 50 that the part of the molten metal body directly adjacent the overhang is surrounded by a closed corner of the cavity, and the fluid thus discharged about the intermediate continuum forming an annulus of fluid tending to flow relatively away from the closed corner of the cavity toward the discharge end thereof.
Generally, the annulus is generated below the top of the pocket so -that the fluid tends to flow upward .into the same.
However, the annulus is also normally generated above the bottom of the cavity so that the fluid also tends to flow downwardly as well, that is, both upward and downward of the cavity, axially thereof.
In many of the presently preferred embodiments of the invention, the gas is discharged into the cavity at a point adjacent the plane of maximum divergence of the metallic mass.
In certain ~'~

~3~3 68456-2~

of these embodiments,-the ~as is disch~r~ed from the peripheral wall of -the cavity at a point disposed opposite -the peripheral outline of the intermediate continuum of the metallic mass. In some embodiments, moreover, the gas is discharged at points on the peripheral wall of the cavity circumposed about -the entire perimeter of the intermediate continuum of the metallic mass, and preferably, at points on the wall arrayed over the entire height of the intermediate continuum.
In one group of the presently preferred embodiments, the gas is relatively depressurized and/or diffused as it flows between the point of delivery and the point of discharge. For example, in certain of these embodiments, a solid but gas-impregnable structural medium is interposed between the point of delivery and the point of discharge that relatively depressurizes and diffuses the gas and discharges it into the cavity at a point adjacent the plane of maximum divergence of the metallic mass.
In some of them, the gas-impregnable medium is positioned at the peripheral wall of the cavity and the gas is delivered to the same so that it discharges at a point opposi-te the peripheral outline of the intermediate continuum of the metallic mass. In many, moreover, the gas-impregnable medium is extended around the entire perimeter of the cavity and the gas is delivered to the same so that it discharges at points circumposed about the entire perimeter of the intermediate continuum of the metallic mass. In many of the latter, moreover, the medium is elongated axially of the cavity and the gas is delivered to the same so that it dis-charges at points arrayed over the entire height of the continuum.
Normally, a lubricating oil is delivered to the pocket of the cavity. In some of the presently preferred embodiments of the invention, the oil is discharged into the cavity through the overhang 123~3 1 at the top of the pocket. Moreo~er, in certain of them3 a por-tion 2 of the oil vapor is trapped in the top of the corner of the pocket 3 during the casting operation.
4 In one group of the presently preferred embodiments of the : invention wherein oil is delivered to the pocket, a gas-impregnable 6 ring is positioned at the top of the cavity tG define the corner o 7 the pocket at an anmllar step therein which is co-~?lanar with the 8 overhang about the top opening of the cavity. The ring is elongated 9 axially o~ the cavity so that the upper and lower end portions thereof are disposed opposite the pocket and the peripheral outline 11 of the intermediate continuum of the metallic mass, respectively.
12 And the oil and gas are delivered to the ring so that the gas dis-13 charges from the same at inner peripheral points on the ring 14 adjacent the continuum, and the oil discharges into the pocket at point~ thereabove, including at points on the step.
16 In one special group of embodiments, a stream of pressurized 17 lubricatin~ oil is delivexed to a point outside the cavity, sus-
18 pended in a highly heat vaporizable liquid carrier, the oil is 1g discharged into the pocket of the cavity at a point on the periphery 2C thereof, and means are interposed between the point of delivery and 21 the point of dischar~e, externally of the cavity, to convert the 22 carrier into an annulus of vapor that extends about the metallic 23 mass at the periphery of the cavity.
24 The present invention also relates to a metal casting device of the aforementioned type wherein a mass of molten metal 26 is introduced into the top of an open-bottomed mold cavity having 27 a support telescoped therein, the molten metal mass is chilled, 28 and t~e mold and support are reciprocated in relation to one 29 another axially of the cavity to form ~he chilled mass into a~
elongated body of the metal. According to the invention, the 1~38'i'S~i3 1 ¦ device f~lrther comprises means for delivering a stream of pres-2 ¦ surized gas to a point outside of the cavity, means for discharging 3 ¦ the gas into the cavity at a point on the periphery thereof, and 4 ¦ means interposed between the point of delivery and the point of 5 ¦ discharge, externally of the cavity, to convert t~e stream of gas 6 ¦ into an annulus of fluid that ext~ends about the metallic mass at 7 ¦ the periphery of the cavity.
8 ¦ As indicated earlier, in c~ertain device~ of the foregoing 9 ¦ type, the molten metal is introduced into the top of the cavity 10 ¦ through an opening having a smaller diameter than the peripheral 11 ¦ wall of the cavity so that the molten metal splays into a metallic ;
12 ¦ mass the meniscus of which tends to contact the peripheral wall of 13 ¦ the cavity in the plane of maximum divergence of the metal, there 14 ¦ being a pocket of relatively metal-free space formed between the 15 ¦ meniscus of the metal and the top corner of the cavity at the over-1~ ¦ hang thereof about the opening. According to the invention, where 17 ¦ this is the case~ the gas discharge means and the external conver-18~I sion means are preferably jointly operable to generate the annulus 1~ ¦ below the top of the pocket, but above the bottom of the cavity.
20 ¦ Moreover, the gas discharge means are often operable to discharge 21 ¦ the gas into the cavity at a point adjacent the plane of maxLmum 22 ¦ dive~gence of the metallic mass. Furthermore, where the metallic 23 ¦ mass assumes a divergent-convergent cross-sectional outline between 24 ¦ the top and bottom of the cavity, the intermediate continuum of 25 ¦ which between the planes of maximum divergence and minimum con- I
26 ¦ vergence, h~s a peripheral outline corresponding generally to the 27 ¦ peripheral outline of the cavity at the wall thereof, the gas ;
28 ¦ discharge means are often operable to discharge the gas from the 29 wall of the cavity at a point disposed opposite the peripheral out-line o the intermediate continuum of the metellic mass, In fact, . _5_ i ~3876~ 68456 2~
in many embodimen-ts, -the gas discharge means ~re operable to discharge the gas a-t poin-ts on -the wall of the cavity circumposed about the entire perime-ter of the intermediate continuum of the metallic mass, and preferably, at points on the wall arrayed over the entire height of the intermediate continuum.
Furthermore, in one group of the presently preferred embodiments, the external conversion means are operable to rela-tively depressurize and/or diffuse the gas as it flows between the point of delivery and the point of discharge. For example, in certain embodiments, a solid but gas-impregnable medium is interposed between the point of delivery and the point of dis-charge, which is operable to relatively depressurize and diffuse the gas and discharge it into the cavity at a point adjacent the plan~ of maximum divergence of the metallic mass. In some of these embodiments, the gas-impregnable medium is disposed at the peripheral wall of the cavity and the gas delivery means are operable to deliver the gas to the same so that it discharges at a point opposite the peripheral outline of the intermediate continuum of the metallic mass. In many, moreover, the gas-impregnable medium extends around the entire perimeter of thecavity and the gas delivery means are operable to deliver the gas to the same so that it discharges at points circumposed about the entire perimeter of the intermediate continuum of the mass.
Furthermore, in many of the latter, the medium is elongated axially of the cavity and the gas delivery means are operable to deliver the gas to the same so that it discharges at points arrayed over the entire height of the continuum.
The presently preferred embodiments of the invention often further comprise means for delivering a lubricating oil to the pocket of the cavity. In some embodiments, the oil delivery means , .:
.

38'76:~ 1 1 ¦ are operable to discharge the oil into the cavity through the 2 ¦ overhang at the top of the pocket~ In certain of them, moreover, 3 1 there are means for trapping a portion of the oil vapor in the top 4 ¦ of the corner of the pocket during the cas~ing operation.
5 I In one group of the presently preferred embodiments, a gas-6 ¦ impregnable rlng of graphite or the like is posit;.oned at the top 7 ¦ of the cavity and the ring has an annular step therein which is 8 ¦ co-planar with the overhang about the top openiny of the cavity 9 ¦ and defines the corner of the pocket. The ring is also elongated 10 ¦ axially of the cavity so that the upper and lower end portions 1l ¦ thereof are disposed opposite the pocket and the peripheral outline 12 ¦ f the intermediate continu~m of the metallic mass, respectively.
13 ¦ The respective oil and gas delivery means are operable to deliver 14 1 the same to the ring so that the gas discharges at inner peripheral 15 1 points on the ring adjacent the continuum, and the oil discharges 16 1 intb the pocket at points thereabove, including a~ points on the 17 ¦ step.
18 ¦ Often, the invention further comprises a support or stool
19 1 for telescoping into a metal casting device such as that described.
20 ¦ According to the invention, the stool comprises a pair of opera-
21 ¦ tively coaxially disposed cap and base mem~ers which are slideably
22 engageable with one another at mutually opposing surfaces thereon
23 ¦ and equipped with cooperatively engageable male and female catch
24 1 mean~ on the surfaces thereof. The female catch means have a
25 ¦ laterally of~set groove therein on the axi~ of the members, and
26 1 the male catch means are insertable in the female means when the
27 members are engaged with one another at the surfaces eccentrically
28 of the axis, and engageable in the groove when the members are
29 laterally displaced in relation to one anothes to a point at which they assume concentricity with the axis. The stool also comprises 3L~38'76~3 first and second latch means which a.re shiftable laterally and axially of the axis, respectively, to latch and unlatch the members against relative axial and lateral displacement, res-spectively, when the members are engaged with one another at the surfaces and relatively laterally displaced to and from said point, and maintained at said point, respectively. However, the second latch means and the cap member are engageable with one another in the latched condition of the cap member to allow for limited lateral displacement of the same in self-aligning with the device.
The invention also concerns an improved billet casting mold for a bottom loaded coolant box casting device of the type wherein the coolant box has registering top and bottom openings in the chamber thereof, the top opening of which has a shoulder thereabout and the bottom opening of which opens into the bottom of the box and has a greater diameter than the top opening of the chamber. According to the invention, the billet casting mold comprises a pair of cooperatively engageable top and bo~.tom.-rinqs, the top ring of which is adapted to be inserted upwardly into the chamber through the bottom opening thereof and abutted against the shoulder about the top opening. The top ring has apertures in the body thereof which are adapted to open into the bottom of the chamber when the ring is inserted into the chamber and abutted against the shoulder. It also has an arcuate step thereon that overhangs the apertures and is circumposed about the inner periphery of the top ring at a level adapted for discharging a -curtain of coolant liquid onto the emerging billet from the chamber. The bottom ring is adapted to telescope within the . . -r ~

~ ~313~

l ¦ top ring and to cooperate with the step in forming an annular ;
2 ¦ passage for the coolant therebetween which communicates with the 3 1 apertures in the body of the top ring and extends upwardly there- ll 4 ¦ from to a point at which it then curves reentrantly downwardly to i 5 ¦ the inner periphery of the top ring for discharge of the curtain.
6 ¦ The bottom ring also has a ~lange thereon which is engageable with 7 1 the bottom of the box to locate one ring within the other when the 8 ¦ passage is formed.
9 ¦ The invention also relates to the combination of a bottom 10 ¦ loaded coolant box casting device of the aforementioned type t and ,ll ¦ an apertured hot top which is superposed thereabove. According to 12 ¦ the invention, the aperture of the hot top registers with the top 13 1 opening of the box but is smaller in diameter than the same, and 14 there is a flanged insulative refractory scupper telescoped in the aperture, the flange of which is disposed below ~he overhang of the 16 aperture in $he top opening of the box.

18 BRIEF DESCRIPTION_ OF THE DRAWINGS
l9 These features will ~e better understood by reference to the accompanying drawings which illustrate several embodiments of 21 the invention when it is employed in a multiple-site, direct chill 22 billet casting apparatus incorporating both the aforementioned 23 ¦ combination and the improved billet casting mold.

~4 ¦ In the drawings, Figure l is a part vertical cross-sectional 25 1 view o~ one casting site when the casting operation is conducted !

26 ¦ with a gas-impregnable ring of graphite or the like at the top of 27 ¦ the mold cavity 1:herein;

28 ¦ Figure 2 :is a part cross-sectional upward plan view of the 29 ¦ site along the line 2-2 of Figure 3;
30 1 Figure 3 is a part cross-sectional view of the site along ~X3~37~
the line 3-3 of Figure ~;
' Figure 4 is a par-tially exploded, part cross-sectional view of the site;
Figure 5 is an enlarged part cross-sectional view of the site along the line 5-5 of Figure 2;
Figure 6 is a more greatly enlarged part cross-sectional view of the site at the gas-impregnable ring thereof;
Figure 7 is a similar view of an alternative form o~
ring;
Figure 8 is another such view of still another form of ring;
Figure 9 is a fourth version of the ring;
Figure 10 is a fifth version of the same;
Figure 11 is a part-perspective view of the fifth version;
Figure 12 is an exploded top perspective view of the support or stool used at the site;
Figure 13 is a bottom perspective view of the stool cap;
Figure 14 is a vertical cross-sectional view of the stool in the latched condition of the cap;
Figure 15 is a similar view of the stool after the cap has been unlatched; and Figure 16 is a third such view of the stool after the cap has been removed.
DESCR.IPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, it will be seen that the billet casting apparatus comprises a multiple site casting device 2 of the coolant box type, a hot top 4 for feeding the respective casting sites 6 of the device, and an assembly of telescoping stools 8 for supporting the elongated billets 10 progressively formed at the sites. The casting device .",~, 1 ¦ comprises a large widely dimensioned box 12 having a corresponding-2 ¦ ly sized chamber 14 therein for circulating a liguid coolant such 3 ¦ as water to the respective casting sites. The bo~ 12 also has 4 ¦ equally sized openings 16 in the bottom 18 thereof, corresponding 5 ¦ in n~ er and location to the castings sites, and equally sized 6 ¦ openings 20 in the top 22 thereof which are vertically aligned with 7 ¦ but smaller than the bottom openings 16 of the box at the respectiv 8 ¦ sites. The top openings 20 each have an annular rabbet 40 (Figure 9 ¦ 3~ a~out the inner peripheral edge thereof, the vertical wall of 10 ¦ which is rabbeted in turn at the bottom thereof to form an annular 11 ¦ shoulder or step 42 thereonO The bottom openings 16 each have a 12 ¦ set of threaded holes 24 (Figure 4) spaced about the perimeter 13 ¦ thereof for an attachment purpose to be explained, and an addi-14 ¦ tional set of thraaded holes 26 (Figure 5) more radially offset therefrom, which are employed in plumbing air and lubricating oil 16 to the site, as shall also be explained.
17 The hot top 4 includes a molten metal distribution pan 32 18 which has a set of apertures 34 therein that are adapted to hold 19 an equal number of insulative refractory scuppers 28 at the respec-tive casting sites. The apertures register with but are smaller 21 in diameter than the corresponding top openings 20 of the box, and 22 are sized to slideably receive the scuppers. Each scupper has a 23 ¦ tapered bore 36 and a cylindrical outer co~figura~ion which is 24 ¦ flanged a$ an intermediate level thereof. The flanges 38 are 25 ¦ sized to fit within the openings 20 of the box. When the pan 32 is 26 ¦ in place, the 'scuppers are mounted in the same by inserting them 27 ¦ upwardly through the respective bottom openings 16 of the box and 2B ¦ then into the oorresponding top openings 20 thereof. As they pass 29 ¦ through the openings 20, they engage in the apertures 34 of ~he 30 ¦ pan. Meanwhile, the flanges 38 on the outside of the scuppers ~ 123~37fi~

1 ¦ telescope into the openings, leaving only the bottom portions 28' 2 ¦ of the scuppers depending within the chamber.
3 ¦ In addition to the box, the casting device also comprises 4 ¦ a set of annular billet casting molds 30 which are likewise 5 ¦ mounted at the respective sites by inserting them upwardly through 6 ¦ the bottom openings 16 of the box. However, in this case, the 7 ¦ molds are abutted against the top 22 of the box and engaged between ~ ¦ the depending portions 28' of the ~cuppers and the rabbeting 40,42 9 ¦ about the openings 20 o~ the box. When so engaged, they seal with 10 ¦ the top of the box, as shall be explained, and trap the flanges 38 11 ¦ of the scuppers in the openings 20 of the box. They also engage 12 ¦ with the bottom of the box, and seal to it as well, as shall be 13 ¦ explained. Ultimately, capscrews 44 are employed to secure the 14 ¦ molds in place, using the threaded holes 24 about the respectiYe 15 ¦ openings 16.
16 ¦ Each billet casting mold 30 (Figure 4) comprises a deep 17 ¦ cylindrically inner surfaced metal casting ring 46, a more shallow, 18 but similarly inner surfaced graphite feed ring 48 of slightly 19 smaller inner diameter, a relatively flat, small diameter, cylin-drically innPr surfaced top ring 50 of insulative refractory ma-2~ terial, a retainer ring 52 for use between the rings 46 and 50, 22 and a widely flanged attachment ring 54 that cooperatively inserts 23 within the casting ring 46 to define a coolant flow passage 56 24 therebetween (Figure 3), as shall be explained. The casting ring has a wide, cleeply inset, inner peripheral rabbet 58 at the top 26 ~hereof, and the bottom of the same has a narrow and more shallow 27 rabbet 60 at the inner peripheral edge thereof. The vertical wall 28 of the wider rabbet 58 is threaded at the top thereof, and after 29 the feed ring 48 and the top ring 50 are seated in the r~spective rabbets 60, 58 in tnat order, the retainer ring 52 is threaded into 38'71~

1 ~ an outer peripheral rabbet 62 in the upper surface of the top ring 2 ¦ 50~ to clamp the assembly in place. Additionally, there is a 3 ¦ narrower outer peripheral rabbet 64 at the top of the casting ~ing, ~ ¦ an annular groove 66 acutely angled into the corner of the rabbet, ;
5 ¦ and an annular dovetail-cross-sectioned groove 68 in the top of G ¦ the ring just inside of the rabbet 64. A pair of ela~tomeric i 7 ¦ 0-rings 69 and 70 is seated in the respective grooves, to form a 8 ¦ seal between the top o the casting ring and the abutting surface 9 ¦ of the rabbet 40 in the top of the box, on one hand, and the corner 1~ ¦ of the rabbet 64 of the riny 46 and the shouldar or step 42 of the 11 box on the other. Meanwhile, the smaller diameter top ring 50 is 12 slideably engaged about the scupper and together with the bottom 13 of the scupper, forms a wide ov~rhang 71 directly above the feed 14 ring. The top ring and retainer ring normally do not abut the ~op of the box, however.
16 At t~e bQttom, the casting ring 46 has a high inner 17 peri~heral rabbet 72, the vertioal wall 74 of which is somewhat 18 radially enlarged at levels above that corresponding to the bottom 19 of the chamber 14 when the mold is inserted therein. Moreover, the top of the step 74 of the rabbet is circumposed about the ring 21 at a level adapted for discharging a curtain of coolant liquid 22 onto the emerging billet from the chamber. The top also has an 23 ¦ arcuate recess 76 therein which terminates just short of the inner 24 ¦ periphery of the ring. At the bottom, the step has a shallow 25 ¦ circumferential recess 78 thereabout which has a serie~ of holes 26 ¦ 80 in outer peripheral wall thereof that open into the outer l 27 ¦ peripheral face of the ring. i 28 ¦ The attachment ring 54 has a greater diameter than the 2g ¦ opening l6 Df the box, but has a deeply inset outer peripheral rabbet 82 about the top thereof so that the top can télescope . ~

~ 123~7~i3 1 ¦ within the step 74 of the casting ring when the remaining flange 2 ¦ 84 of the attachment ring abuts against the bottom of the box.
3 ¦ Registering holes 86 and 88 in the flange and the bottom of the 4 ¦ casting ring, respee~tively, enable capscrews 90 to be used in 5 ¦ secu~ing the rings ~oyether when they are mated and abutted in-6 ¦ board of the flange, as shown :in Figure 3. In addition, there is 7 ¦ an annular dovetailed groove 92 in the flan~e o~ the attachment 8 ¦ ring at the radius of the joint: between the casting ring and the 9 ¦ opening 16 of the box to accommodate an o-ring 94 for sealing the 10 ¦ joint.`
11 ¦ The attachment ring 54 also has additional holes 108 in the 12 ¦ flange 84 thereof which are symmetrically spaced about the out-13 ¦ board portion of the flange to register with the threaded holes 24 14 ¦ in the bottom of the box. When the mold 30 is telescoped in the 15 ¦ box, the capscrews 44 are inserted through the holes 108 and 16 ¦ threaded into the h~les 24 to secure the member to the box. , 17 1 At its top, the attachment riny 54 is rounded to a semi-18 ¦ toroidal configuration corresponding to that of the recess 76 of 19 ¦ the step in the ring 46~ but smaller in radius than the recess so 20 ¦ that an arched continuation 56' of the annular passage 56 is ~1 ¦ formed ~etween the two rings at the respective rabbets 82, 72 22 ¦ thereof. The attachment ring is also rel~eved at the inner 2~ ¦ periphery thereof t~ have ~ slightly conical recess 96 about the 24 upper end portion thereof which descends to a greater diameter recess 98 about the bottom portion thereof. The recess 96 is 26 si2ed to a greater inside diameter than the rounded top of the 27 ring, 50 that when coolant escapes through the reentrant passage 28 56, 56', it discharges freely onto the billet ketween the remain-29 ing lip 100 and toe lQ2 of the respective rings 46, 54~ The recess 98 has a plurality of symmetrically angularly spaced, ll ~38~i3 1 ¦ bottom chamferred ribs 104 thereabout to serve as guides for the 2 ¦ cap 106 of the associated ~tool 8, as shall be explained.
3 ¦ There are also four symmetrically angularly offset palrs of 4 ¦ cooperating fluid flow passages llO and 112 ~Figure 5~ in the 5 ¦ rings 54 and 46, respective:ly, which are individually interconnecte 6 ¦ with one another from one r:ing to the other to supply air and lub-7 ¦ ricating oil, respectively, to a pair of circumferential grooves B ¦ 114 and 116 in the vQrtical wall of the rabbet 60 of tha ringO
9 ¦ The respectlve pairs of passages are supplied by a corresponding 10 ¦ number of radially outwardly directed holes 118 in the mouth of 11 ¦ the opening 16 of the box, which are supplied in turn through the 12~¦ threaded holes 26 in the bottom of the box. Each passage 110 in 13 ¦ the ring 54 includes a radially inwardly directed hole 120 in the 14 ¦ outer peripheral edge of the flange 84 thereof, which interconnects 15 ¦ at its insiae end with a ver~ical hole 122 in the abutting face of 16 ¦ the flange. Each passage 112 in the ring 46 includes a vertically 17 1 upwardly directed hole 124 in the bottom of the xing, which inter-18 1 connects with an obli~uely inwardly directed hole 126 or 126l in 19 1 the outer peripheral face of the same. Every other obliquely 20 ¦ directed hole 126 tPrminates in the groove 114, whereas the remain-21 ¦ ing holes 126' terminate in the groove 116. Otherwise~ the respes-22 ¦ tive pairs of passa~es 110, 112 are simil~r in that the holes 118 23 ¦ and 120 in the box and flange of the ring 54, are interconn~cted 24 by registering vertical holes 128 and 130 in the bottom of the box and the abutting face o E the flange, respectively; and the holes 26 122 and 124 in the flange and ring 46 register with one another 27 acxoss the :Eace of the flange. In addition, the holes 118, 120, 28 126 and 126' are plugged at their mouth end~. ~s a result, when 29 the hold 30 is telescoped in the box, fluid fed to the respective holes 26 in the box makes its way through the respective pairs o~

1~3~'7~3 passayes 110, 112 to either the groove 114 or the yroove 116, depending on which is the terminus of the passage 112 in the ring 46.
A feed hose 134 coupled to a threaded nipple 136 at each of the holes 26 supplies the respective fluid. Additionally, the holes 130 and 122 are counterbored at the face of the flange 84 to accommodate a pair of O-rings 132 which are seated in the same to seal the joints between the pairs of holes 128, 130 and 122, 124.
Referring now to Figures 1, 5 and 6 in particular, it will be seen that as the molten metal 138 emerges from the scllpper 28, it splays into a metallic mass the meniscus 140 of which tends to contact the peripheral wall 142 of the cavity 143 of the mold 30 in the plane of maximum divergence of the metal.
Moveover, the metallic mass has a divergent-convergent cross-sectional outline between the top and bottom of the cavity, the intermediate continuum 144 of which between the planes of maximum divergence and minimum convergence has a peripheral out-line corresponding generally to the peripheral outline of the cavity at the peripheral wall 142 thereof. Meanwhile, there is a pocket 146 of relatively metal-free space formed between the meniscus 140 of the metal and the top corner 71, 142 of the cavity at the overhang 71 of the opening 20. In the prior art, a stream o~ pressurized air was delivered to the top of this pocket, and the pressurization of the pocket itself, internally of the cavity, was employed as a means for generating a sleeve-like annulus 148 of gas which would tend to flow downwardly about the metallic mass at the periphery of the cavity, given certain idealized conditions in the pocket. According to the invention, however, a stream of pressurized gas such as air is pumped into , ~2387~3 68456-24 the groove 114, outside of the cavity, and means such as the graphite of the ring 48 are interposed between the groove and the periphery of the cavity to convert the stream into a : ~ ~ 16a _ .

lZ3~ 3 1 ¦ sleeve-like annulus 148 of fluid at the inner periphery 142 of the 2 ¦ ring as the ring discharges the gas into the cavity. The graphite 3 ¦ is an air-impregnable facing medium which effectively diffuses and 4 ¦ depressurizes the gas so ~hat it can be discharged into the cavity 5 ¦ adjacent the plane of maximum divergence as shown. In fact, the 6 ¦ gas can be discharged into the CclVity opposite the ~itus of the 7 ¦ intermediate continuum 44 itself, as shown, so as to generate the ~ ¦ annulus directly a~ the location where it is needed, regardless of 9 ¦ conditions in the pocket.
10 ¦ Meanwhile, lubricating oil is pumped to the upper groove 11 ¦ 116 and delivered to the pocket 146 through the upper end portion 12 of the ring.
13 The grooves 114 and 116 are commonly vertically symmetri- I
lA cally spaced from one another and from the bottoms of the rabbets 58 and 60 of the ring 46. Also, the respective fluids, oil and 16 air, are ccmmonly pumped to the grooves at about 20-30 psi. The l 1~ graphite is commonly a molded, very fine grain, essentially flaw- I
t~ 1~ freè, high strength graphite such as the ATJ graphite sold by the 19 Carbon Products Division of Union Carbide Corpora~ion, Chicago, IL. I
Preferably, it also machines to a fine su-face finish and has a 21 high thermal conductivity.
22 In Figures 1~6, the air and oil are delivered to points 23 114, 116 at the ou~er peripheral surface of the graphite facin~
24 medium 48. In Figure 7, the graphite medium 151 has delivery 25 holes 150 and 152 in the outer peripheral surface thereof, which 26 open into the respective gxooves 114 and 116 and extend radially 27 inwardly therefrom, but terminate short of the inner peripheral 28 face 142 of the ring. In this way, the rs~spective fluids are 29 delivexed to points within the bo~y of the graphite medium where 30 1 they can diffuse through the face of the medium over an arc of I ~ t~r~e ~rK

1;Z38';'~i3 1 ¦ shorter radius.
2 ¦ If desired, the respective sets of delivery holas may be 3 ¦ angled away from the horizontal, such as are holes 154 and 156 in 4 ¦ Figure 8, which are angled upwardly from the grooves 114, 116, but ~ ¦ again terminate short of the inner peripheral face 142 o~ the ring 6 ¦ 157. Furthermore, ~epending on the situs of the intermediate con-7 ¦ tinuum 144 of the metal, the oil and air need not be delivered to ~ ¦ grooves above and below one another,respe~tively. In Figure 9, 9 ¦ the oil is delivered to the bottom groove 114, and sharply upwardly 10 ¦ inclined holes 158 in the outer peripheral surface of the graphite 11 ¦ medium 159 are employed to deliver the oil to a level which is 12 ¦ disposed above the holes 160 for the air and corresponds to the 13 ¦ level of the pocket in the cavity of the mold. Meanwhile~ the air 14 ¦ is delivered to the upper groove 116, which in turn delivers the 1$ ¦ air to the forward ends of the holes 160 for the same.
lS ¦ In Figures 10 and 11, the air i5 delivered to a~ annular 17 ! groove 162 in the o~ter peripheral surface of the graphite ring 18 ¦ 164 itself, and the oil is delivered to a higher groove 166 having ~g ¦ a scabbard-like extension 16i of the same extending somewhat down-20 ¦ wardly therefrom radially inwardly of the ring. In addition, the 21 ¦ bottom of the top ring 50~ has an annular rabbet 170 about the 22 outer peripheral edge thereof, and the graphit~ ring is elevated 23 ¦ into the corner of this rabbet, and rabbeted itself to have an 24 ¦ annular inner peripheral step 172 about the bottom thereof, the ~5 ¦ top of which is generally co-plan~r with the bottom 71 of the top 26 ¦ ring. However, the top of the step has a swale-like recess 174 ~7 ¦ ther~in which lies slightly ahead of the forward end of the ex-28 ¦ tension 168 of the groove 166. Thus, in this embodiment, oil is 29 ¦ bled into the top of the pocket 146 at ~he overhang itself~ as well 30 ¦ as into the side of the pocket in the manner of the earliex 3L238~3 68456-24 embodiments. Providing a recessed feed surface 174 for the oil also aids in trapping more oil vapor at the top of the pocket to decrease the cooling effect at that point.
In an alternative form oF the invention, the castor oil, peanut oil or other lubricating oil delivered to either of the grooves 116 and 166, is suspended in a highly vaporizable li~uid carrier such as alcohol, and the heat generated in the graphite ring during the casting operation is relied on to vaporize the carrier by the time it discharges at the inner peripheral face of the ring. The vapor of the carrier then becomes a part of the annulus about the metallic mass and may substitute entirely for the gaseous medium normally supplied to the grooves 114 and 162, thus obviating any need for delivering gas to the same. Alternatively or additionally, the vapor of the carrier may be employed to modify the gaseous vaporous character of the annulus, and/or to increase the top cooling of the metallic mass.
Referring now to Figures 12-16, it will be seen that each stool cap 106 rests on a pedestal-like base 176 and is engaged with the top 178 of the base so as to be capable, within limits, of shifting laterally of the base when the stool is telescoped into the corresponding mold 30 of the device. The top of the base is hollow and has a tapering skirt 180 about the bottom thereof. The top also has an annular rabbet 182 about the top surface 184 thereof, and there is a keyhole-shaped hole i86 in the surface which opens into the hollow bore 188 of the top at the periphery thereof. The hole 186 has a circular main section 190 at the periphery of the bore, and an adjoining part circular side section 192 radially ~ ~3~ 3 inside thereof, the center of which is disposed on the vertical axis of the base.
The top 193 of the cap is cylindrical and sized to telescope -19a-- .

lZ~3~'7~3 1 ¦within the bore of the casting ring 46. However, the bottom 194 2 ¦ f the cap i9 more enlarged to telescope only within thP circle of 3 1 ribs 104 on the attachment ring 54~ and there is a shoulder 196 4 ¦ between the two portions of the cap which tapers radially outwardly 5 ¦ and downwardly thereof at the same inclinat;ion as the bottoms 104' ~ I of the ribs. The shoulder l9Ç is also disposed at such a height on 7 the cap that it will engage the bottoms 10~' of the ribs before the 8 top of the cap enters the castin~ ring, thus assuring that the cap 9 is aligned with the ring befora it telescopes within the same.
The cap also has a wide annular groove 198 in the bottom 11 surface 200 thereof, which is disposed to register with the rabbet 12 182 on the top 178 of the base 176 when the two member~ are coaxial 13 with one another. In addition, at the center of the surface 200, 14 there is a flanged catch 202 which 1 sized at the flange ~04 thereof to pass through the main section 190 of the hole 186 in 16 the base. The flange is also spaced sufficiently below the bottom 17 surface of the cap to be able to sl~deably engage with the under-18 side 208 of the top 178 of the base when the surfaces 200, 184 of 19 the cap and base are engaged and the cap is shifted laterally in-wardly of the base to engage the members against relative axial 21 displacement, as shall be explained. The shank 206 of the catch, 22 on the other hand, is sized to fit within the side section 192 of 23 ¦ the hole, when the c~p is so shifted.
~4 ¦ In addition to the cap 106 and the base 176, the stool 8 25 ¦ also comprises a ring 210 which is sized to slideably engage about 26 ¦ the top of the base in the rabbet 182 thereof. ~hen the ring is in 27 1 this position, moreover, it is siæed to stand well above the sux-28 1 face 184 of the base and to fit within the groove 198 of the cap 3Q l when the cap is rested on the surface 184 of the base, coaxially l thereof. The ring 210 is also sized to be elevated into the groove, ~238~;3 1 ¦flush with the surface 200 of the cap, as shall be explained. The 2 ¦groove 198, on the other hand, is greatly oversized in widthwise 3 ¦relation to the ring, so that when the cap is rested on the base 4 ¦and the ring i~ registered wi1:h the groove, the cap can shift 5 ¦laterally of the rirAg for purposes of aligning its.elf wi~h the 6 ¦casting ring of the device as mentioned. There is a point, how-7 ¦ever, at which the cap and ring will abut one another, and this 8 ¦point is in advance of the point at which the cat~h shifts into 9 ¦ver~ical alignment with the main section 192 of the hole 186 in 10 ¦ the top of the base.
11 ¦ The stool 8 is assembled hy lifting the ring 210 into the 12 ¦ groov~ 198 of the C2p, lnserting the catch 202 in the hole 186 of 13 ¦ the base, and then while the cap is rested on the top of the base, 14 ¦ shifting it laterally thereof to engage the shank 206 of the catch in the side section 192 of the hole. ~he ring i~ then re-16 le~sed to engage with the step 212 of the rabbet 182, as in Figure 17 14. In this conditi.on, the cap and base are latched against 18 ¦ relàtive axial dlsplacement, but khe cap can slide laterally of 19 the base on the sur~ace 184 of the same, within the limits afforded by the loose engagement between the ring 210 and the groove 198.
21 When it is desired to remove and replace the cap, for 22 example, with a cap of a different size, the ring 210 i5 raised 23 into the groove 198 and the cap is slid into alignment with the 24 main section 190 of the hole 186 so that it can be lifted away from the base, as in Figures lS and 16.
26 It will be apparent that the invention is applicable to the 27 casting of all cross-sectional outlines including round, square and 28 rectangular; and that it is applicable to both vertical and hori-29 zontal casting, including continuous casting. Also, only a single nipple 136 ~nd pa~sage 110, 112 is needed for eac~ fluid; and many ' ~ ~Z38~

1 ¦other change~ and additions can be made in and to the invention 2 ¦without departing from the scope and spirit of the same as defined ,y the follow ng cl~ims.

2~1 29 .
~0

Claims (26)

THE EMBODIMENTS OF THE INVENTION IN WHCIH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. In the process of direct chill casting a metal in an open ended mold cavity having a support telescoped in the dis-charge end thereof and an opening at the other end thereof whose diameter is smaller than the peripheral wall of the cavity so that the inner peripheral edge of said other end opening forms an overhang relatively over the wall, the steps of:
continuously filling said other end opening of the cavity with molten metal so that the mass of molten metal splays about the inner peripheral edge of the other end opening and forms a body of molten metal in the cavity whose cross-section has a divergent/convergent outline between the ends thereof, the intermediate continuum of which between the planes of maximum divergence and minimum convergence thereof, has a peripheral outline corresponding generally to the outline of the cavity at the peripheral wall thereof, circumposing graphite or graphite-like wall defining means about the molten metal body in the peripheral wall of the cavity at a level below the overhang adapted so that the intermediate continuum is surrounded by a solid but fluid permeable wall section of said means, simultaneously forcing a lubricating oil and an additional fluid medium selected from the group consisting of a highly heat vaporizable liquid medium and a gaseous medium, through the fluid permeable wall section so that the oil and additional fluid medium discharge into the cavity at points on the inner peri-pheral surface of the wall section opposite the intermediate continuum, and simultaneously chilling the molten metal body from points below the intermediate continumm and reciprocating the mold and support in relation to one another endwise of the cavity to elongate the body, the wall of the cavity co-terminating with the overhang at the aforesaid other end of the cavity so that the part of the molten metal body directly adjacent the overhang is surrounded by a closed corner of the cavity, and the fluid thus discharged about the intermediate continuum forming an annulus of fluid tending to flow relatively away from the closed corner of the cavity toward the discharge end thereof.
2. The process according to Claim 1 wherein a stream of fluid is impinged on the molten metal body at a level below the plane of minimum convergence, to chill the body, and that part of the body disposed between the level of impingement and the aforesaid fluid permeable wall section, is surrounded by a section of the wall which is impermeable to said fluid.
3. The process according to Claim 1 wherein the oil and additional fluid medium are forced into the fluid permeable wall section through the outer peripheral portion thereof.
4. The process according to Claim 3 wherein the additi-onal fluid medium is a gas, and the oil and gas are forced into the fluid permeable wall section at levels spaced apart from one another endwise of the cavity.
5. The process according to Claim 4 wherein the oil and gas are forced into the fluid permeable wall section through a pair of spaced circumferential grooves extending about the wall section at the outer periphery thereof.
6. The process according to Claim 5 wherein the grooves have sets of holes extending peripherally inwardly therefrom, but terminating in the wall section short of the inner peri-pheral surface thereof.
7. The process according to Claim 1 wherein the graphite or graphite-like wall defining means are circumposed about the molten metal body at a level adapted so that the part of the body directly adjacent the overhang is also surrounded by the fluid permeable wall section, and the oil and gas are forced into the wall section at levels adjacent the overhang and the plane of minimum convergence, respectively.
8. The process according to Claim 1 wherein the fluid permeable wall section extends beyond the overhang in the end-wise direction of the cavity, and has a step therein which is directed peripherally inwardly of the wall to define a portion of the overhang, and wherein the oil is forced into the wall section at a level adjacent the step.
9. The process according to Claim 1 wherein the corner is curved opposite the meniscus to control the size of the dis-charge pocketed therebetween.
10. The process according to Claim 1 wherein the mold cavity is disposed so that the end openings thereof are centered on a vertical line.
11. Apparatus for direct chill casting a metal comprising:
means defining an open ended mold cavity having a discharge end adapted to have a support telescoped therein, and having an open-ing at the opposing end thereof whose diameter is smaller than the peripheral wall of the cavity so that the inner peripheral edge of said opposing end opening forms an overhang relatively over the peripheral wall, whereby when said opposing end opening of the cavity is continuously filled with molten metal, the mass of molten metal splays about the inner peripheral edge of the opposing end opening and forms a body of molten metal in the cavity whose cross-section has a divergent/convergent out-line between the ends thereof, the intermediate continuum of which between the planes of maximum divergence and minimum con-vergence thereof, has a peripheral outline corresponding gener-ally to the outline of the cavity at the peripheral wall thereof, means for chilling the molten metal body from points below the intermediate continuum, graphite or graphite-like wall defining means disposed in the peripheral wall of the cavity at a level below the overhang for surrounding the intermediate continuum of the molten metal body by a solid but fluid permeable wall section, and fluid delivery means for simultaneously forcing a lubricating oil and an additional fluid medium selected from the group consisting of a highly heat vaporizable liquid medium and a gaseous medium, through the fluid permeable wall section so that the oil and additional fluid medium discharge into the cavity at points on the inner peripheral surface of the wall section opposite the intermediate continuum, while the molten metal body is chilled and the mold and support are reciprocated in relation to one another endwise of the cavity to elongate the body, the wall of the cavity co-terminating with the overhang at the aforesaid opposing end of the cavity so that the part of the molten metal body directly adjacent the overhang is surrounded by a closed corner of the cavity, and the fluid thus discharged about the intermediate continuum for-ming an annulus of fluid tending to flow relatively away from the closed corner of the cavity toward the discharge end thereof.
12. The apparatus according to Claim 11 wherein the fluid delivery means are operable to force the oil and additi-onal fluid medium into the fluid permeable wall section through the outer peripheral portion thereof.
13. The apparatus according to Claim 12 wherein the fluid delivery means are operable to force oil and gas into the fluid permeable wall section at levels spaced apart from one another endwise of the cavity.
14. The apparatus according to Claim 13 wherein there is a pair of spaced circumferential grooves extending about the wall section at the outer periphery thereof, and the fluid delivery means are operable to force the oil and gas into the wall section through the grooves.
15. The apparatus according to Claim 14 wherein the grooves have sets of holes extending peripherally inwardly therefrom, but terminating in the wall section short of the inner peri-pheral surface thereof.
16. The apparatus according to Claim 14 wherein the graphite or graphite-like wall defining means are disposed in the wall of the cavity at a level adapted so that the part of the body directly adjacent the overhang is also surrounded by the fluid permeable wall section, and the fluid delivery means are operable to force the oil and gas into the wall section at levels adjacent the overhang and the plane of minimum conver-gence, respectively.
17. The apparatus according to Claim 11 wherein the fluid permeable wall section extends beyond the overhang in the end-wise direction of the cavity, and has a step therein which is directed peripherally inwardly of the wall to define a portion of the overhang, and the fluid delivery means are operable to force the oil into the wall section at a level adjacent the step.
18. The apparatus according to Claim 11 wherein the cor-ner is curved opposite the meniscus to control the size of the discharge pocketed therebetween.
19. The apparatus according to Claim 11 wherein the mold cavity is disposed so that the end openings thereof are centered on a vertical line.
20. The apparatus according to Claim 11 wherein the over-hang is defined by a insulative refractory member, and the mem-ber and wall section are disposed so that they abut one another at the overhang.
21. The apparatus according to Claim 20 wherein the aforesaid opposing end opening of the cavity is defined by an insulative refactory scupper for a hot top, and the scupper is centrally located within the overhang defining member.
22. The apparatus according to Claim 11 wherein the fluid permeable wall section is annular and has a cylindrical inner peripheral surface.
23. The apparatus according to Claim 11 wherein the gra-phite or graphite-like wall defining means take the form of a circumferentially continuous ring of graphite.
24. The apparatus according to Claim 11 wherein the means for chilling the molten metal body include means for impinging a stream of fluid on the body at a level below the plane of minimum convergence, and wherein that part of the body disposed between the level of impingement and the aforesaid fluid permeable wall section, is surrounded by a section of the wall which is impermeable to said fluid.
25. The apparatus according to Claim 24 wherein the diameter of the inner peripheral surface of the fluid permeable wall section is smaller than the diameter of the inner perip-heral surface of the fluid impermeable section of the wall.
26. A billet casting mold for a bottom loaded coolant box casting device of the type wherein the coolant box has registering top and bottom openings in the chamber thereof, the top opening of which has a shoulder thereabout and the bottom opening of which opens into the bottom of the box and has a greater diameter than the top opening of the chamber, compri-sing a pair of cooperatively engageable top and bottom rings, the top ring of which is adapted to be inserted upwardly into the chamber through the bottom opening thereof and abutted against the shoulder about the top opening, the top ring having apertures in the body thereof which are adapted to open into the bottom of the chamber when the ring is inserted into the chamber and abutted against the shoulder, and an arcuate step thereon that overhangs the apertures and is cir-cumposed about the inner periphery of the top ring at a level adapted for discharging a curtain of coolant liquid onto the emerging billet from the chamber, the bottom ring being adapted to telescope within the top ring and to cooperate with the step in forming an annular passage for the coolant therebetween which communicates with the apertures in the body of the top ring and extends upwardly therefrom to a point at which it then curves reentrantly downwardly to the inner periphery of the top ring for discharge of the curtain, and the bottom ring having a flange thereon which is engageable with the bottom of the box to locate one ring within the other when the passage if formed.
CA000426155A 1982-10-20 1983-04-19 Direct chill metal casting apparatus and technique Expired CA1238763A (en)

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CH (1) CH675086A5 (en)
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FR (1) FR2534832B1 (en)
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FR2599650B2 (en) * 1985-07-30 1988-08-26 Pechiney Aluminium METAL LOADING DEVICE
FR2585597B1 (en) * 1985-07-30 1987-10-09 Pechiney Aluminium METHOD AND DEVICE FOR CASTING IN METAL LOAD
DE3533517A1 (en) * 1985-09-20 1987-04-02 Vaw Ver Aluminium Werke Ag METHOD AND DEVICE FOR CONTINUOUS CASTING
US5325910A (en) * 1985-09-20 1994-07-05 Vereinigte Aluminium-Werke Aktiengesellschaft Method and apparatus for continuous casting
US4693298A (en) * 1986-12-08 1987-09-15 Wagstaff Engineering, Inc. Means and technique for casting metals at a controlled direct cooling rate
CA1320335C (en) * 1988-12-08 1993-07-20 Friedrich Peter Mueller Direct chill casting mould
DE4212531C1 (en) * 1992-04-15 1993-10-21 Vaw Ver Aluminium Werke Ag Gas and release agent supply and distribution system for a continuous casting device
DE59603003D1 (en) * 1996-06-06 1999-10-14 Alusuisse Lonza Services Ag Continuous casting mold
US6158498A (en) * 1997-10-21 2000-12-12 Wagstaff, Inc. Casting of molten metal in an open ended mold cavity
DE69914239T2 (en) 1998-03-13 2004-06-17 Honda Giken Kogyo K.K. Method and device for lubrication in the continuous casting of light metals
US7204295B2 (en) 2001-03-30 2007-04-17 Maerz-Gautschi Industrieofenanlagen Gmbh Mold with a function ring
WO2009072558A1 (en) * 2007-12-05 2009-06-11 Showa Denko K. K. Continuous casting device and molten metal pouring nozzle

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GB686413A (en) * 1950-05-26 1953-01-21 Sankey & Sons Ltd Joseph Continuous casting mould and lubrication method therefor
US3089209A (en) * 1960-01-06 1963-05-14 American Smelting Refining Method for continuous casting of metal
CH451416A (en) * 1965-07-24 1968-05-15 Vaw Ver Aluminium Werke Ag Process for supplying the lubricant during fully continuous casting of metals in stationary molds
US3612151A (en) * 1969-02-14 1971-10-12 Kaiser Aluminium Chem Corp Control of continuous casting
IT1028954B (en) * 1975-04-28 1979-02-10 Continua Int TUBULAR INGOT MOLD WITH UNIFORM FLOW WATER SHIRT
CA1082875A (en) * 1976-07-29 1980-08-05 Ryota Mitamura Process and apparatus for direct chill casting of metals
US4369832A (en) * 1979-10-15 1983-01-25 Olin Corporation Continuous lubrication casting molds
DE3008781C2 (en) * 1980-03-07 1982-08-26 Herbert Dipl.-Ing. 5870 Hemer Woithe Process for the continuous casting of metals
GB2082950B (en) * 1980-09-02 1984-06-20 British Aluminium The Co Ltd Apparatus for direct chill casting of aluminium

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DE3338185A1 (en) 1984-05-03
GB8304236D0 (en) 1983-03-23
JPS5992147A (en) 1984-05-28
NO160246B (en) 1988-12-19
AU1413783A (en) 1984-05-03
AU567872B2 (en) 1987-12-10
FR2534832B1 (en) 1988-04-22
NO830858L (en) 1984-04-24
SE8300849L (en) 1984-04-21
FR2534832A1 (en) 1984-04-27
GB2129344A (en) 1984-05-16
SE459325B (en) 1989-06-26
JPS6147622B2 (en) 1986-10-20
JPS61262449A (en) 1986-11-20
NO160246C (en) 1994-05-04
DE3338185C2 (en) 1990-09-13
GB2129344B (en) 1986-11-19
SE8300849D0 (en) 1983-02-16
CH675086A5 (en) 1990-08-31

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