CA2260758A1 - Rotary wheel casting machine - Google Patents

Abstract

A casting wheel is provided carrying a rotating inner-radius mold wall (8) along its rim and featuring a non-rotating mold sector (11) comprising at least one rigid mold segment (10) incorporating an outer-radius mold wall (12), circumferentially oscillated about an external stationary support (34).
The casting wheel includes circumferential guide tracks (5, 6) around the wheel periphery, along which cam guide rollers (15) carrying the non-rotating segments (10) act to maintain a closely controlled interface clearance between the inner (9) and outer-radius (21) mold wall edges throughout the rotation.
The non-rotating mold sector (11) may be constructed as a single enclosure, or multiple segments (10) hinged together for oscillation by a single oscillator (32), each segment incorporating its own guide roller system. Each box inside wall doubles as the mold envelope outside wall (12) which may be cooled by water sprays (39) directed from nozzles (38) or direct sealing and pressurizing of segments (10) through which controlled coolant flow is maintained. Because of the rigid construction of both wheel and closure, the invention is also adaptable to casting of wide slab sections for flat-rolled products, simply by increasing the width of the wheel in relation to the depth of the mold envelope. The invention includes embodiments providing adjustable-width side dams (44) for adjusting cast slab width, extra clearance for submerged entry nozzles for casting of thin slab sections, and is adaptable for a variety of near net shape products including structural sections. An embodiment includes non-oscillated roller segments (90) carrying a series of idler rollers (69) in place of the outer-radius mold wall (12), following the formation of a cohesive solid skin on the section being cast. This eliminates significant closure friction and assures non-sliding contact at controlled pressure between stock and wheel, thereby propelling the stock by static friction along the arc of contact with the wheel , rather than by pulling with withdrawal rollers following discharge, or with driven rollers along the containment section. Various other features and advantages of the apparatus are disclosed.

Description

CA 022607~8 1999-01-18 ROTARY WHEEL CASTING M~(:~INE . ' ' ~, .. . ', .~ ..

The invention relates to the continuous casting of steel and other metals and, more particularly, to an improved rotary wheel-type casting machine for continuous casting of billets, blooms, slabs, bars, rods and the like.

In the prior art of vertical continuous casting wheels, peripheral closure of the casting mold channel generally is accomplished by either a moving, endless metal belt pressed against the wheel rim by rollers to realize closure and synchronous peripheral motion with the ~vheel, or by multiple closure sel~m~ntC~ or cl~m.chPil-style molds, spaced in abutting sectors around the entire wheel circumference and rotating with it, which are closed pro~imate the point of pouring steam entry, and reopened at bar e~;it from 10 the casting sector during each revolution of the wheel. Known technology also includes a stationary closure belt, pressed in frictional contact against the wheel periphery spanning the casting arc.

Disadvantages of the endless belt include: heat from the casting warps the belt, also imparting a wrinkled and warped surface to the cast stock on the belt side of the section; return rollers are bulky and occupv useful space: a closed and sealed collector and conduit for spent belt-cooling water is difficult. if 15 not impossible, to realize; belts require a regular schedule of repl~cPmPnt through wear and warpage; belts do not m~int~in uniform contact and pressure to hold the casting firmly against the wheel as the casting proceeds around the wheel; and ma~imum width of cast stock is very limited due to belt fle~ure and warpage. Despite these disadvantages, most commercial production mar.hinPs employ a moving endless fle~ible metal belt to effect mold closure.

Disadvantages of segmPnt~d molds include mP~h~nir~l complexity with inherently very large number of cooperating parts and components; diffficulty in ~ sg necessary close tolerances between large number of interacting wheel sectors usually 2~ or 36, each sector including a clam-shell mold pair.
hl'et-ou.l~;. w~.er pipirig, ml ~h,-i1iç, 1 l~ng~,8 and ac~ iOI1; pru'ulcrlls ~viuh m~tai ~nd ~ia~ spiashes interfering with mold closure and mold-mold interfaces; and ad-liti- n~l tundish pouring clearance necessary 25 to accommo-l~te individual mold sector height above metal m~ni~cl~5~

Disadvantages of the static closure are inridPnre of sticking between the moving surface of the initially solidified stock and the stationaIy surface of the closure, resulting in possible skin ruptures and the like; also wear and operating problems asso~,iat~d with contact friction between wheel perimeter surface and the closure surface.

Casting wheels having an osçill~ting closure have also been proposed, for example, as described by patent publication JP-A-58205660, 30 November, 1983, in which a guide mold is osrill~ted in contrast with the casting wheel, but lacking provision for m~int~ining a constant controlled clearance with the wheel -1- AMENDED SHEFl CA 022607~8 1999-01-18 rim. High inertia is another common characteristic of prior art devices, maKing rapid oscillatiori difficult. ~ -A low-inertia closure assembly allowing rapid ~ srill~tion~ in combination with close clearance control, is lacking in the prior art. Further, the prior art lacks means for precise positioning of c~-nt~inm~nt rollers relative to the wheel rim, along with control of the c.J"t~;"",~.nt roller pressure against the cast section 5 below the mold, together with capture and disposal of spent coolant, as an integral part of the wheel assembly, rather than of a bulky e~cternal structure without coolant capture. ~)ractic31 means for ~h~nginsJ
the width of cast slab sections, without ~ ngin~ molds, is also not evident in the prior art of rotary wheel casters.

It is a principal object of this invention to provide a rotary wheel continuous casting machine 10 which does not have the disadvantages cited above for prior art casting wheels.

Another object is to provide a casting machine which realizes a much higher output per strand of equivalent cross-section than do conventional vertical, curved or horizontal casting m~ ini s, and thereby can involve less cost and comple~city for equivalent output.

A further object is to provide, in various embo~im~nt~7 a casting machine capable of casting billet 15 and bloom type sections for rolling into rod, bar and tubing sections and, in a modified embodiment, flat slab sections suitable for subsequent rolling into plate, sheet and strip products, with the invention particularly suitable for casting near net shape products such as thin slabs and beam blanks. Varying the width of slab section without c~nging the wheel channel is a related object.
.

An ~ ition~l object is to provide a casting machine in which the principal force and pressure 20 propelling the cast section forward is inherently effected at the location of the cross section being cast rather than by the pulling force and tension created by the withdrawal pinch rollers following e~it from the casting mold and cont~inm~-nt spray chamber area, thus ~limin~ting the main source of skin stresses and tears, with associated substantial increase in casting rate.

A still further object is to provide a casting machine capable of casting product with very good 2j surface and intemal metallurgical quality.

The invention Cu~ iSeS basic features in c~mmon with the prior art, namely a rotary wheel continuous casting machine c~ ing a rotary wheel incorporating a ~,h~ ial inner-radius mold wall with two parallel annular inner mold-wall edges, integral to the wheel rim; a non-rotating casting-mold sector comprising at least one rigid mold segm~nt~ illco~ol~ g an outer-radius mold wall having 30 two outer mold-wall edges which are parallel to, and interface with, said inner mold-wall WO 98/03286 ~ 7, j pc~ ~Ao~oo473e- a~

.~ ~ O ~ ' 7 .
edges~ formmg a c~sling mold envelope~ between said iMerff~nd outer-radius*~mold wDlls;
molten metal pouring means adapted for inlrodueing molten met~ proxi ate Lhe entry end*~of sDid mold envelope*~ to pDSS lhrouEII in lhe c~sting direcLion of eirculDr wllcel rotatjon and Dt Ie~st pDrtially solidify a cast mct~ seclion for exit from the exit end ( 70~ of sDid mold envelopc *~; eYtcmnl S support mearLs of s~id segment*4t adDpted lo maintain it in a substantinlly fixed nngular posilion in relation to said wheel; ~oe I ocal oscillation means eonn~cd lo said segment (10) adDpled to effecl relative annular oscill ~ti~n movement of sDid outer radius mold wDll*~lternDLely in sDid casling and reverse direetions in relation to sDid support means Dnd thereby between said ouler-rndius mold wall ( l 2) and said solidifying east section lhe invenlion comprising eombinnlion of lhcsc with nl IeDsl one 10 annular outer-rDdius mold-wnll cdge guide Lrnck~*Lntegrnl to said rolary whcel proxima~e the wheel rim nnd which is p~rnllel lo sDid pnr~llel mold-wall cdges*;~* ~nd Dt Ienst one guide trDck follower ( I S) fixed to s~id non-rotDling segmcn~ ( 10) which is m,~in~:lin~i in con~act wilh said guidc tr~ck (5 G) durin~ rotation of said whecl adDplcd lo m,~int,~in a subs~nti~llv const~ll dimcnsional clearance belwcen said irmer-rndius*tnnd ouLcr-rndius ( I ) mold-wall cdges A preferred embodimcnl includcs two of s~id guide trncks (5 G) one locaLed on eiuher side of lhe central plane of rotalion of snid inncr-radius mold wall*~ and at Ieas~ ~wo of said followcrs ( 15) for eDch of said g ude lracks (5 6)j Dnd said followcrs comprise cam rollcr rollowcrs ( l 5) which run in con~ac~
with sDid trDck~and incorpor~le me~ns of resLrDining relDlive movemenl in the a~iDI ns well ns rndinl dircclion of said cDrn roller followers~relntive to snid trnck and thcreby be~ween snid inncr (~
20 outer ( 12) mold-wnll edges during whoel rot~lion.

The r3dially guiding surfaces of eDch said guide track (5 6) typically face rDdially oulw~d5 from the rolation a~is of said wheel ~nd said c~m follower rollers~ride on lhcsc surfaccs and thereby do nol restrain said casling-mold segrnents ( 10) from movemenl in Lhe rDdiDlly outwDrd direclion In one embodirnent the wheel cDrries Dnother Dnnular bnl~ncine guide track ( 5) with fDces direc~ed rDdinlly 25 inwards compl~ ..L~y to each outw~rd-facing tr~ck (5 6) ~gDinst which rides at ICDst onc bDlancing cam follower (~7) attached lo said non-rotating cDsLing-mold sc~mcnt~ul~crcby m~innlining cont~c bctween said guide track followers~and said guidc trDck (5 6) by rDdially rcstraining movcmcnt of said casting mold segment*~in Ihe direction radially oulwards from said whccl In anoLhcr ~m~o~i nPn~ c casling mold sc~cr ~ ; Jj also cDrry a suppleme-l~y guidc ;rack*~ agDins; -~ i ch 30 fluid-pressure loDded b~l~nring cam followers~l*maint~in contlnuo ~ prcssurc ~nd contact of lhc guidc trDck followers*~Dgainst thc wheel rim with the b~l~n~ine followcrs ( I 14) in turn bcing au~pOI 1~ and po ;l i~.. r~ from D îîxed support of thc machinc housing or the like 1 hc supplcmcntary track prefcrably includes D reversc cDpturing IlDnge~l 16) for thc b ~l~nrin~ followcr cnabling lhc casting AMENDED S~E~

WO 98/0328G - ~ rCTJSA96100473. .
... . ..
. ~.' ' 1 . ~ .
seV"f ~1~ to be lifted off Lhe whecl and held in Sncprncion during inspcction or mnin~rnnn~r Mold s~g, ls*~most suitably C~ CS a rigid7 semicircular enclosure hDving two box sidc WDJIs (13), a box outcrcoverw311(143) nnd a box inner wnll c~ ing s3id outcr-rndju5 mold wDll*~on its face, in which said cxternal support mcans and s3id oscillation means ~fC at~3chcd to Lhc segmenl*43 5 ~hereby being adapLed to oscillaLc said outer-rDdius mold wall ( I ) back and for~h in LI1C circumferenLiat direction nbout a s~bst~nti ~lly fiYed nngul~r locntion on the c~sLing whcel periphery Sprny noz-,Jes t3X) arc suitably eon1~in~ wiLhin s~id enclosure dircctcd radi311y inwDrds, to sprny cool3nl dircclly ngninst said outer-radius mold walls*~3rld spent coolnnt is confined wiLhin Lhc cnclosurc nnd dischargcd Yia an appropriate outlet duct (10) AlLernatively, Lhc enclosurc may form a pressurized water jncket7 inLcrnnlly 10 b~led to provide ~n annulus for flow of pressurized coolant against Lhc ouLside of mold-wall ( I
Appropriately, Lherc are four studdcd cam roller trtck follo-vers ( 15), wiLh lwo mounLed lo project outwardJy from e3ch box sidc wnll ( 13) of segment ( 1 0)j ~nd lwo bnl~ncillg c3m rollcr assemblies, one mounted on thc ouLside of e3ch side w~ll ( 13) of segrnent ( I 0)-intermedi~tc bchveen s3id trDck followers ~ inrlllfiing means for applying a continuous con,~rollcd prcssure Or Lhc bnl3ncing rollcrs ('7) ngninst 15 the trncks~ Sllffirirnt to mmnt~nill thc guide tr~ck followcrs ( I S) in contim10l~C conL ct ~ iLh the outward-facing guide trackc (5,6) AnoLher asput of thc invention provides n con~inmrnt-rollcr selctor ('8) adjoining thc mold envelopc exit end~, similar to Lhe casting mold sector ( I I ) but carrying transversc cont~inmrnt id,cr rollers4~journalled in bearings (7 ~) supponcd by thc segrncnt sidc waJls ( 13), with faces posi~ioned 20 ~nd adapted to press radially inwards against the outcr face of Llte sccLion bcing cnst LO mnintain Lhe inncr face of Lhe section pressed against the inner-radius mold wall*~ the ~ngrnti~ll componcnt of Lhis pressurc nchng to exert a circumferentinl forward propclling forcc on Lhc secLion in the casting direcLion Menns 3rc providcd for conLrolling t~lc radi31 movcmcnL and prcssurc of Lhesc rollers (fi9) n~ninst ~hc fnv of thc scction bcing cast Other acpcct~s of the invention include appar3tus for positionin~ of mov3ble side-darn bars (44) ~ptcd for varying the widLh of tlte meLtl scction being c~st, a t~ngrn~i ~I de"~ ~u. ;**of thc ouLer mold-wall at the entry end*;~of Llte mold ~ .,lo~ to provide il"~,o~el 3cccss for introducing liquid me~l; a mold ~!f _ - glid;ng ~ ~U~ t ,."p,,! eable ~o spray coolcd sc!id~ ' coppe. c"sting wh~!
mold rings *3~, Dnd a universal hinge coupling assembly*~conn~~ing Dfljf~ining sc~nrnt~ ( 10, 90) which aJlows c3ch individu31 to tr3ck indcpcndcn~ly on thc whccl rim, without coupling b3cklash Various other objects, fe3tures and adv3nt~gcs of the proccss Dnd DppDrD~uS of this invcn~ion will AME~lD~D SHEET

W O 98~3286 PCTICA96100473 LeCOmel~r ~ ~ from the following detailed d~:r ant claims, and by ~ef~. e to theP , ,~g Ih~.u~g~, m which:
Fig. I is an illu t-_ ~v side view of a rotary wheel casting mschine . nL " ~nt sccording to the u~ lio4 i" ~ 'E a wheel sector itl~t~ dt~t in section, along the plane of rotation intc. ~ the mold 5 center line;
Fig. 2 is a section view along plane 2-2 of Fig. I i~.vv~Jv~dti~g a mold cavity of general shape suitable for the casting of blooms, billels, bars and rods l~ pl;~ to ~ t~livn of long 1,.- 'Fig. 3 is a section view along plane 3-3 of Fig. I;
Fig. 4 is a side vi-~v of the apparatus illustrated in Fig. 3; snd 10 Fig S is a ~-----r ~ ~ sv~ctiOn vicw to that illustratet in Fig. 2 ~ ~ ~ a mold cavity of generat shspe suitable for casting slsbs, plates, sheets and strip, ss 1")'~ ~ ' - to the ~,~ ' of flat-rolled p.~tu~,b, Fig. 6 is a psrtial front el., . a~ view of a - ' d .. ;d~h ~ f ' adapted for casting various nst-rolled product widths without ~' . e the wheel mold;
Fig. 7 is a s~-in~ ' view along plane 7-7 of Fig. 6;
Fig. 8 is an ill~t~ c partial sectional view of sn 5'~ e ab s ~' ' ~ ~- '- ~ ~ g î ~ idk r rollers in place of the outer mold wall in the lower portion of the non-rotsting casting sector;
Fig. 9 is a partial top view along plane 9-9 of Fig. 8 Figs. 10, and I 1 illustrate two vanations for c - ~ idlcr roller bearing support, p< ~ , and pressure a~
Fig. 12 is a cw~ g section view of that illustrated in Figs. 2 and 5, incorporating a mold cavity adapted for the near net shape casting of ~t~ ...,Iu. ' sections and the like;
Fig. 13 is a split cross ~ ~ .ll~t. _ of a c ~ roller segrnent - ' - ' t;
Fig. 14 is a partial side view of the roller segment of Fig. 13;
25 Fig. 15 is a side cl~ - vicw of an entry mold segment ass~l.bly;
Fig. 16isssectionvicwslongplane 16-160fFig. 15;
Fig. 17A is a section view along plane 17A of Fig. 15;
Fig. 1 7B is a section view along plane 1 7B of Fig. 15;
Fig. 18 is a section vicw slong plsne 18-18 of Fig. 16;
30 Fig. 19 is a side ek,~ generat 5 _ ~' view of an cn t s ' ~' 1~- e mold and roller segment bslancing dc~ices ;,ul",u~t directly from the fixed machine frame;
Figs. 20, 21 arld 22 illustrate detaits of the e~.- atly supported balancing hC '~ as shown in Fig.
19;
~ Fig. 23 is a section view of a suitabte segment s 35 Fig. 24 is a section view along plane 24-24 of Fig. 23;

Fig. 25 is a side el~ view of a ~ ~ roller segment n~ " ~.nt;
Fig. 26 is a section view along plane 26-26 of Fig. 25;
Fig. 27 is a seetion view along plane 27-27 of Fig. 25;
Fig. 28 is a section view along plane 28-28 of Fig. 25; and Fig. 29 is a seetion view along plane 29-29 of Fig. 27.

Referrin8 to the <1~.. ,, wheel hub f ~ 'y 1, is j- "~ ' upon bearings ' on fixed supports and the rot~lted by an 1~ r ul) ~ electro - ' ' or bydraulic drive unit, p.cf~_' ~ at variable and controlled speed. In the embodiment iUu~b tt d, the rotary wheel structure c~ a ~ - ' ' ' - body 2 with radial stiffener ribs 19 s, e between hub I and Ushspcd wheel rim 24, also 10 defining cooling waterJadcet annulus 4. A typical wheel size would be 2-4 meters in ~' , although a wide range of sizes are possible. It is to be ,, . ~ ' that a b~ ' part of the ~.. ,~s ~re diagrarnmatic only, par~cularly I~g~.g aspeets known in the art. Wheel mold cooling water is introdueed, and spent wat.,r dia~,h~ d, via ..~,.y,. A rotary union ~ i into hub r ~Iy I, supplied to and retun~d from whoel rim 24 via a~ r uj)~ ' ~I wheel mounted water pipes 35.
I S The detsils of this aspect .,nd ..~s other features of the whoel casting machine are not shown or d~,. .I,cd herein, being well known in the art, and wiLh many known and obvious options as to selection and CO~b~ available.

Casting whoel rirn 24 carries annular inner radius ~1 d .. ~ " support rings 3 and also two outer-radius - ' ~ 1 edge g~ute tracks S, 6 r,~ .ng .,~ ' radial surfaoes, di~cted radially outw_rt, 20 one on either side of axial central plane of rotation 7 of the inn~ radius molt w. ll, in the c ~-jll ~ ' Theinnerr.dius ~ 8mayalsoulcludesidefaccsl8 C " g radiallyo.~l.. ' as in the ~ ~, ~ ' illustrated for casting of a square cross section, ~ r u~latCIy at right angles to the inside faee of mold wall 8. The mold wall usually of copper or copper alloy, is fastened to support rings 3 such as by saews spaced around the wheel rim pe. "~ y. On most casting wheels, side faces 18 are 25 tapered to div~ge h ~ lyO.Jh. '~, for - . ~t, at a slope of I or 2 por cent, thcreby r ssuring ' - for I ~ - ' t;s~,h~ b., of the c. st metal se.,tion at exit 20, without edge friction or binding between the section and side faces 18.

N., r_ C casting mold soctor 11 i.~,u. outer radius DIC~.. " 12 as its inner face thcrcby forming a casting ~Id c..~clo~ 43 bctwecn said ir~r 8 and outcr 12 mold walls Sector 11 30 yc~- u 1~ asinglcrigidc..~ ~f~ moldsegmentorbemateupinmultiplemoldsegments 10.
In thc ~ ' ~ ' 1 ill~h - ~, sector 11 c ~ es thrcc rigit r ~ '- mold ~ l 0 having thc abutting cnds of scgmcnt sidc walls 13 ~nt~kavcd and co ~ i togcther by hinge pin~A 14. E~

scgmcnt 10, in tLLrn, has four cam track followers 15 mouDtcd on sidc walls 13 as two oppositc pairs, ~ ~ - ' to run in contact with guide tracks 5,6. A~ u~ y, thc rollcr rnounting studs u~a c~ L ' 1" 16, to cnable casy ~ ~ I ' of thc clwance 17 bctwe~en thc ~ r ' g inncr 9, and outer 21, paralld annular -'' .. 'I edgcs. At, of thcsc k - . in thc ' - ' 5 jl' i may bc cffectcd manually using an Allcn wrench applied to a ~ 1~5 ~' sockct in thc stud cnd of cam roller 15, whilst ~ g the clearanccs with feclcr gauges. ~! ' - down to the 25 micron area can bc ~ C~rd without any contact across the intcrface, thus r ' e a - mold wall whilst avoiding wear and galling of these mating surfaccs. At typical casting t~".~ s a~ ~ ~ J~ing the liquidus, the r b; ~ ' p7 ~ _ of surface tension, viscosity and transient s~ in the 10 prescnce of cold, high~u.,li~,ly mold wall material, gencrally then preclude cntry of metal betwecn the mc'~ c~g~ faccs proximatc the ,....,.;c...~ The rollcrs 15 arc also provided with flangcs 22 to ridc against ~u~ -'iL ~ guide surfac~es 23, u~u~lJu~ into guude tracks 5,6 to maintain ~ _~ (side-to-side) outer ~ r~i~mPn~ s~ y ~ - brackets, or thc like, of course may be cmployed to z ug t, or as r~ ~ to, the ~ 16 for ~j oftrackfollowerpositionandthereby :1 17. Outler-radiusmoldwall 12maybe ~ ly ~ ~, for . "' e, rocessed betv"een thc edges to provide a rounded billet corncr and eliminate thc sharp right-angled comcr at 17 ' iaL~, of a flat platc shcc, a sourcc of possible rolling mill difficulty.

In order to holt each molt scgment 10 in place u~d assune - contact of cam rollcrs 15 20 with g ude tracks 5, 6 dwing the course of rotation and ap~ llc of prcssurc from the scction bcing cast, the inncr IIJ ~.all support rings 3 also includc a second set of annular b-' C guidc tracks 25 dirccted ratially inwards, against which ride b~l g cam followers 27~ ln the . L- ' I illustrated, thcre is one sct c~ p~ .g twû of these rollas 27 applied to cach hinged mold segment 10, each set -g thc co .~ r ~' g two sets of rollers 15, leveraget to apply ~, r ~ ' ' Iy cqual force to 25 each sct. Thc rollcrs 27 are mountet on ' -' L slide arm 29, guitet for . in the ratial direction only within supp~t ring sidc brackct 30, ant stroked by b-'- g cylinter 31. Such t-' B
actuators can bc powcrcd by any al"" ùl ~ fluit, but co...~ gases such as air have a clcar atvantage when in a prcssurc~trol modc of this app~ , by _ . C for whecl and traclc ;r;~y and .---; it~ c without usc of s ,,' ~ p-u~ ~ or scrvo control 30 valvcs or thc likc to meter fluids back ant forth. O5ci"a ' of segrnent 10 along the path definet by cam rollers 15 along tracks S,6 is cffected, such as by h~ ' ' osc~ 32 acting bctwecn ~~ ' '- brackct 33 fixod to scgrncnt 10 and CA~IIY fixcd suppon brackct 34. A widc r~ngc of forms of hydraulic and electro ~ ' osc~ rs as well as casting control systerns, arc known in the art of c casting W O 98~3286 PCT/CA96/00473 The inner mold walls are 1" ~ foree water-cooled with water suppliet and returned via at least one set of ~ water pipes 35. Esch segment 10 is supplied with eoolant, usually water, via an inlet through box side walls 13 or outer co~er wall 143 into enclosed header pipe 37 feeding coolant spray nozzles 38 which direct the coolant spray 39 to impinge on the exterior surface of outer 5 rstius 'c~ . " 12. Spent coolant flows by gravity through outlets 40 into 1~ r U}ll '~' hosing to a sump or the like, usually for ~~u~ ' Ease of eoolant e..~ , as compared to flexible belt casters, is also to be noted. RL..W._' 'r eover plates 41 i,~a~ ' into ~ ~ 10 provite access to the sprays f~ - -e ant the like, as well as rotation _ ~ of cam roller eccentric ~ ' g 16. These ~,~,f~_"y inclute quick-release ~ a ant sealli.

Start-up and ~r are ~ d~ e i in Y~ "y the sa ne mann~ as a COI.. - ' flexible-bdt - ' ~, molten metal being pouret from tundish 36 into the entry en i 42 of mold ~.. _lq~ 43 and the cast metal section ~ ilhb~.... from the exit end 20 by means of powerei ~ .. ' rolls 26, details om~tted as ..~1! ~own.

Fig. S !-- _ an _ ' - " adaptei for casting of thin slab products. Except for the shape 15 and size of the mold c..~_lopc, it will be seen that the basic machine features are ~ y the same as those for casting billets and blooms, as i" I by Figs. 2 and 3.

Figs. 6 ~nd 7 illustrate a ! , r ~ r ' to facilitate the casting of vsrious slab widths without major c~l,-;p~ or ~-~hs~ Ratha than c - = of the cast section between side faees 18 Of the inner radius mold wall 8, the side faces 89 Of partially so~ ifi~i thin slab 61 20 are confinP~ between the two movable mold side-dam bars 44, also r ~ and ' - i on an arc to a ~ ~ fit betvllocn irmer 8 and outer l2 mold wall faces. Bars 44 are confined l~ _ly between side r'i" brsckets 47 of movsble carriage 46, snd ~.u.,~.~.c -"y by the I between pin 50, ~s fixed to c~rriage 46 by bracket 48, ~nd mold o;~l- ' ~ " braclcct 49. Carri~ge 46 is carried on two pairs of ~ ' rollas S3 which run on ~ ~_~ guide track S 1, providmg linear guided 25 ~ ._ only in the transverse direction. Track S 1, in turn, is fasta~ed to track support bracket S2 attached to segment 10, and thereby transmits the c~.c~..&g circumferential oscillation ) ~ ~ of thc outer rnold wall to mold side~n bars 44. Rollers 53 are preferably mounted on s;; i., bushings 62, providing for easy and accurate adjus~nent of alignment and cl~ with guide track 51. By providing a close fit between side brackets 47 and bar 44, these bwhings also facilitate procise 30 ~ t~ of the transv~se slope of bars 44.

Carriages 46 are fixed tra.~ _ly by threaded take-up nuts 59 riding on support bracket 60, vsriably F ;' ;-~i axially by rota~ion of oppn~ threaded carriage drive scre vs 58, as driven by ccntrally locsted hydraulic trsverse motor 54. As ill~tl ~, this is a ~ . ' ~ motor ~ on splined drive shaft 64, as csrried between flange bearulgs 56 of motor support bracket 55, in turn fixed to the outer wall of box G~lu~ 0. Torque couple-arms 66 act agamst torque pins 63 to prevent motor body rotation. Shaft 64, Dn turn, is cn ) ~A~' ~1 at either end to drive screws 58 by c~up' n&~ 57. Mûld s~ bar 44 1~, upr.~tely c~,.,.~,, .ies a ~ - ~ ' tube of copper alloy, blanked off at both ends, with coolsnt p..,..d~ via llexible hoses c ~ ~ into coolant inlet and outlet s: ~ - 45, one of which is internslly piped to the bottom ~ uly of ~ ' . bar 44. The faces of bar 44 may slso be drilled for lubricant ducts and outlets, to provide face h ~ ~i such as by rapeseed oil during 10 u~

During casting, it is well known that the stock cros~ p.u~ shrinks with cooling snt so~ - during its tescent wilhin the mold, and slso that the outer Isyer of "skin" of the casting is e~ ly self-sealing once a co-~ surface has been formed around the casting perimeter, unless stresses are present ~ - ' to create a rupture and ~ ' "break-out" of rnolten metal In 15 w..~. : ~' o~sei~ n~ mold casters, ~ y all of the withdrswal lorce is usually applied ~o!'- ~ in~ tischarge from a roller sprsy cha nber, or ss assisted by a selected few driven rollers within the sprsy chamber t~ ~ ~ area. The forccs are thus applied at a remoto point from the solidifying section st mold exit, or a limited number of selected points along the casting Iength, relying on bar slcin /eu,,"~r~;,iu~ strength between these points to maintain cnsting integrity. Because of the stresses 2û this creates, a n ' "._ly thick frozen skin is y at mold exit, ' -'ly limiting the .
cssting speed, to allow s ~ time for fo. of this skin.

Within the mold e..._lopc, a taper can be added lo the outer-radius mold walls 12 by ~ ~,1 P e the portion of the fsce of oulcr-radius mold walls 12 within sides 18. In addition, Fig. 8 shows a varistion g a containment roller wheel sector 28 i.~-~ e - roller .. ,5, - ~ 90 which carTy 2S ~inm~t idler rollers 69, in place of outer r~dius -~ 12, with coolant sprays 39 thereby directly upon the surface of the csst rnelal section. Along the arc of wheel sector 28, the forces csn lhcn be applied directly by the rollers 69 at the cross section being cast, by g ststic L ' contact and pressure between the stock slcin surface and the inner radius mold walls 8, as they move and propel the casting along at esscntially identical surface speod. Tensional casting stress is thereby nearly elin~inated, allowing a very substantial increase in praetieal easting speed for similar effeetive mold lenB~s. Sinee the casting wl~d rotation is funishing the propulsive force, the powercd withdrawal rollcrs 26 src also usually supcrfluous. For casting wide slab scctions, rollcrs 69 msy also bc split into multiplc lengths .. ~.~.u. e ~ .. ~liate ~ ~, a~ ' g CA 022607~8 1999-01-18 It is obvious that minor leakage of spent cooling water can take placè via cleararices I~l, in the '-absence of sealed contact between side walls 13 and inner mold-wall edges 9. A supplementary seal may be added to minimi~e this leakage (not illustrated) Suitable practice could provide on the order of a meter of wheel arc, e.g. one box enclosure 10 at the top, as illustrated, incorporating outer mold ~valls 12 ~nd the two bottom segments 90 be equipped with rollers 69. It will also be obvious that only the top sector l l need be oscillated, as an option. One or more of the cont~inm~nt rollers 69 may also be applied to effect thickness re~ ction of the cast metal section by increasing the roller pressure, optionally including liquid core rerl--ction when the section is only partially solidified. These rollers may be undriven idlers or, alternatively, powered so as to rotate the roller surface at a ratc s~nchronized with the surface speed of the 10 cast met~l section.

For starting of casting, a starter block or starter bar is usually inserted into the mold cavity, designed to move in unison with the wheel once casting cnmm~n~ PS. When the block can be confined between the wheel rim and cont~inm~nt rollers, only a relatively short starter bar is required or, alternatively, a short starter block head having a longer, flexible elastomer bar att~rhP~, which can be 1~ hollow ~Id col1toured to fit snugl~ .n the ~vheel groove, in order to assist with section guidance following exit from the machine. The block characteristically includes a protruding top hook or claw designed to hold the starter block and freshly cast metal together in one piece until they are separated following exit.

One practical diffficulty in the casting of thin slab product is the desired narrow slab thi~kn~5s in relahon to the dimensions of submerged-entry nozzles. Figs. 8 and 9 illustrate means to mitigate this 20 problem by a funnel-shaped departure on only the outer-radius mold wall at the nozzle 65, wherein wall 12 is e~t~ndPd vertically and t~ng~onti~lly upwards, as at 67, at right angles to the wheel horizontal center line 80 in the plane of rotation of the wheel, at the transverse location of submerged entr nozzle 6~, on either side of which mold-wall 12 is graduated into the straight-sided cylindrical wall, in the form of a half funnel-segment 68 with maximum width at the location of molten metal entry 42. In the embodiment 2~ illustrated, where the thickness of nozzle 65 is nearly equal to the casting thickness, it may be seen that adequate insertion is obtained, in~ ing good wall clearance, by vertical insertion of nozzle 6~ parallel to this vertical funnel wall.

Fig. 10 illustrates a co"~;l;"",~ " roller positioning and pressure-adjustment assembly 127 for L~ v~.~e cont~inm~nt rollers 69 against the outer section surface. The roller shafts 71 are journalled 30 within sealed cartridge bearings 72, riding in guided chocks 73, as recessed in the structure of side-walls 13 of segment 90. The chocks 73 and thereby rollers 69 are loaded and retracted by air or hydraulic cylinders 70, through which the position or force of each roller against the cast metal section surface 104 .. -10-AMENDED SI~EFr CA 022607~8 1999-01-18 n n ~ '' can be adjusted.

Fig. 11 illustrates another embodiment of po~itioning and pressure-adjustment assembly 127 for rollers 69, whereby the outer race of bearings 72, mollntP,d on roll shaft 83, are carried within an eccentric bushing 76. Rotating means for bushing 76, such as a pivotally mounted cylinder or rotary actuator (not 5 shown) actl~tinD lever arm 77 of the bushing, can effect both controlled pressure and controlled position of roller 69. Cooling water can also be supplied via rotary union 78 through internal ducting within shaft 83 to roll water cooling annulus 79. The bearings 72 can also be located outside of wall 13 in other embodiments. such as by extension of shafts 71~ 83 shown in Fig. 10 or Fig. I l .

Fig. 12 illustrates an embodiment in which the mold envelope is in the form of a near net shape 10 structural beam blank. It ~vill be evident that a variety of such mold shapes and sizes can be applied as variations on the basic features of the apparatus of the invention.

Figs. 13 and 14 illustrate a cont:~inment roller segment variation, in conjunction with a wheel in which a spmy-cooled copper block mold ring 93 comprises the wheel rim, combining the fimctions of inrcr mold wall 8 and annular outer radius mold wall edge guide track 6. Cam roller track followers 15 ride 15 directly on the mold rim, (guide track 5,6) with flanges 22 riding against bevelled edge surface 94 of mold ring 93. Balancing rollers in this case may more conveniently be mounted to act between the roller segment and a fixed support attached to the machine base, backing frame or the like, rather than the rotating wheel. Mold ring 93 is appropriately cooled by means of inside coolant sprays 159 and side sprays 160. Roll shaft ~4 is fixed, except for rotahon together with eYtPrn:llly eccentric bushmgs 85 keyed 20 or otherwise fixed to shaft 84, and also concentrically supports the inner race of bearing cartridge 72 carrying roller 69 on the outer races. Pneumatic or hydraulic cylinders 91 function similarly to rotarv actu~tors by stroking eccentnc lever arm 92 to control position and pressure of cnnt~inmPnr rollers 95 against the outer surface iO4 of the soiidifying cast metai section. Thls arr~ngPmPnt ~rilit~tps close control of the face position of roller 69 in rela*on to surface 1 û4, such as by precise pocitioning of cylinder 25 91, for example, employing posi*on sensors for the rod of a hydraulically operated cylinder, in~ ing a tr~ncd-lcer to accomplish remote electronic ~lt- m~*c posi*on control, to m~int~in set-point posi*ons. In a case where roller pressure control only is deemed required, the rollers could be directly and individuallv supported with reference to the machine base or backing plate only, ~ rollers l j,22 and allowing radial roller position to follow the vari~tione in position of cas*ng surface lû4 as the wheel rotates, 3û cylinder 91 being operated pnPllm~ti~lly. I~ever a~ns 92 of adjacent rollers may also be linked together providing for actll~tion of two or more rollers 69 with one cylinder, but with the poten*al AMENDED SHEET

,, , . . .. . . .. _ _ dissdvantage of unequal roller p.~u.es or stock-to-roll~ ~'~ e 1-1 orter to sllow rvll t L ~ g, in r t with a full ~ t~_ on awsy from the wheel for - ~ and the like, a three-position duplex cylinter or c~ _' coult vc - , ~ i in place of single cylinder 91.

Figs. lS, 16, 17A ~ 17B and 18 illustrate ld ' ~' or dternative embodiments of the molt 5 segment . ~ _- ~ 10. This includes a ~ ,~u--~ wster-filled inlet chstnber 106 separstet from outht cbamber 107bydivitingwall 108,-.~. Ebaflleplatc lO9,asheltinpositionbyd~_.. t-' -110, to ~sure high ~_l~ity water flow within annulus 1 1 1 for cooling of outer radius mold wall sboe 1 12.
Draw-bolts 1 10 sre sealed by wsy of sn c ., vlJ- l 0-ring gland 1 13. The outer ratius mold wsll shoes 11 2 are sealed by an el~ coated metal gasket 1 30 ant fastencd in position by s~ews 1 31 . Among other features ill~b 1' ~ 1 is a cent~l mold overflow channel 149 st mold entry, to reduce the risk of molten metal j~ g the entry junction between wheel and outer mold wall, should o . _. nO .. ~ - 1 ~ ~ - occur during casting. The b-' ~ ,g assc..ll,ly is baset upon an external support frsme, to locslte and control the force of nanged rollers 114 agsirLsl ~-' E track 115. Rollers 114, in tum, sre rnounted with C4 but csptured with~n ~ lio.~ nange 1 16, thus providing for retrscting the s~ c rsdislly~5 outwsrd and off the wheel to hold them in eCsen~ y fixet position when desired for mold i_, ~ ~, ~' _ r of wheels snd the like.

This segment e .~ ~ ~ includes ' ~ -' rsdiD.I ~ ~ of trsck fo~ 15, in view of the much lower cost of re -~ ~ ,1 ~ E used outer ratius mold wall shoes 112 sRer use; in c ~ r '- Wilh .~,lr ~ wilh ne w ones. Adj-~c~in~ scrcw 122 effects r ~ -nt of pillow blocks 121, to be held in 20 position by locking screws 123. In order to avoid potential a~cial segment yawing snd vil.. ~, one of thefollowers 15ofescho~ Cpii isspring-p..,l~ ub~ bywsyof~ 1, spring 124 acting between cap 125 and lhc facc of linear bushing 126, thus - ~ ~ c -- running contact bet veen flanges 22 and inner mold cdges 94. Sid~ 1, ' follow~ rollers, having onc of each pair spring or fluid pre-loaded is a more e' ' ~ ~.al.._ nol illustraled. A single i ~. ' hinge-25 coupling z~ ly 120 connects adjacent ~ ~ togcther, camprising opposed spl ~ - ' plain ~rust bearings 117, th.. g against end nanges 82 Ors-~ nt~: 90 confined by brl~ . ass~ bl~ 118 and at an r ~ ~1~ tistance of s~p~ ~ bctween nan,ses 82, and also ~ pre-load spnng 119 wilh spring rate force s~firient to eli - clc.u, ~ and any bac~ h, whilst allowing both h ~ and angulDr mi~ i~ment between " ' As applied to mold segments 10, in orter to 30 ~ mold shoe tllermal ~ s in thc evcnt lhat adjacent mold shoe ends are closely butted together at st~rt-up. Belleville s~.ulg-wpshcrs are ap~,..",. - 'y ulserted betwo~ the nuts and bearings 117, A~ si~d to balance the o~ ag force of sprin~ 119, and with r ~ - - ~' travel s~ff - ~ to ~ ' ~ the ~ after start-up.

CA 022607~8 1999-01-18 o ~
.' ' ~ ' r7 " ~ 7 ~ ~ --Fig. 17B also illustrates the variation of a contoured transversè prof~e of Vouter-radius mold wàll 112, in which side faces 18 are e ctended past clearance 17 into a reeess of outer mold wall shoe 112. This elimin~tes the acute angle at the seetion corner entering into gap 17 and also allows a rounded corner 127 of the cast metal section. As otherwise illustrated to be flat, any metal flash into clearance 17 between 5 shoe and wheel oeeurs at the seetion comer, rendering it diffieult to hot roll or e~ctrude without introdueing lap surfaee defects or the like, whereby wheel-and-band casters usually mili vffthe corner flash prior to hot working. Contounng of the outer mold shoe face also e~ctends the range of shapes and sizes whieh can be cast.

Flexible band closure casting wheels commonly used for casting eopper and ~lumimlm billets and 10 rods normally utilize a mueh larger seetor of the wheel than those for steel, that is, most cnmm~-nly, entry is at 1-2 o'cloek and e~;it at 9-10 o'elock position, rather than 3 and 6 o'elock. Fig. 19 illustrates the invenhon as applied to such a wheel, and with segment balancing effected by an air cylinder 145 mounted within a square tube 146, the e:itension of which carries the segment b~ ncing rollers 114, and guided by sliding bearing pads 1~4 riding against the inner walls of another square tube 147 fi~ed to machine frame 15 148. Ossillator crank arm 99 transmits osci!lating motion to mold segments 10. ~s ,ener~ted b~ cscil'ltor drive assembly 156, which is also supported by fi~ed machine frame 148. Figs. 20, 21 and 22 illustrate details of the segment balancing units as appropriately cantilevered out from a backing frame also supporting the main casting wheel hub and bearings. Please note that piping and wiring and the like is omitted from Figs. 15-22 for clarity.

Fast casting speeds require rapid mold closure oscillation, towards m~int,lining sufficiPnt negative strip with minimal surface osei~ tion marks. Figs. 23 and 24 illustrate a suitable oscillator, in which housing 95 carries bearings 96 for rotation of drive shaft 97 bv means of adjustable speed hydraulic motor 98 as an altemative to air motor 74 with gear bo~c and belt drive 75, as illustrated in Fig. 19. Eccentric cranic e,ctension 99 revoives around the center a~cis of shaft 97 carrying connPeting rod dnve bearing 105.
In order to adjust the stroke length as infli~tPd by the graduated index 155, location ring 154 of cantilevered stub shaft 150 is rotated by nut 151 and locked at the desired stroke length by bolted locking plate 152. Crank 99 may be connPeted directly to mold segment wrist pin 153. Thus, a sinusoidal reciprocating osei~ tion~ of selected adjustable stroke length, is tr~nemitted to the mold segmPnt~.

Figs. 25, 26, 27, 28 and 29 illustrate additional or alternative embodiments ofthe roller segment apparatus 90. The cr~nt~inmpnt roller positionin~ and pressure-adjustrnent assembly 127 eomprises drive eCcpntric disk 137 and driven eeeentrie disk 138 whieh are equally eeePntnc to roller shaft 84 and keyed to ~ it by parallel cross keys 134 and 135, as p~AE~

CA 022607s8 1999-01-18 fixed by dowels 136, thus comprising a rigid f ' ~y to maintain parallel rotation of thc shaft 84 axis about the axis of disks 137, 138. C~: ~ idler roll~ 69, as s.""~ by bearings 72, is then about shaft 84 by L ~ -' contact with thc moving facc of thc cast mctal sec~ion. Cu~ t~;c disks 137, 138 rotatc within ~ ~ ;c L ' )g 161 mo~ted within axidly alignet circular ~ i ~ in 5 oppositc box side wdls 13, and thc rotation of drivc c~tl.c disk 137 is cffcctcd by a rotary actuator assembly. In the csnbodiment illustratcd, this cosnpriscs t shaft 162 jr ~"~ within bcarings 163 of housing 164, which is bolted to side walls 13 with axis concc~lb,~, to disks 137, 138. S.'neumatic or h, ' ' - cylinder 91, via crank arm 165, rotates shaft 162, which L - e 'Iy purc torsion force to disk 137 by way of splined or sq~e shaft end 166 ~ the like. Thc c stroke of cylintcr 91 is 10 lisnited by ~ of thc rollcr 69 ~ against whecl rim tracks S,6. Thc le~a stroke limit, as showr~ is adjustable by stop-screw 169, as carried on brackct 168 attachcd to housing 164, against pin 167 which rotates integrally with shaft 162. Operatcd pncwnaticalb, this provides for prcssure control of rollcr 69 sgainst cast metal section surfscc 104 during stroke . ~,.., . ~ g for section ..,~ . . ~
~' -' and swfacc u~c" ' itics whilst -- e c~ .. Iy constant roll~ force. Al~. .~
15 O~ e with cylinder retracted or zero - air pressure, providcs for ~ ~ ;;t; ' only, cven allowing the cast section to relense frosn the whcel, _ - ~" e to the setting of stop-scrcw 169. The rolla segment r ' 1~ 90 iS adapted to providc combined air-watcr cooling via air fi~ 139 and water manifold 140 fecding spray block 141 into air-most nozzlcs 142, as wcll as spray watcr only, onto rollers 69 vi8 watcr nozzles 144. As shown, thesc s~ ; are not t '- i although they could be so 20 arrangedifdcesired. Segment-to-scE,...~ hingingandsegmentb-'- ~ e~ arc '~6 t~
those of the mold s~ 10, 8s illu~b_ It will be appreciated that a rotary wheel casting machine has been d ~ ~ ikd and " _ - ~ and that ~ r ~ " ~ ant ~ - may be matc by Ihosc skilled in thc art, without t -ps i ~e from the scopc of the .. deflned in the . r ~ ~ claims.

Claims (31)

I Claim:

1.A continuous casting machine comprising a rotary wheel incorporating a circumferential inner-radius mold wall (8) with two parallel annular inner mold-wall edges (9), integral with the wheel rim;
a non-rotating casting-mold sector (11) comprising at least one rigid mold segment (10) incorporating an outer-radius mold wall (12) having two outer mold-wall edges (21)which are parallel to, and interface with, said inner mold-wall edges (9), forming a casting mold envelope (43) between said-inner (8) and outer radius (12) mold walls;
molten metal pouring means adapted for introducing molten metal proximate the entry end (42) of said mold envelope (43) to pass through in the casting direction of circular wheel rotation and at least partially solidify a cast metal section for exit from the exit end (20) of said mold envelope (43);
external support means of said segment (10) adapted to maintain it in a substantially fixed angular position in relation to said wheel;
reciprocal oscillation means connected to said segment (10) adapted to effect relative annular oscillation movement of said outer radius mold wall (12) alternately in said casting and reverse directions in relation to said support means and thereby between said outer-radius mold wall (12) and said solidifying cast metal section, in combination with:
at least one annular outer-radius mold-wall edge guide track (5,6) integral with said rotary wheel proximate the wheel rim and which is parallel to said parallel mold-wall edges (9,21); and at least one guide track follower (15) fixed to said segment (10) which is maintained in contact with said guide track (5,6) during rotation of said wheel, adapted to maintain a substantially constant dimensional clearance between said inner-radius (9) and outer-radius (21) mold-wall edges.

2. A continuous casting machine according to claim 1 which includes two of said edge guide tracks (5,6), one located on either side of the central plane of rotation of said inner-radius mold wall (8), and also including at least two of said guide track followers (15) for each of said guide tracks (5,6), and wherein said followers comprise cam roller followers (15) adapted to run in contact with said tracks (5,6).

3. A continuous casting machine according to claim 1 which includes two of said guide tracks (5,6), one located on either side of the central plane of rotation of said inner-radius mold wall (8), and also including at least two of said followers (15) for each of said guide tracks (5,6), and wherein said followers comprise cam follower rollers (15) which run in contact with said tracks (5,6) and incorporate means of restraining relative movement in the axial as well as radial direction of said rollers (15) relative to said track and thereby between said inner (9) and outer (12) mold-wall edges during wheel rotation and in which the radial guide surfaces of each said guide tracks (5,6) face radially outwards from the rotation axis of said wheel, and said cam follower rollers (15) ride on these surfaces and thereby do not restrain said segment (10) from movement in the radially outward direction, wherein said wheel carries another annular balancing guide track (25) with faces directed radially inwards complementary to each outward-facing track (5,6), against which rides at least one balancing cam follower (27) attached to said segment (10), thereby maintaining contact between said guide track followers (15) and said guide track (5,6) by radially restraining movement of said segment (10) in the direction radially outward from said wheel

4. A continuous casting machine according to claim 1 wherein said mold segment (10) comprises a rigid, semicircular box enclosure having two side walls (13), an outer cover wall (143), a top entry-end wall and a bottom exit-end wall, and an inner wall carrying said outer-radius mold wall (12) on its inner radius;
coolant spray nozzles (38) contained within said enclosure directed radially inwards, and means for pressurized fluid coolant supply to said nozzles (38), thereby being adapted to direct coolant sprays (39) directly against said outer-radius mold wall (12); and a coolant exit duct (40) proximate said bottom exit-end wall adapted for draining spent coolant from within said enclosure by gravity.

5. A continuous casting machine according to claim 1 wherein said inner radius mold wall (8) is integral with an annular casting wheel mold ring (93) and said guide track (5,6) comprises the annular rim of said mold ring (93).

6. A continuous casting machine according to claim 1 wherein said inner radius mold wall (8) is integral with an annular casting wheel mold ring (93) and said guide track (5,6) comprises the annular rim of said mold ring (93), which includes coolant sprays (159) directed to impinge radially outwards against the inside surface of said ring, adapted for removal of heat conducted radially inward through the body of said mold ring (93).

7. A continuous casting machine according to claim 1 which includes two of said guide tracks (5,6), one located on either side of the central plane of rotation of said inner-radius mold wall (8), and also including at least two of said followers (15) for each of said guide tracks (5,6), and wherein said followers (15) comprise cam follower rollers (15) which run in contact with said track (5,6) and incorporate means of restraining relative movement in the axial as well as radial direction of said rollers (15) relative to said track and thereby between said inner (9) and outer mold-wall edges (21) during wheel rotation and in which the radial guide surfaces of each of said guide tracks (5,6) radially outwards from the rotation axis of said wheel, and said cam follower rollers (15) ride on these surfaces and thereby do not restrain said mold segment (10) from movement in the radially outward direction, which also includes a balancing assembly for said segment (10) comprising:
a support frame (147) mounted on a fixed external support (148);
a movable carriage (146) guided from said support frame (148) carrying at least one balancing cam roller (114) positioned to exert pressure radially inwards against an annular track (115) integral to said segment (10) and thereby maintain each of said guide track followers (15) pressed radially against said guide track (5,6) during rotation of said wheel; and controlled radial pressure actuation means (145) for said carriage (147) adapted to adjust and maintain a controlled radial force of said balancing cam roller (114) against said track (115) during operation whilst allowing reciprocating annular oscillation of said segment (10).

8. A continuous casting machine according to claim 5 or claim 6 which includes two of said edge guide tracks (5,6), each of which comprise opposite edges of said mold ring (93), one located on either side of the central plane of rotation of said inner-radius mold wall (8), and also including at least two of said guide track followers (15) for each of said guide tracks (5,6).

9. A continuous casting machine according to claim 5 or claim 6, which includes two of said edge guide tracks (5,6), each of which comprise opposite edges of said mold ring (93), one located on either side of the central plane of rotation of said inner-radius mold wall, and also including at least two of said followers (15) for each of said guide tracks, and wherein said followers comprise cam follower rollers (15) which run in contact with said track (5,6) and incorporate means of restraining relative movement in the axial as well as radial direction of said rollers (15) relative to said track and thereby between said inner (9) and outer (21) mold-wall edges during wheel rotation and in which the radial guide surfaces of each said guide track (5,6) face radially outwards from the rotation axis of said wheel, and said cam follower rollers ride on these surfaces and thereby to not restrain said mold segments (10) from movement in the radially outward direction, in combination with:
external radial balancing means acting from a fixed support external to said wheel, adapted to maintain contact between said guide track followers (15) and said guide track (5,6) by radially restraining movement of said casting mold segment (10) in the direction radially outwards from said wheel.

10. A continuous casting machine according to claim 1, 2, 3, 4, 5, 6, or claim 7, wherein said mold segment (10) comprises a rigid, semicircular enclosure having two side walls (13), an outer cover wall (143) and an inner wall carrying said outer-radius mold wall (12) on its inner radius, and in which said external support means and said oscillation means is attached to said enclosure (10) by way of said oscillation means, which is thereby adapted to oscillate said outer-radius mold wall (12) back and forth in the circumferential direction about a substantially fixed angular location on the casting wheel periphery.

11. A continuous casting machine according to claim 1, 2, 3, 4, 5, 6, or claim 7, wherein said mold segment (10) comprises a rigid, semicircular enclosure having two side walls (13), an outer cover wall (143) and an inner wall carrying said outer-radius mold wall (12) on its inner radius, and in which said external support means and said oscillation means is attached to said enclosure (10) by way of said oscillation means, which is thereby adapted to oscillate said outer-radius mold wall (12) back and forth in the circumferential direction about a substantially fixed angular location on the casting wheel periphery;
and fluid coolant spray nozzles (38) contained within said enclosure directed radially inwards, and means for supply of pressurized coolant to said nozzles adapted to direct coolant sprays (39) directly against said outer-radius mold walls.

12. A continuous casting machine according to claim 1 carrying a radially outward-facing edge guide track (5,6), and a radially inward-facing balancing guide track (25) on either side axially of said wheel rim, each parallel to said annular mold wall edges (9,21); and wherein the mold segment (10) comprises a rigid enclosure having two side walls (13), an outer cover wall (143) carrying said outer-radius mold wall (12) on its inner radius;
four studded cam roller track followers (15), two of which are mounted to project outwardly from one said enclosure side wall, one on either side of the transverse center line of said mold segment (10), and two corresponding roller follows (15) mounted on the opposite side wall, to run in contact with said outwardly-facing guide tracks (5) and (6) respectively, two balancing cam roller assemblies, one mounted on the outside of each of said enclosure sidewalls, intermediate between said track followers (15), comprising a follower roller (27) supported from said box enclosure and riding in contact with said inward-facing track (25), with means for applying a continuous controlled pressure of said balancing follower roller (27) against said track (25), sufficient to maintain said four cam roller track followers (15) in continuous contact with said outward-facing guide track (5,6) during wheel rotation.

13. A continuous casting machine according to claim 12 wherein said means for applying a continuous controlled pressure of said balancing follower roller (27) against said balancing guide track (25) comprises a fluid-pressurized cylinder (31) mounted on a bracket (30) projecting axially from the side wall of said enclosure, having the cylinder rod projecting radially inwards and the cylinder rod end carrying said balancing follower roller (27) with its axis at right angles to the cylinder axis, thereby being adapted to apply a continuous and controlled force of said balancing roller (27) against said inward-facing balancing guide track (25).

14. A continuous casting machine according to claim 12 wherein said cam roller guide track followers (15) include a circumferential radially-projecting flange (22) adapted to abut a circumferential transverse alignment guide surface integral said wheel rim and also parallel to said mold-wall edges (9,21), thereby maintaining substantially constant transverse alignment between said enclosure and said wheel rim.

15. A continuous casting machine according to claim 12 wherein said non-rotating casting mold sector (11) comprises a plurality of said mold segments (10) abutting end-wise, hinged together to present a substantially continuous outer mold wall (12) from said entry end (42) to said exit end (20).

16. A continuous casting machine according to claim 1, 2, 3, 4, 5, 6 or claim 7, which also includes a non-rotating containment-roller sector (28) comprising at least one roller segment (90) adjoining said exit end of said mold envelope (43), from which exits the partially solidified cast metal section, said roller segment (90) comprising two side walls (13) with inner edges parallel and adjacent to said wheel rim, with inner wall open into the casting mold envelope (43) bounded by said inner-radius mold wall (8) and side faces (18), a plurality of guide track followers (15) mounted on said side-walls (13), and maintained in contact with said edge guide tracks (5,6), adapted to maintain a substantially constant dimensional clearance between said inner edges of said side walls (13) and the wheel rim;
transverse containment idler rollers (69) journalled in bearings (72) supported by said side walls (13), with faces positioned and adapted to press radially inwards against the outer face of said cast metal section to maintain the inner face of said section pressed against said inner-radius mold wall (8), the tangential component of this pressure acting to exert a circumferential forward propelling force on said section in said casting direction; and fluid cooling means for the outer face of said cast metal section.

17. A continuous casting machine according to claim 1, 2, 3, 4, 5, 6 or claim 7, which also includes a non-rotating containment-roller sector (28) comprising at least one roller segment (90) adjoining said exit end (20) of said mold envelope (43), from which exits the partially solidified cast metal section, said roller segment (90) comprising two side walls with inner edges parallel and adjacent to said wheel rim, with inner wall open into the casting mold envelope (43) bounded by said inner-radius mold wall (8) and side faces (18), a plurality of guide track follower (15) mounted on said side-walls (13), and maintained in contact with said edge guide tracks (5,6), adapted to maintain a substantially constant dimensional clearance between said inner edges of said side walls (13) and the wheel rim;
transverse containment idler rollers (69) journalled in bearings (72) supported by the side walls of said roller segment (90) with faces positioned and adapted to press radially inwards against the outer face of said cast metal section to maintain the inner face of said section pressed against said inner-radius mold wall (18), the tangential component of this pressure acting to exert a circumferential forward propelling force on said section in said casting direction;
an outside cover wall (143) of said containment roller segment (90).
coolant spray nozzles (38) contained within said cover-wall directed radially inwards, and means for pressurized liquid coolant supply to said nozzles (38), adapted to direct liquid coolant sprays (39) directly against said outer face of said cast metal section; and at least one discharge duct (40) for spent coolant from within said roller box enclosure (90) proximate its lower extremity.

18. A continuous casting machine according to claim 1, 2, 3, 4, 5, 6, or claim 7, which also includes a sector (28) comprising at least one roller segment (90) adjoining said exit end (20) of said mold envelope (43), from which exits the partially solidified cast metal section, said roller segment (90) comprising two side walls (13) with inner edges parallel and adjacent to said wheel rim, with inner wall open into the casting mold envelope (43) bounded by said inner-radius mold wall (8) and side faces (18), a plurality of guide track followers (15) mounted on said side-walls, and maintained in contact with said edge guide tracks (5,6), adapted to maintain a substantially constant dimensional clearance between said inner edges of said side walls and the wheel rim;
transverse containment idler rollers (69) journalled in bearings (72) supported by said side walls (13), with faces positioned and adapted to press radially inwards against the outer face of said cast metal section;
containment roller positioning means adapted to move said containment idler rollers (69) in direction towards and away from contact with said outer face of said section; and containment roller pressure-adjustment means adapted for controlled adjustment of the amount of force exerted by said containment rollers (69) against said cast metal section upon contact with said section, as required to maintain non-sliding frictional contact between the inner face of said section pressed against said inner-radius mold wall (8), the tangential component of this pressure acting to exert a circumferential forward propelling force upon said section in the casting direction.

19. A continuous casting machine according to claim 1,2,3,4, 5, 6, or claim 7, in which said entry end (42) and exit end (20) of said mold envelope (43) are respectively above and below the horizontal center line (80) in the plane of rotation of said wheel, wherein a portion of said outer-radius mold wall (12) extends substantially tangentially and vertically upwards from a point proximate said horizontal center line (80) extending to said entry end (42), creating a funnel-shaped entrance into said mold envelope (43), adapted to provide increased clearance for the vertical insertion, juxtaposed with said outer-radius mold wall (12), of a submerged entry nozzle (65) from a position above said non-rotating casting mold sector (11).

20. A continuous casting machine according to claim 1, 2, 3,4, 5, 6, or claim 7, in which said casting mold envelope (43) has a rectangular cross section with longitudinal axis parallel to the axis of said rotary wheel adapted for casting of metal slab sections, which also includes two semicircular side-dam bars (44) inserted into said mold envelope (43) from said entry end (42), spanning between said inner (8) and outer-radius (12) mold walls, adapted to transversely confine the sides of said molten metal and partially solidified cast metal section within said mold envelope (43); also including means for width-adjustment of the transverse distance of separation between said side-dam bars (44) and thereby the width of said metal section.

21. A continuous casting machine according to claim 1 in which said casting mold envelope (43) has a rectangular cross section with longitudinal axis parallel to the axis of said rotary wheel adapted for casting of metal slab sections, which also includes two semicircular side-dam bars (44) inserted into said molt envelope (43) from said entry end (42), spanning between said inner (18) and outer-radius (12) mold walls, adapted to transversely confine the sides of said molten metal and partially solidified cast metal section within said mold envelope (43); also including means for adjustment of the transverse distance of separation between said side-dam bars (44) and thereby the width of said cast metal section, which includes:
a transverse guide track fixed (51) to said non-rotating casting mold segment (11);
two movable carriages (46) supported on guide followers (53) which run on said transverse guide track (51);
support means for said side-dam bars (44) upon each of said carriages (46) proximate the entry end (42) of said mold envelope; and means for transverse positioning of said carriages (46) along said guide track (51), thereby being adapted for adjusting the distance of separation between said two side-dam bars (44) according to the required width of said cast metal section

22. A continuous casting machine according to claim 21 wherein said support means for said side-dam bar (44) comprises side alignment brackets (47) between which the side faces of said side-dam bars (44) are slidably confined;
a slotted hinge connection (48, 49, 50) incorporating a slot allowing bracket self-centering movement in the radial direction, whilst preventing relative movement between said carriage (46) and side-dam bar (44) in the circumferential direction, thereby being adapted to oscillate each of said side-dam bars (44) circumferentially in unison with said carriage (46) and non-rotating casting mold segment (11), whilst allowing for radial self-alignment of said side-dam bar (44) within said mold envelope.

23. A continuous casting machine comprising a rotary wheel incorporating a circumferential inner-radius mold wall (8) with two parallel annular inner mold-wall edges (9), integral to the wheel rim;
a non-rotating casting-mold sector (11) comprising at least one rigid mold segment (10) incorporating an outer-radius mold wall (12) having two outer mold-wall edges (21) which are parallel to, and interface with, said inner mold-wall edges (9), forming a casting mold envelope (43) confined between said-inner (8) and outer radius (12) mold walls;
molten metal pouring means adapted for introducing molten metal proximate the entry end (42) of said mold envelope (43) to pass through in the casting direction of circular wheel rotation and at least partially solidify a cast metal section for exit from the exit end (20) of said mold envelope (43);
at least two annular guide tracks (5,6) mounted proximate the wheel rim and rotating with the wheel one track located on either side of the plane of rotation of said inner-radius mold wall (8);
a non-rotating containment-roller sector (28) comprising at least one roller segment (90) adjoining said exit end (20) of said mold envelope (43), from which exits the partially solidified cast metal section, said roller segment (28) comprising at least one rigid semi-circular containment-roller segment (90) having two side walls (13) with inner edges parallel and adjacent to said wheel rim, with inner wall open into the casting mold envelope (43) bounded by said inner-radius mold wall (8) and side faces (18);
a plurality of guide track followers (15) mounted on each of said side-walls (13), which run in contact with said guide tracks (5,6), adapted to hold said containment roller segment (28) in a substantially fixed radial position relative to said wheel rim and maintain a substantially constant dimensional clearance between said inner edges of said box side walls (13) and the rotating wheel rim;
transverse containment rollers (69) supported by said side walls (13), with faces positioned and adapted to press radially inwards against the outer face of said cast metal section;
containment roller positioning and pressure-adjustment assembly (127) adapted to move said rollers (69) in direction towards and away from contact with said outer face of said sections and effect controlled adjustment of the amount of force exerted by said containment rollers (69) against said cast metal section upon contact with said section, as required to maintain non-sliding frictional contact between the inner face of said section pressed against said inner-radius mold wall (8), the tangential component of this pressure acting to exert a circumferential forward propelling force upon said section in the casting direction.

24. A continuous casting machine according to claim 23 also comprising an outside cover wall (143) of said containment segment (90);
coolant spray nozzles (38) contained within said cover-wall (143) directed radially inwards, and means for pressurized liquid coolant supply to said nozzles (38), adapted to spray liquid coolant directly against said outer face of said cast metal section; and at least one discharge duct for spent coolant from within said roller box enclosure proximate its lower extremity (40).

25. A continuous casting machine according to claim 23 or claim 24, wherein said containment idler rollers (69) are fixed to a shaft (83) coaxial with said rollers (69), said shaft (83) carrying bearings (72) journalled within circular bushings (76) journalled, in turn, within each of said side walls (13), with a common axis of said bushings (76) eccentric to the axis of said shaft (83), and wherein said positioning means comprises actuator means adapted for rotary angular displacement of said bushings (76).

26. A continuous casting machine according to claim 23 or claim 24, wherein said containment idler rollers (69) are mounted on bearings (72) adapted for rotation about a shaft (84) co-axial with said rollers (69), said shaft (84) carrying rotationally fixed circular bushings (85) journalled within each of said side walls (13), with a common axis of said bushings (85) eccentric to the axis of said shaft (84); and wherein said positioning means comprises an actuator adapted for rotary angular displacement of said shaft (84);
and said pressure-adjustment means comprises actuator means (91) adapted for controlling the torque affecting angular displacement of said shaft (84).

27. A continuous casting machine according to claim 23 or claim 24, wherein said containment idler rollers (69) are mounted on bearings (72) for rotation about a shaft (84) coaxial with said rollers (69), and said bearings (72) are carried by chocks (73) adapted for movement in the radial direction within parallel surfaces integral to said segment side walls (13), and wherein said positioning means comprises fluid pressurized cylinders (70) with rods connected to said chocks (73) to stroke in the radial direction, said cylinders (70) being integrally mounted upon said segment (90); and said pressure-adjustment assembly includes controlled changing of the fluid pressure within said cylinders (70).

28. A continuous casting machine according to claim 7 wherein said non-rotating sector (11) includes at least one capture member of said balancing follower roller (114) limiting its free movement radially outwards; and radial withdrawal means of said carriage (146) and thereby of said segment (11) for holding in a position clear of said wheel adapted for carrying out inspection and maintenance.

29. A continuous casting machine according to claim 1, 2, 3, 4, 5, 6 or claim 7 wherein said entry end (42) of said mold envelope (43) includes a metal overflow channel (149) proximate the axial plane of said wheel having the entry invert of said channel at an elevation lower than the highest junction between the entry ends (42) of said inner-radius (8) and outer-radius (12) mold walls.

30. A continuous casting machine according to claim 1,2, 3, 4, 5, 6, 16, 17, 18, 19 or 20 which comprises at least two segments (10, 90) wherein adjacent segments are connected together by a universal hinge coupling assembly (120) proximate the central plane of said wheel, said assembly (120) comprising:
two externally-restraining spherical thrust bearings (117) abutting flanges (82) carried by each respective enclosure (10, 90) thereby limiting separation distance between said flanges (82);
and adjustable length bolt assembly (118) limiting separation distance between said thrust bearings (117); and a compression pre-loading spring (119) between said flanges (82) adapted for maintaining pressurized contact between the mating faces of said thrust bearing (117) and between said bearing (117) and said flanges (82) during operation.

31. A continuous casting machine according to claim 2, 3, 4, 5, 6, 7 claim 7, which includes two of said edge guide tracks (5,6), one located on either side of the central plane of rotation of said inner-radius mold wall (8), and also including at least four cam follower rollers (15) mounted in axially opposite pairs ant adapted to press axially against said guide tracks (5, 6), which includes an axial spring means axially pre-loading one roller of each pair of said followers (15), thereby being adapted to eliminate axial clearance and prevent yawing or vibration of segments (10) during oscillation.