CN101104198A

CN101104198A - Direct cold casting mould

Info

Publication number: CN101104198A
Application number: CNA2006101015419A
Authority: CN
Inventors: R·V·提拉克
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-07-10
Filing date: 2006-07-10
Publication date: 2008-01-16
Anticipated expiration: 2026-07-10
Also published as: CN101104198B

Abstract

The invention relates to a mould, comprising a mould body with a direction surface and a coolant box combined to the mould body. The mould further can also comprise a coolant ring with an adjusting surface; on the adjusting surface, the coolant ring can be combined to the coolant box so that the adjusting surface and the direction surface can be combined together to form a nozzle. The mould can further comprise a mould starting head.

Description

The direct chill casting mold

Technical field

The present invention relates to liquid metal casting technique continuous and that semi-continuously be shaped with respect to forming face.More particularly, the present invention relates to by directly on blank article, applying the direct chill casting that liquid coolant carries out blank.

Background technology

Casting comprises melted material is incorporated into makes object in the mould, in described mould, and along with heat is removed from material, material solidification.Stream casting (slip casting: or " slip-casting ") or direct casting (continuous casting) can be a kind of by the heat absorption ring by gravity molten metal feed, technology that motlten metal is solidified.Have the starting head (starting head) that is installed in the base on the hydraulic push rod (hydraulic ram) and form the bottom that is independent of the heat absorption ring.Heat absorption ring and starting head constitute the basic components of slippage mould (slip mold).

When motlten metal is filled in the mould and begins to solidify, the starting head can be reduced with controlled speed.The metal that solidifies can withdraw from the heat absorption ring so that form base substrate.The metal shell that solidifies can remain in the top and heat absorption ring of base substrate, is used for stablizing the motion of base substrate between heat absorption ring and starting head.In the storage tank (sump) of this shell, can replenish motlten metal.Motlten metal enters this shell storage tank, and by the heat absorption ring, the length of base substrate can increase.

Base substrate (perhaps ingot) can be regarded as the metal that is cast as an elongation of standard shape by the base substrate supplier, be convenient to store or transportation.Base substrate can have the shape of the cylindrical cross-section of heat absorption ring, can make with aluminium or aluminium alloy.Although the height of heat absorption ring can be lower than two inches, base substrate can have 20 feet long, and has from 3 inches to 36 inches diameter.Further by hot mechanical forging, extruding, rolling, finishing or drawn blanks, processing column shape base substrate is suitable for product sold so that produce to the producer, for example be used for indoor curtain rod, engine support, undercarriage, metallic plate peculiar to vessel is used for the I-shaped crossbeam of building.

For the heat of controlling base substrate is better transmitted cooling processing, can when leaving the heat absorption ring, solid metal directly on the surface of solid metal, apply water.Thereby, along with starting head descends, be contained in the water jet of mould inside can be on base substrate injection water so that cool off its surface, further with metal freezing.This continuous directly cold (DC) casting process of being invented by W.T.Ennor (U.S.Pat.No.2,301,027) in nineteen forty-two, generation has the fine grain metal structure of minimum segregation.When simultaneously when mould table adopts multiple DC casting mould, can reach very high speed of production in foundry.

Although after nineteen forty-two, obtain some progress in this area,, at the industrial direct chill casting mould system assembly that still needs to produce the best metallographic structure of cast article with required surface smoothness.Compare with traditional industrial mold system assembly, this direct chill casting mould system assembly will be operated safer, and easier operation and maintenance will make the maximization of Foundry Production rate, and making and turn round can be very not expensive.

Summary of the invention

One embodiment of the present of invention are a kind of mold.This mold comprises mold body with direction face and the cooling fluid tank that is attached on the mold body.Mold further can comprise the cooling agent ring with adjusting range, and on this adjusting range, the cooling agent ring can be incorporated on the cooling fluid tank, so that adjusting range and direction face are brought together, forms nozzle.Mold may further include mold starting head (starting head).

Description of drawings

Fig. 1 represents DC mould system 100 of the present invention;

Fig. 2 is the detailed view along the mould system 102 of line 2 taking-ups of Fig. 1;

Fig. 3 A direction face 122 that ring 120 becomes with materials processing by cooling fluid tank 116 of representing to absorb heat;

Fig. 3 B represents the adjusting range 164 by the materials processing one-tenth of cooling fluid tank;

Fig. 3 C represents the embodiment that each mold body 110 and air ring 118 can be regulated;

Fig. 3 D shows the method 300 that is used to produce base substrate 132 of the present invention;

Fig. 4 represents DC casting method 400 of the present invention;

Fig. 5 represents the isometric view of baffle ring 430;

Fig. 6 represents the isometric view of ceramic header 440;

Fig. 7 represents DC mould system 700 of the present invention;

Fig. 8 is the isometric top view of the mould table 702 of Fig. 7;

Fig. 9 is the isometric bottom view of mould table 702 that includes the mold 400 of Fig. 4; And

Figure 10 represents the base substrate 1000 by the present invention's production.

The specific embodiment

An embodiment comprises mold.Mold can comprise the mold body with direction face, and is attached to the cooling fluid tank on the mold body.Mold may further include the cooling agent ring with adjusting range, at this adjusting range place, the cooling agent ring can be incorporated on the cooling fluid tank, so that adjusting range and direction face are brought together, to form nozzle, particularly make jet hole, spraying turbulent flow and the cooling agent angle of shock can be fast, convenient and spend not highland variation.Mold may further include mold starting head.

I.DC casting and mould system

Fig. 1 represents DC mould system 100 of the present invention.DC mould system 100 can comprise mould system 102, accessory system 200 and control system 250.Each of mould system 102, accessory system 200 and control system 250 can be the subsystem of working together, so that form DC mould system 100.Mould system 102 can be counted as comprising a DC mold.

A. mould system 102

Mould system 102 can comprise mold body 110, mold starting 112, feed pipe 114, cooling fluid tank 116, cooling agent ring 118.

Fig. 2 is the detailed view along the mould system 102 of line 2 taking-ups of Fig. 1.As seeing in Fig. 2, mold body 110 can comprise heat absorption ring 120 on the inner surface of the inside of mold body 110.The horizontal cross-section of heat absorption ring 120 can be limited by any symmetry used in extrusion technique or direct chill casting technology or asymmetric rotation.For example, the level of heat absorption ring 120 or X cross section can be limited by an annular, square, star, avette or rectangle.Because the preferred shape of base substrate is cylindrical, so in one embodiment, heat absorption ring 120 is limited by annular.The example of asymmetric shape comprises: be used for the rectangular shape that has fillet of flat (rolling) ingot, be used for the flat shape that has concave edge of strip foundry goods, be used for the "T"-shaped shape of butt of melted ingot foundry goods again.Ingot, slab and the material that solidifies the casting of usefulness standard shape object also can be produced with the present invention.

Mold body 110 can comprise direction face 122, internal thread 124, external screw thread 126 and flange 128.Direction face 122 can be used for required angle 134 (Fig. 2) cooling agent curtain stream (flowof coolant curtain) 130 (Fig. 1) being aimed at billet surface 133.Angle 134 can be at 60 degree to the scope of 85 degree.In one embodiment, angle 134 can be spent in the scope of 75 degree 60.Angle 134 can be with respect to the horizontal plane.In another embodiment, angle 134 is spent in the scope of 72 degree 67.

As seeing in Fig. 2, feed pipe 114 can be installed in the mold body 110 from the top, thereby gravity can help feed pipe 114 is fixed on the mold body 110.Internal thread 124 can be used for further feed pipe 114 being fixed to mold body 110, and provides a liner 136 can compress thereon surface.Liner 136 can be between the machine components that are used for mating so that prevent the various sealing gaskets that overflow such as fluids such as motlten metals or seal a kind of.The material of liner 136 can have heat endurance in the temperature up to 2100 Hua Shidu, for melted material to be cast is chemically noninfiltrated, can seal any He all inside porous by compressing, it can be material with low-thermal conductivity, can be under the temperature in negative 40 to 2100 Hua Shidu scopes, have the low thermal expansion or the material of constriction coefficient.Liner can comprise the Ceramics by Thermal, Inc., the compressible felt of ceramic Kaowool (TM) type that of Augusta, Ga. make and sell.Liner 136 can also comprise by Unifrax, Inc.of Niagara Falls, the compressible ceramic paper of the Fiberfrax of N.Y. produce and market (TM) J970 type.

In an important embodiment of the present invention, mold body 110 can be installed to from below in the cooling fluid tank 116.Can utilize external screw thread 126 that mold body 110 further is fixed on the internal thread of cooling fluid tank 116.As being clear that in Fig. 1, flange 128 can extend radially outward by a point below external screw thread 124, so that provide a liner 138 can compress thereon face.

Liner 138 can be between the machine components that are used for mating so that prevent the various sealing gaskets that overflow such as the quenching water or other fluid or seal a kind of.Liner 138 can comprise Viton (TM) (viton rubber), Buna (buna), perhaps silicon materials.

Liner 138 can have the shape of " O " type ring.Depend on the development length (and this development length depends on the overall diameter of base substrate 132 conversely) of flange 128, the cross section of liner 138 can change.The cross section of liner 138 can be circular or rectangle avette or that have fillet.The compressibility of this liner 138 is disposed at the gap in 0.005 to 0.250 inch the scope between the face of coupling therebetween for liner 138, sealing can be provided.

Because the base substrate 132 of Fig. 1 can form by making melted material 152 encircle 120 by heat absorption, so, can between base substrate shell 140 and heat absorption ring 120, comprise and reduce the parts that rub.For example, the parts as reducing friction can be incorporated into lubricant in the gap 144 of Fig. 2 by lubrication channel.Will point out in more detail that as following lubricant 142 can be liquid, for example oil, perhaps gas, a kind of inert gas for example.The perhaps mixture of gas, perhaps their combination.

Mold body 110 comprises aluminium alloy, and copper-beryllium alloy is perhaps based on the material of graphite.Aluminium alloy can be AA6061 aluminium alloy or AA5052 aluminium alloy.Be used for the inertia that the material of mold body 110 can demonstrate heat endurance and treat the material of casting.And then, the material that is used for mold body 110 can provide enough heat conduction to, and provide the possibility of the dimensional tolerance that keeps accurate under the extreme temperature conditions that in process and in casting, may run into.

In another embodiment, mold body 110 and cooling fluid tank 116 are single parts.For example, Fig. 3 A represents heat absorption ring 120 and the direction face 122 by the materials processing one-tenth of cooling fluid tank 116.Wherein, cooling fluid tank 116 comprises heat absorption ring 120 and direction face 122, and, wherein, the heat absorption ring 120 of Fig. 1 and direction face 122 limit mold body 110, internal thread 124, external screw thread 126, flange 128 and liner 138, and do not require the part as mould system 102.Wherein, internal thread 124 can require the part as mould system 102, and feed pipe 114 can omit as shown in Figure 3A, thereby heat absorption ring 120 can directly receive the supply that is used for processing the motlten metal that enters base substrate 132.Can cancel lubrication channel 146.For example, the coefficient of friction between heat absorption ring 120 and melted material head 154 is enough low, so that make melted material via heat absorption ring 120 positions of passing through, can cancel lubrication channel 146.

As shown in Figure 1, mould system 102 can also comprise mold starting 112.Mold starting 112 can comprise pedestal 148 and hydraulic push rod 150.Mold starting 112 can be as with respect to heat absorption ring 120 bottom independently.Hydraulic push rod 150 can be incorporated on the platen.

Mould system 102 can also comprise the feed pipe 114 that is attached on the mold body 110.Feed pipe 114 can feed pipe 114 can flow to first opening on the heat absorption ring 120 as melted material head 154 with melted material 152.Melted material head 154 can provide positive differential pressure, makes it by heat absorption ring 120 so that drive base substrate 132.

It is unfavorable making molten material cools before melted material 152 reaches heat absorption ring 120.Therefore, feed pipe 114 can adiabaticly be transported to melted material head 154 heat absorption ring 120.In order to finish this conveying with minimal heat loss, can utilize any manufacturing in various firm, the frangible heat-resisting and corrosion-resistant materials.

Feed pipe 114 used materials demonstrate low pyroconductivity, the low coefficient of volume expansion, and high thermal fatigue resistance, high strength at high temperature, and do not soak into behavior for the chemistry of melt material to be cast.In one embodiment, feed pipe 114 comprises nonmetallic materials, for example clay.In another embodiment, feed pipe 114 can comprise ceramic material.Described ceramic material can be based on pure σ aluminium oxide and kaolin.Ceramic material can comprise alumina silicate.In another embodiment, the material of feed pipe 114 can be made by the vacuum forming silica slurry, and holder is added with suitable high-temperature adhesives in described silica slurry.Can the resulting slurry of sintering, so that reach caking property and intensity.

Can also comprise cooling fluid tank 116 in the mould system 102.In order to hold and conduct coolant 134, cooling fluid tank 116 can comprise cavity 156 and the coolant entrance 158 that is provided with communicatively with cavity 156 fluids.As noted, mold body 110 can be attached on the cooling fluid tank 116 by external screw thread 126.Cooling fluid tank 116 can comprise 1020 steel that scribble priming paint or such as the stainless steel of SS316 type etc.In one embodiment, cooling fluid tank comprises the plate that aluminium alloy AA5052 or AA6061-T651 eliminate stress.The material that cooling fluid tank 116 is comprised can be worked into point-device tolerance, for example positive and negative 50 microns or two mils, and this tolerance can be kept a long time, for example several years.

As the project that the part of mould system 102 may comprise, be cooling agent ring 118.The cooling agent ring can comprise lip 160, external screw thread 162, adjusting range 164.As can being clear that from Fig. 1, lip 160 can be below external screw thread 162 one lights radially and stretches out, so that provide liner 138 can compress thereon face.External screw thread 162 can be used for cooling agent ring 118 is fixed on the internal thread of cooling fluid tank 116.

As shown in Figure 2, in the time of in cooling agent ring 118 is installed to cooling fluid tank 116, the adjusting range 164 of cooling agent ring 118 can intersect with the direction face 122 of angle 168 with mold body 110, so that limit inner nozzle district 166 and nozzle opening 170.Angle 168 can be spent in the scopes of 90 degree 0, because the cooling agent 134 that ejects from nozzle 176 is more along direction face 122.In one embodiment, angle 168 is spent in the scope of 12 degree 4.In another embodiment, angle 168 is 6 degree.Nozzle opening 170 can be by the averga cross section between the minimum Y-point on minimum Y-point on the direction face 122 in first X-Y plane and the adjacent adjusting range in first X-Y plane 164 apart from qualification.The averga cross section distance of nozzle opening 170 can be in 0.050 to 0.150 inch scope.In one embodiment, the averga cross section of nozzle opening 170 distance is in 0.075 to 0.108 inch scope.

Nozzle opening 170 also can be limited by nozzle height 172 and nozzle distance 174.Nozzle height 172 can be limited by the distance between the minimum Y-point adjacent on minimum Y-point on the direction face 122 in first X-Y plane and the adjusting range in first X-Y plane 164.Nozzle distance 174 can be used as between the center of nozzle opening 170 and billet surface 133 that the width in space is defined on directions X.

Nozzle height 172 can be in the scope of 0.200 inch of plus or minus.In one embodiment, nozzle height 172 is in 0 to 0.100 inch scope.In another embodiment, nozzle height 172 is multiples of 0.010, and is irrelevant with used unit.In a further embodiment, nozzle height 172 is 0 inch.Be that adjusting range 164 does not reach outside the direction face 122 under 0 inch the situation at nozzle height 172.As described below, under included situation, adjusting range 164 can not encourage the Lower Half of cooling agent posts so that leave the first half of this cooling agent post from nozzle 176.

Nozzle distance 174 can be in 0.06 inch to 0.36 inch scope.In another embodiment, nozzle distance 174 is irrelevant with employed unit, is one multiple in 0.001 and 0.006 at least.In a further embodiment, nozzle distance is one of in 0.090 inch and 0.106 inch.

Inner nozzle district 166 can with nozzle opening 170 together as nozzle 176, regulate also guiding comes from nozzle 176 as cooling agent curtain 130 fluid stream (for example, cooling agent 134).Cooling agent curtain stream 130 can be the laminar flow that is configured near the continuous cooling agent the billet surface 133.The laminar flow of cooling agent curtain stream 130 can not have the interrupted space as the feature of the traditional cooling agent in the DC mold, so that better heat transfer characteristic is provided.

For the fluid volume of regulating cooling agent curtain 130 and the direction of power and cooling agent curtain 130, one embodiment of the present of invention comprise the ability of the height of regulating nozzle 172, by regulating the height of nozzle, then can regulate the angle of cooling agent curtain 130 collision base substrates 132.

Gear teeth 178 can radially stretch out from the lip 160 of cooling agent ring 118.In order to closely cooperate,, can comprise cooling agent rim gear wheel 180 as the part of mould system 102 with gear teeth 178.Cooling agent rim gear wheel 180 can be set like this, make it and gear teeth 178 engagements and 118 rotations of permission cooling agent ring.The rotation of cooling agent ring 118 then allows adjusting to leave the shape and the volume of the cooling agent 134 of nozzle 176.Can increase the part of additional reduction friction on mould system 102, for example bearing and grease are so that enable more easily shape cooling agent ring 118.

In the DC mold, the function of the Reynolds number (Reynolds number) of the cooling agent stream when being volume, impingement angle and cooling agent collision base substrate surperficial of thickness, cooling agent of coolant velocity, cooling agent film from the heat transmission of base substrate.Suppose that other variable remains unchanged, up to a threshold value, coolant velocity is high more, and heat is transmitted high more.Although the increase of coolant pressure can increase the speed of cooling agent,, the capacity of cooling medium pump is generally fixed.The shape of cooling agent of nozzle 176 is left in adjustment and the ability of volume can be represented coolant velocity, film thickness and the collision angle ability of one of them at least of adjusting.Therefore, adjust the shape of the cooling agent 134 leave nozzle 176 and the ability of volume, can provide almost is the ability of the feature transmitted of the heat of instantaneous change DC mold.

In operating process, when cooling agent rim gear wheel 180 during to the rotation of direction, cooling agent ring 118 is coated with 2 nozzle height 172 to the direction rotation that is coated with 1 arrow A thereby reduce.Reduce nozzle height 172 and can dwindle nozzle opening 170.Suppose coolant pressure, the volume 134 of the cooling agent of profile nozzle 176 reduces, so that provide more sharp-edged for cooling agent curtain 130.And then, reduce nozzle height 172 and the surface of the middle mind-set base substrate 133 of nozzle opening 170 can be moved, thereby reduce nozzle distance 174, when cooling agent 134 is pulled to cooling agent ring 118, increase the angle of cooling agent curtain 130 collision base substrates 132.When rotating cooling agent gear 180 in the opposite direction, can be to the direction rotation cooling agent ring 118 of the arrow B of Fig. 1.

In the alternative embodiment of another one, cooling agent ring 118 and cooling fluid tank 116 are single parts.For example, Fig. 3 B represents that adjusting range 164 is formed by the materials processing of cooling fluid tank 116.Comprise at cooling fluid tank 116 under the situation of adjusting range 164, can not require lip 160, external screw thread 162 and liner 138 a part as mould system 102.

Shown in Fig. 3 B, can be by being attached near the cooling agent ring teeth 181 that are configured in the lip 182 body 110 that adjusts the mould, so that change nozzle opening 170.

In the alternative embodiment of another one, each mold body 110 and cooling agent ring 118 can be conditioned, so that change the cross section of nozzle opening 170 on the direction at least in X, Y and Z direction, and regulate so that change the average X diameter of nozzle opening 170.Fig. 3 C represents each embodiment that can be conditioned of mold body 110 and cooling agent ring 118.Here, each of mold body 110 and cooling agent ring 118 can be conditioned, to change the position of nozzle opening 170.In this embodiment, for a bigger melted material head 154 is provided, can feed pipe 114 be attached on the inner surface of mold body 110 by screw thread, and can by gear 190 and be configured near the tooth the service pipe 114 the engagement remote control move up and down.Under feed pipe 114 is frangible situation, near feed pipe 114, ring gear can be used so that 190 engagements of threshold gear.

In an alternative embodiment, the adjusting of one of them at least of mold body 110 and cooling agent ring 118 can be carried out on one of them at least in Y direction, directions X, pitch direction, rotating direction, yawing moment and polar coordinates direction.

The aspect of a key of the present invention is that wherein, mold body (110) is installed on the cooling fluid tank (116), brings significant improvement for the cast metal technology.The advantage that is obtained is to improve the quality of metal casting, and easy operating for ease of maintenaince, improves security, reduces the manufacturing cost of equipment.As described in paragraph below, the present invention is very significant for improving security and castability.

By fire-resistant connection that need not to destroy mold body and supply casting system just can be from cooling fluid tank dismounting mold body, the easiness of arrival Operation and maintenance.In addition, in case the cavity of mold from cooling fluid tank unloaded, by the inside that can directly enter cooling fluid tank clean, R and M, reach the easiness of operation.The easiness of this operation also improves the security in the workshop, because: well-known, if the interaction of motlten metal and water can be blasted and it is extremely dangerous to be, and can not make the easy maintenance and operation of casting system, and can increase the fault of casting system and the possibility that endangers safety.

B. accessory system 200

DC mould system 100 shown in Figure 1 can comprise accessory system 200.Accessory system 200 can comprise hydraulic fluid tank 202, hydraulic fluid tank 204, cooling agent cassette for supplying 206, stuffing-box 208 and lubricant case 210.Hydraulic fluid tank 202 can be incorporated on the cooling agent rim gear wheel 180, so that the motion of control cooling agent ring 180, thereby control cooling agent curtain 130.Hydraulic fluid tank 204 can be by being attached in the mold starting 112, so that the motion of control mold starting 112 via hydraulic push rod 150 such as platen.Hydraulic fluid tank 202 and hydraulic fluid tank 204 can be for example by fluid, particularly the single headstock of being operated under pressure by water and air.

Cooling agent cassette for supplying 206 can be incorporated on the coolant entrance 158, to the cooling agent 134 of cooling fluid tank 116 supplies as quench fluid.In one embodiment, cooling agent 134 is a liquid.Described liquid can be water, perhaps the water that mixes with ethylene glycol (for example, the ethylene glycol of 3% to 25% volume).

Stuffing-box 208 can comprise the material 214 that will be processed into base substrate 132.Material pioneer official 208 can be incorporated into the inside of feed pipe 114, so that be provided for being processed into the melted material 152 of base substrate 132.Material 214 can be by utilizing heat and pressure any material that one of them can be from the solid state change to the liquid state at least.

In one embodiment, material 214 is metals.Metal can comprise aluminium, aluminium alloy, magnesium, magnesium alloy, copper, copper alloy, lithium, lithium alloy or noble metal and alloy thereof.In another embodiment, material 214 is plastics.Plastics can comprise thermoplastic resin, comprise polystyrene, perhaps polyethylene.In another embodiment, material comprises glass.Described glass can comprise coloured glass.In another embodiment, material comprises biphase mixture.This biphase mixture can comprise metal matrix composite materials.One of metal matrix composite materials can comprise metal and ceramic particle, and in metal and the amorphous glass particle.In another embodiment, described material can comprise the thixotroping slurry that is under the semisolid condition.

Lubricant case 210 can be incorporated on the lubricant passageway shown in Figure 2 146, so that carry the parts that reduce friction to gap 144.Lubricant 142 can be a liquid, for example oily, gas, for example inert gas, solid-state material, perhaps their combination.

Lubricant can demonstrate and the material (for example material 214) to be cast and the physical compatibility and the chemical compatibility of employed cooling medium.The factor of lubricant physical compatibility comprises the flowability of flash-point, proportion, specific heat, surface tension and lubricant.The factor of lubricant chemical compatibility can comprise the reactivity on surface, catabolite, and the invertibity of chemical reaction, the separation property of lubricant from the cooling medium, and consider the processing of the lubricant of using from the angle of environment.Fluid lubricant preferably can comprise the vegetable oil that biology can decompose, for example peanut oil and castor oil.Also can use synthetic mineral oil.And then, can use the artificial oil that adds alpha-olefin.

Gas lubricant can be the mixture that has or do not have the inert gas that mixes with air.Solid-state lubricant can be the graphite annulus insert, graphite powder and molybdenum bisuphide powder.

C. control system 250

DC mould system 100 shown in Figure 1 can comprise control system 250.Control system 250 can comprise computer server 252, communication line 254.Computer server 252 can be any device that calculates, particularly a kind of programmable electronic equipment, described electronic equipment can be finished mathematics or logical operation at a high speed, and can gather, storage, information and information is interrelated, perhaps process information on the contrary.Communication line 254 can be used for transmitting signal of communication between computer server 252 and hydraulic fluid tank 202, hydraulic fluid tank 204, cooling agent cassette for supplying 206, stuffing-box 208 and lubricant case 210.Signal of communication can be by cable or wireless cable one of them detection transmission at least.

Control system 250 can also comprise by network and is connected to client computer 256 on the computer server 252.Network 258 can be by for example interconnective any computer systems of information channel such as telephone wire, cable and radio wave, so that the information of sharing.In one embodiment, network 258 is internets.The internet can be any global information system, described information system can be to connect together according to the subsequent expansion of Internet protocol (IP) or this agreement/only address space part, the follow-on whole world, can utilize TCP (TCP/IP) group or its subsequent expansion/next generation, and/or other IP compatible protocols supporting communication.In one embodiment, the internet can provide publicly or in confidence, use or can reach high-caliber service to communication and relevant infrastructure layering.In another embodiment, network 258 is a plurality of user terminals.

D. operation

The first method of the object that casting such as base substrate 132 is such comprises provides mold body, cooling fluid tank with direction face and the cooling agent ring with adjusting range.Next procedure is to form nozzle, and the mode that forms nozzle provides the possibility of regulating nozzle opening for providing near direction face configuration adjustment face.This can be undertaken by cooling fluid tank being attached between cooling agent ring and the mold body.Can regulate nozzle, so that change nozzle opening.This adjusting can be static state or dynamic.

Described method may further include and makes cooling agent pass through nozzle, so that form cooling agent curtain stream, and by making melted material by mold body and cooling agent ring and melted material and mold starting are contacted, melted material is hardened.

Can make the material of sclerosis by cooling agent curtain stream by reducing mold starting head then.If necessary, when the material that hardens makes by the cooling agent curtain, can regulate nozzle.In one embodiment, the adjusting of nozzle comprise swing pinion and add shim liner at least one of them, wherein, gear contacts with one of them rotation of cooling agent ring and mold body at least, and, wherein, shim liner be configured in cooling fluid tank and and the mold body between and between cooling agent ring and the cooling fluid tank at least between one of them.

Fig. 3 D represents to show the method 300 that is used to produce base substrate 132 of the present invention.In step 302, the mold of Fig. 1 starting 112 is near heat absorption ring 120, makes to have a gap between mold starting 112 encircles 120 with heat absorption.In step 304, can regulate cooling agent ring 118 so that obtain required nozzle opening 170.As described below, can regulate by starting cooling agent rim gear wheel 180 or by inserting/remove shim liner.In step 306, can start cooling agent cassette for supplying 206, so that force cooling agent 134 to pass through nozzle opening 170 (Fig. 2) as cooling agent curtain 130.In step 308, can the threshed material case so that in feed pipe 114 the transporting molten material.This can form melted material head 154.In step 310, melted material head 154, for example because and mold starting 112 and absorb heat and encircle 120 and contact, because, can form shell 140 in sclerosis on the surface of periphery in the significant temperature difference of melted material head 154 with mold starting 112 and 120 two parts of heat absorption ring.

Metallostatic pressure can change on the entire depth of column fluent material, and the density that can be expressed as material multiply by the height that gravity constant multiply by liquid column.When material head 154 or solidify or during partial coagulation, can take place by the phase transformation of melted material head 154 to shell 140, thereby the material of phase transformation demonstrates the metallostatic pressure of enough intensity (for example, thickness) tolerance material head 154.Along with the sclerosis of the material head 154 of fusion,, can the direction of pedestal 148 along arrow C be reduced in the path of cooling agent curtain 130 in step 312 by starting hydraulic fluid tank 204.For more uniform base substrate 132 is provided, along with the reduction of pedestal 148, under the situation of the cross section of heat absorption ring 120 permission, rotating basis 148.

Along with in step 312 pedestal 148 being reduced in the cooling agent curtain 130, in step 314, cooling agent 134 is at surperficial 133 places collision base substrate 132, so that further take heat away.Along with the progress of time, can further reduce pedestal 148 in step 316, up to the base substrate 132 that obtains Len req.

Solidify for the whole X cross section of melted material 152, need spended time.Therefore, leave the Y center line material cooled farthest of base substrate 132, can form base substrate shell 140.The formation of base substrate shell 140 can form groove 182.Groove 182 and base substrate shell 140 can meet at liquidus surface 184 places.The cross section of liquidus surface 184 is limited by spill parabola.The parabolical character of this spill during based on melted material 152 cooling since pedestal 148 move the meniscus that forms on the top of base substrate 132.

The cooling agent that comes from the cooling agent curtain 130 of about 30 to 120 Hua Shidu can impact billet surface 133, and wherein, billet surface 133 is greatly about 900 Hua Shidu.Because big temperature difference (830 Hua Shidu) is under the situation of liquid at cooling agent 134, cooling agent 134 flashes to vapor phase.For example, be under the situation of water at cooling agent 134, water can flash to small steam bubbles, on the surface of described bubble attached to base substrate 133.

Point out as top, when first group of water slug base substrate 132, on billet surface 133, form small steam bubbles.Fine steam bubbles is mainly formed by the first half of the cooling agent post that comes from nozzle 176.Subsequently, when second group of water slug base substrate 132, second group of water is sheared fine steam bubbles get off from billet surface 133, forms its oneself fine steam bubbles.The Lower Half that fine steam bubbles is mainly come from the cooling agent post of nozzle 176 cuts off from billet surface 133.

Nozzle height shown in Figure 2 172 greater than 0 inch situation under, extra the adhering between the projection of cooling agent 134 and adjusting range 164, can promote to come from nozzle 176 the cooling agent post Lower Half from the first half of same cooling agent post from.The Lower Half of cooling agent post from same cooling agent post facility half part from situation under, since the internal shear power in the steam and the Lower Half of cooling agent post two factors of increase of impacting the distance that must advance before the billet surface 133 at least one of them, the speed that the cooling agent Lower Half is impacted base substrate reduces.The shear property that this has reduced the steam bubbles of cooling agent makes more steam bubbles rest on the billet surface 133.Along with more steam bubbles rests on the billet surface 133, from the heat transmission minimizing of base substrate 132.Therefore, for the impact velocity gradient on the whole vertical section of cooling agent post is reduced to Min., for some material, nozzle height 172 shown in Figure 2 is preferably 0 inch.

Under the situation of founding materials to the sensitivity of quenching, it is preferred postponing along the heat extraction of billet surface 133.Use for these, wish on the vertical section of whole cooling agent post, to have velocity gradient, thereby the nozzle height 172 of Fig. 2 can be different from 0 inch.

Steam bubbles is wiped out from billet surface 133,, make it to contact, promote heat transmission with cooling agent 134 by removing the zone of billet surface 133.Select the value of the angle 134 of Fig. 2, can promote steam bubbles is wiped out from billet surface 133.Surpass 12 inches span outside the point of cooling agent shock surface 133, heat transmission also can be taken place.Except that promoting the wiping out of steam bubbles, the value of selecting for angle 134 can be reduced to bottom line with the amount of the cooling agent 134 that return from billet surface 133 springs.Experiment shows, as previously described, the preferred angle of angle 134 is 60 to spend to 75 degree.

Along with the cooling agent 134 that comes from cooling agent curtain 130 impacts base substrate 132, cascade 186 shown in Figure 1 falls billet surface 133.In one embodiment, cascade 186 with each second 6 feet speed fall billet surface 133.Cascade 186 can fall the billet surface 133 of base substrate 132, goes forward side by side into tank 188.In order to make 20 feet long base substrates, pedestal 148 can be reduced about 90 minutes.During this period of time certain a bit, base substrate 132 can be reduced in the tank 188.

Rest on the bubble on the billet surface 133, can become the steam that freely rises.Bubble freely from billet surface 133 is wiped out can be brought in the tank 188 by cascade 186, and at this place, they do not become the steam that freely rises.Therefore, tank 188 can help to control the formation of steam, and a container is provided, recirculation cooling agent 134 from this container.Tank 188 can be 8 to 10 feet dark.

Control cooling agent curtain 130 can help to control the formation of steam.If produce too many steam, perhaps can not cool off base substrate 132 rightly, can in the process that pedestal 148 moves, regulate cooling agent ring 118, so that obtain required nozzle opening 170, so that more bubble is brought in the tank 188 by driving cooling agent rim gear wheel 180.

Fig. 4 represents DC mold 400 of the present invention.DC mold 400 can comprise mold body 410, mold starting 412, feed pipe 414, cooling fluid tank 416 and cooling agent ring 418.As seeing from Fig. 4, mold body 410 can comprise heat absorption ring 420 on the inner most surface of the inside of mold body 410.Heat absorption ring 420 can comprise porous ring 422 and mold tang (mold tang) 424.

Melted material of the present invention can move when it solidifies.Therefore, porous ring 422 can play a part to allow fluid by aperture in the material of porous ring 422 or space, so that at porous ring 422 and between such as base substrate shells such as base substrate shells 140, provide the face of reducing friction.This fluid is liquid or gas or their combination, and the face that can provide the angle to reduce friction between melted material and porous ring 422 is so that allow melted material by porous ring 422.

In order to allow fluid by aperture in the material of porous ring 422 or space, porous ring 422 can comprise the allotrope of the carbon of crystallization.In another embodiment, porous ring 422 comprises graphite.In another embodiment, the porous ring comprises carborundum.

The horizontal cross-section of porous ring 422 can be limited by any symmetry that adopts in extrusion technique or direct chill casting technology or asymmetric shape.For example, the horizontal cross-section of porous ring 422 can be limited by annular, square, star, avette or rectangle.Because the preferred shape of base substrate is cylindrical, so in one embodiment, porous ring 422 is limited by annular.

The mold tang 424 of Fig. 4 can be as the bottom of case 426, except taking away some heats from the groove 182 of melted material head 154, also to base substrate 132 provide the structural supports.

From the heat that the melted material head in the groove takes out, mainly formed the base substrate shell by the porous ring.After forming the base substrate shell, melted material continues to harden near the porous ring, and handle becomes the part of base substrate shell.When sclerosis, material is shunk back from the porous ring.After the porous ring is shunk back, come from the heat of the melted material in the groove and outside radial pressure the base substrate shell is softened, push material to the porous ring.Along with this softening material moves to the porous ring, material is underhardening again.When hardening once more, material is shunk back from the porous ring, stands to come from the heat of the melted material in the groove and outside radial pressure.This cyclic representation repeats, and its effect limits near liquate band under the surface on the Y surface of base substrate.The liquate band is characterised in that undesirable subsurface solidifying segregation under this surface.

It is desirable that subsurface liquate band is reduced to bottom line.Subsurface liquate band can be the following factor function of one of them at least, described factor is: the outside radial pressure that comes from the motlten metal in the groove, the solidification temperature range of material, the shock point of cooling medium and the melted material meniscus distance between the first make contact on the ring 442, the impact velocity of cooling medium, the value that the temperature of melted material exceeds than standard fusing point, and the speed of push rod 150 reductions.The outside radial pressure that comes from the melted material in the groove can be the function of the degree of depth of groove.Along with the reduction of the degree of depth of groove, the outward radial pressure that comes from the liquid melted material can reduce.Come from the reduction of the outside radial pressure of melted material, can reduce subsurface liquate band satisfactorily.Therefore, it is very desirable the degree of depth of groove being minimized.In the embodiment of a specific continuous casting, can not change the material feeding level of the inside of feed pipe 114 soon, because the temperature of these variable materials may have very high inertia, here, high inertia may be partly to be because the variable of supplying melted material continuously in the melting furnace of material and being kept causes.

The degree of depth of groove is reduced to MIN a kind of technology, is the Y face that utilizes X face ground, the top impact base substrate of the as close as possible base substrate of cooling agent.In other words, coolant water is the closer to the Y face of the top X face impact base substrate of base substrate, and the degree of depth of groove is shallow more.

Cooling agent impacts the residing X face of base substrate Y face, can be the function of the vertical span of heat absorption ring at least.The vertical span of heat absorption ring is long more, and cooling agent impacts the Y face of base substrate more away from the top X face of base substrate.The vertical span of heat absorption ring is short more, and cooling agent impacts base substrate Y face the closer to the top X face of base substrate.But the vertical span of heat absorption ring must surpass a minimum length, leaks from the bottom of heat absorption ring so that prevent melted material.

We remember that the mold tang 424 of Fig. 4 can be as the bottom of case 426, except taking away the heat from melted material head 154, also to base substrate 132 provide the structural supports.The vertical span of mold tang is long more, and cooling agent impacts base substrate Y face away from the top X face of base substrate more.Usually, the industrial standard of the ring that is used to absorb heat comprises one inch high graphite annulus and the high mold tang of [5/8] inch, so that provide a 1-[5/8] the industrial standard heat absorption ring of inch vertical span.

The surprising result of cooling agent curtain of the present invention is that the efficient of this cooling agent curtain allows the vertical span of heat absorption ring 420 low to [7/8] inch.The reduction of the height of heat absorption ring 420 can provide 25% improvement with respect to traditional industrial standard.Heat absorption encircles 420 low vertical span, can reduce the degree of depth of groove significantly, reaches the metallographic structure of founding materials simultaneously.

Metallographic structure can be regarded as collective's term, can describe the following attribute of founding materials.If described attribute comprises one of content described below at least, metallographic structure can be very outstanding: (i) thinner interdendritic spacing; (ii) Zui Xiao subsurface liquate; (iii) in the microscopic segregation of intragranular minimum; The (iv) microscopic segregation of the minimum on the axle from the surface to the base substrate; (v) fine crystallite size; (vi) there is not shrinkage porosity; And (vi) avoid undesirable eutectic and peritectoid primary phase.And then, by utilizing a lot of in advance metals that impact of cooling agent, can increase casting speed.By reaching higher casting speed, can one class the productivity ratio maximization in 8 man-hours of present embodiment will be utilized.

In one embodiment, the vertical height of heat absorption ring 420 is less than 1-[5/8] inch.In one embodiment, the vertical height of heat absorption ring 420 at [7/8] inch with 1-{ mark (4/8) in the scope of inch.In another embodiment, the height of porous ring 422 [3/8] to [7/8] inch scope in, the vertical height of mold tang 424 { mark (2/8) } inch to { mark (6/8) } inch scope in.

In another embodiment, the vertical height of porous ring 422 is one of [3/8] inch, [5/8] inch and { mark (6/8) } inch, and the vertical height of mold tang 424 is one of { mark (2/8) } inch, [3/8] inch and { mark (4/8) } inch.

Cooling fluid tank 416, the staticizer as regulating cooling agent stream can comprise baffle ring 430.Fig. 5 represents the isometric view of baffle ring 430.As shown in Figure 4, baffle ring 430 can be slidingly matched or interference fit with cooling fluid tank 416, and be cooled agent ring 418 and mold case 426 remain on the Y direction.Owing to baffle ring 430 can be configured in the cooling fluid tank 416, two need not processing baffle ring maintenance lip in the material of cooling fluid tank 416, so, compare with traditional DC mold, utilize this embodiment of the present invention, can remarkably reduce manufacturing cost and reduce the waste of material.

Except porous ring 422 and mold tang 424, mold body 410 can also comprise mold case 426 and retaining ring 428.As shown in the figure, the mold case 426 that is installed to the Fig. 4 in the baffle ring 430 from the top, can utilize retaining ring 428 and gravity that mold case 426 is fixed in the cooling fluid tank 416.As shown in the figure, can utilize liner 432 to prevent to overflow such as fluids such as motlten metal or cooling agents.Mold case 426 can comprise direction face 434 and screwed hole 436.

Can comprise mold starting 412 in the DC mold 400.Mold starting 412 is similar to the mold starting 112 among Fig. 1.Mold starting 412 can comprise the cavity of pedestal and major thread, and hydraulic push rod can be fixed in this cavity.And then mold starting 412 can be as with respect to heat absorption ring 420 bottom independently.

Feed pipe 414 can comprise ceramic ring 438.Ceramic ring 438 can be installed in the mold case 426 from the top, makes that gravity helps ceramic ring 438 is fixed on the mold case 426.

Mould table can comprise one or more molds, from same horizontal liquid circulation road supply melted material.Be under the situation of a part of mould table at cooling fluid tank 416, the horizontal liquid circulation road of mould table with between the inlet of mold body 410, provide in the middle of to be connected be very radical.Therefore, feed pipe 414 may further include ceramic header 440.Pottery header 440 can comprise header opening 442.Fig. 6 represents the isometric view of ceramic header 440.

For ceramic header 440 is fixed on the ceramic ring 438, and despot's ceramic ring 438 is fixed on the mold case 426, and one embodiment of the present of invention can be by being configured near the hold-down bolt 41 and the tubular support 465 of the below of header retaining ring 444.For the header retaining ring 444 on the end face that is configured in ceramic header 440, can place header to become in the ring 444 hold-down bolt 441 and in the tubular support 465, and be fixed in the screwed hole 436 of mold case 426 by opening.Tubular support 465 when assembling DC mold 400, can prevent to use excessive torque.And this can keep the frangible integrality of ceramic ring 438 a longer time conversely, can reach several years.

As shown in the figure, can utilize ceramic gasket paper to prevent that melted material from leaking from feed pipe 414.Can utilize the deflocculated graphite filler, for example filler 447, be further used as liner and prevent the leakage of melted material, so that give otherwise be the lubricated character in surface one of coarse ceramic ring 438, and the filling corner makes not have the crack on the travel path such as the melted material of melted material 152.

The another one project that is included in the DC mold 400 can be a cooling agent ring 418.Cooling agent ring 418 can comprise lip 450 and adjusting range 452.As being clear that from Fig. 4, lip 450 can stretch out along radial direction, so that a face is provided, cooling agent ring 418 can be fixed on the cooling fluid tank 416 by this face.In one embodiment, cooling agent ring 418 is fixed on the cooling fluid tank 416 by the bottom side of a series of bolts from cooling fluid tank 416.In another embodiment, cooling agent ring 418 is fixed on the cooling fluid tank 416 by a series of bolt-locks, and each bolt-lock can comprise a rod, and this rod is enclosed within on the hook, and is fixed by being pressed downwardly onto on the bar that is combined on the described rod.At another is among the embodiment, and cooling agent ring 438 can utilize on the inner surface that is threadedly engaged to baffle ring 430, and can utilize gear mechanism to carry out remote control to make it to move up and down.

For the cooling agent ring 418 that is installed in the cooling fluid tank 416, the adjusting range of cooling agent ring 418 can with the direction face 424 of mold case 426 with certain angle of intersection, so that limit inwardly projecting orifice zone and nozzle opening.Described angle, mentioned nozzle area and nozzle opening can with angle 168, the inwardly projecting orifice zone 166 of Fig. 2, and nozzle opening 170 is similar.

In order to regulate the power of fluid volume and cooling agent curtain stream, and the direction of cooling agent curtain stream, can or remove shim liner between lip 450 and the cooling fluid tank 416 by configuration, the nozzle opening 170 of present embodiment is retrofited.Shim liner can be regarded as one thin, usually be the material piece of taper, be used to regulate the parts that needs cooperate as required.Described shim liner can comprise aluminium foil, the stainless steel substrates of thin size, perhaps any gasket material.

One embodiment of the present of invention can comprise one group of shim liner, and wherein, the number of shim liner group can from 1 to 100.One embodiment of the present of invention as the part of the tool assembly that comprises DC mold of the present invention, can comprise one group of 10 shim liner.Each shim liner in 10 one group shim liner group can be limited by the thickness in 0.001 to 0.01 inch the scope, and wherein, the thickness of each shim liner is only in the group of one group of 10 shim liner.Other one group of 10 thin slices can be limited by 0.01 inch thickness, and wherein, each shim liner 0.01 is thick.

Different alloys has different heat transfer characteristics.For example, about 60 kinds of aluminium alloys are arranged, each all has different heat transfer characteristics.Traditional practical operation, for each alloy that will cast, require to use different tool assemblies, perhaps, for each alloy, use the careful combination through research of push rod speed, coolant volume and pressure, material temperature, casting promoter program etc.But each shim liner of the present invention can provide the ability of the heat transfer characteristic that changes mold, makes and can utilize same tool assembly, adopts predetermined casting practical operation step, can cast different alloys.Utilize the possibility of the same tool assembly of the present invention alloy different with same casting practical operation casting, for each alloy that will cast or utilize different tool assemblies or utilize the practical operation of one group of new practical operation step, form fairly obvious contrast with traditionally.

Fig. 7 represents DC mould system 700 of the present invention.In DC mould system 700, can comprise mould table 702 with DC mold 400.DC mold 400 can be the DC mold that is included in the mould system 102.As noted, mould system 700 can also include various control systems and accessory system.

Fig. 8 is the isometric top view of the mould table 702 of Fig. 7.As shown in the figure, the service duct 704 of mould table 702 is provided with path, is used for melted material and reaches each header opening 442.

Because base substrate can be passed heat absorption ring 420 formation of Fig. 4, so, between billet surface and heat absorption ring 420, can reduce the parts that rub in the surface, so that assisting device passes through.In one embodiment of the invention, by lubricant service duct 454 lubricant is incorporated into the outside diameter of porous ring 422.Lubricant service duct 454 can be flexible, and can be attached on the mold case 426 by cooling agent ring 418, so that lubricant service duct 454 can not disturb with the cooling agent curtain.This can reach by lubricant passageway being set for following route, promptly, the lubricant service duct is from the bottom of cooling fluid tank 416, between the outside of the inside of cooling agent ring 418 and cooling agent curtain stream, and lubricant passageway 454 is fixed on the mold case 426.As the axle head of lubricant passageway 454, can pass through threaded engagement or ball and ratchet engages fixed to mold case 426.

In the preferred embodiment of DC mold of the present invention, under the situation that mold is installed from the mould table bottom, the lubricant service duct is also selected from the route of the bottom of mould table.The route selection of lubricant service duct 454 is become to rise to the bottom of cooling fluid tank 416, and between the outside of the inside of cooling agent ring 418 and cooling agent curtain stream, allow the unit are of mould table that more DC mold is arranged, and need be in the sealing between baffle ring and the lubricant service duct.Need not the sealing between baffle ring and lubricant passageway, can strive for reaching the chance that lubricant is mixed with cooling water and be reduced to bottom line.

Fig. 9 is the isometric bottom view of the mould table 702 of Fig. 7.Can in this view, see cooling agent ring 418 and the lubricant service duct 454 of Fig. 4.Figure 10 represents the base substrate 1000 by the present invention's production.Base substrate 1000 can be narrow or can have big diameter.For example, base substrate can be 20 feet long, and has 26 inches diameter.6 feet people 1002 of standard expresses the base substrate 1000 of large scale a reference is provided for having 4 inch diameters with 20 feet long.

II. example

Although for from the material of heat to the heat transmission of cooling medium flowing after deliberation surpass a century, for the heat transmission of direct chill casting after deliberation surpass half a century, but, the neither one researcher is not making some supposition and is receiving under a lot of approximate situations, with whole being brought together of the transmission of the heat in direct chill casting dynamic model.Lack global analysis.This part ground is owing to can suddenly jump over one to two order of magnitude in the speed of nucleateboiling district heat transmission.

When utilizing common water as cooling agent, the temperature range that nucleateboiling takes place is that 330 Hua Shidu are to 390 Hua Shidu.Particularly, under the situation of direct chill casting Birmasil, when utilizing recirculated water as the cooling medium practical operation, the initial surface temperature that is presented on the aluminium in the steam of water can be at 1100 Hua Shidu in the scope of 1200 Hua Shidu.When be in room temperature (perhaps room temperature ± 50 Hua Shidu) when water ran into 1200 Hua Shidu surperficial, various reactions took place on the interface.Physical reactions and chemical reaction when basically, these react in fact.

Utilize the law of thermodynamics and transient conditions and advection heat-quality (heat-mass) equation of transfer, the researcher briefly is formulated out various heat transfer models.But these models can not fully be foretold the casting behavior and the metallographic structure of founding materials.One of them reason may be, constantly change in the lip-deep Temperature Distribution of founding materials, real " stable state " Temperature Distribution be one in certain pattern of the condition of the variation of internal vibration at interval.The condition of these variations can be represented by following factor: (a) casting variable, as: speed, the volume of water, the geometry of mold, metal temperature, and the specific physical property of alloy, and (b) extraneous factor, for example, entry condition, mold filling speed, the pace of change of feeding material temperature, heat transmission by ceramic feed pipe, the oxidation of melted material, and some other parameter are such as atmospheric temperature, humidity, each of these factors are all set up outside the equational scope of model being used to.Thereby a main approach of exploitation and test direct chill casting mould system is experiment.Be to be accompanied by experiments more of the present invention below.

A. example 1

Configuration: manufacturing is used for the instrument of base substrate mould system according to the foregoing description, is used to use running water as the cooling medium Birmasil.Making described instrument is used for (i) casts 6 inches (" on the mould table with 30 mold capacity) base substrate of diameter; (ii) on mould table, cast 7 " base substrate of the diameter, " base substrate of diameter of (iii) on mould table, casting 8 with 18 mold capacity with 24 mold capacity.In each of above-mentioned three kinds of situations, cooperate the mold body that guide surface is provided from the downside on the top of cooling fluid tank.And then, from the downside of the bottom of cooling fluid tank, the water ring (cooling agent ring) with adjusting range is installed.Lubricated axle passes cooling agent ring and cooling fluid tank.Configuration is not included in the DC foundry pit prepares gland steam exhauster.The manufacturing cost of above-described entire tool is at U.S.$160, and 000 ± U.S.$20 is in 000 the scope.Described cost comprises that cooling fluid tank is the cost of the mould table of an integral part.

In the middle of operation, it is constant that the height of porous drip ring keeps, and is 0.81 inch, and it is constant that the height of mold tang keeps, and is 0.66 inch, and therefore, the total height of heat absorption ring is maintained at 0.147 ".Direction face angle with respect to the horizontal plane is maintained fixed with 68 degree.In the downstream of online coolant filtration device, under 9 pounds supply pressure per square inch, it is constant that the cumulative volume of the cooling agent of being supplied keeps, and is 720 gallons of per minutes.The temperature of the cooling agent of supply side remains in the scope of 75 ± 5 Hua Shidu.The temperature of melted material remains in 1250 to 1350 the wideer scope.The titanium (online) of interpolation 0.003% is used for grain refinement in melted material.Peanut oil as lubricant medium, in the time interval in per 20 seconds, will be adjusted to 0.005 cubic inch to the supply of each mold.In first group of test, nozzle opening is kept constant, be 0.93 inch, nozzle height is 0 inch.

In process of production, for each base substrate size, for alloy A A6063 (Aluminum Association (AA) Specification: ABAL (AA) specification) finish foundry goods more than a dozen.In the scope that the length of base substrate is from 225 to 240 inches, the overall average weight of each foundry goods is about 21,000 pounds.

The observation of example 1: in the middle of observing, can under the situation that aspect the dimensional stability of mould system, does not run into any problem, cast.Mould system keeps rigidity, and demonstrates with respect to beginning to the tolerance of the excellence of finishing caused heat fatigue by the casting circulation.In mold assembly use repeatedly, in motlten metal, coolant media and lubricating oil pipe line stream, do not observe leakage.To the position of base substrate and in below the mould table and the downstream of the point above the mould, do not observe steam in water slug.The surface of base substrate is that its smooth quality meets the industrial standard of setting for direct extrusion application.In the center of base substrate, the metallographic structure of base substrate demonstrates 75 microns crystallite dimension and about 30 microns unit cell dimension (gap between the dendrite).Subsurface its degree of depth of liquate band changes in 0.015 to 0.060 inch scope, on average approaches 0.030 inch.Break not causing, under the situation of tearing or leaking, the casting speed that can reach, for 8 " diameter be 4.95 "/minute, for 7 " diameter be 5.5/ minute.For 6 " diameter be 5.95 "/minute.

B. example 2

Configuration: except utilizing recirculation water as the cooling agent, all the other keep and example 1 described in condition.Recirculation water typically has following chemical property:

I) every liter of solids (, being 250 milligrams) that dissolves 1,200 milligram for running water;

Ii) total suspended solid of the about every cubic centimetre of 0.15kg that in casting process, produces, the perhaps pressure differential of 2 pounds (psi) per square inch by pot strainer (0.064 inch of sieve aperture);

Iii) every liter of total oil and content of oil and grease are 60 milligrams.

The observation of example 2: under observation,, do not observe harmful effect for the function of mould system as the result who utilizes recirculation water.In the foundry practice of base substrate, do not require and make change, utilize recirculation water and to utilize running water the same, can keep identical casting speed threshold value.In the metallographic structure of base substrate and the example 1 viewed do not demonstrate any different.

C. example 3

Configuration: compare with example 2, nozzle opening is narrowed to 0.79 inch, nozzle height changes to 0.01 inch from 0.It is identical that the configuration of all other parameters and example 2 keeps.Make base substrate " 21 foundry goods of diameter that are of a size of 8.The length of base substrate changes to 236 inches from 120 inches.

The observation of example 3: under observation, the function of whole mould system is improved.But this can obtain proof with the possibility of higher casting speed cast metal under the situation of the whole castability of surface that does not influence metallographic structure, cast article or alloy." base substrate of diameter demonstrates the casting speed above 5.85 inches of per minutes for 8.The productivity ratio of this total surface surpasses 18% improvement.Enlarging markedly of this casting speed is owing to the surface heat transfer coefficient of the excellence that causes by change nozzle opening and nozzle height.The area that this changes over the nuclear boiling district conversely provides higher impact velocity to keep the interior shear flow of cooling agent curtain simultaneously, and this will help steam bubbles to remove quickly from the surface of base substrate.

D. example 4

Configuration: except the chemical composition of material change into alloy A A2024 (AluminumAssociation (AA) Specification: ABAL (AA) specification), keep and example 3 in the same condition that provides.Alloy A A2024 material comprises copper and magnesium, because its bigger solidification temperature range and because it stands higher solidification shrinkage than alloy A A6063, so have higher for the sensitiveness of breaking.

The observation of example 4: under observation,, can be easy to carry out the practice of this material of casting by the above embodiment of the present invention according to the data and the hot transfer curve of groove.The metallographic structure of casting alloy AA2024 meets and makes the final widely extrusion whole requirements relevant with forging of using.

E. example 5

Configuration: except the direction face angle with respect to the horizontal plane except the cooling agent that impacts changes to 72 degree from 68 degree, it is identical with example 3 that all conditions keep.

The observation of example 5: under observation, for casting diameter 8 " AA6063 alloy base substrate, repeatedly reach the casting speed of 6.04 inches of per minutes.These casting speeds far surpass traditional direct chill casting industrial standard, and for the base substrate producer, provide significant bottom line advantage.

III. advantage

DC mold of the present invention and mould system provide a huge advantage, and they can produce excellent metallographic structure, are easy to assembling, and repairing/maintenance easily increases the Foundry Production rate, the more important thing is, allows Field adjustment, so that control heat is effectively transmitted.When making new alloy, this helps to reduce search time and expense.The instrument that this height of described embodiment is oversimplified can be from the top assembling of mould table, so that utilize gravity that the mold sealing is prevented that cooling water from leaking.And then the route of lubricant service duct can be set for and begins from the bottom of mould table and by the cooling agent ring.

The cooling capacity of the gram dynamic adjustments of embodiment DC mold recited above provides a kind of ability,, can control the castability of material effectively, till the casting condition that reaches stable state that is.Tearing for hot tearing, cold cracking, surface and oozing out in the continuous casting and D.C.casting of the material that demonstrates sensitiveness, strictly require this ability.Typically, these materials demonstrate following character: (i) very high solidification shrinkage (promptly, when its state from liquid during to solid state change, the contraction that material stands), (ii) bigger solidification temperature range (that is, temperature range till a last drop of liquid disappears occurring from groove) from first solid granulates, and (iii) with outside (promptly, in the surface) heat transfer coefficient compare lower internal heat conductivity.

Because the component count purpose reduces in described embodiment, the cost of each unit is markedly inferior to traditional DC mold and mould system.For example, be used for the DC mold of 30 traditional frames of the base substrate of 7 inch diameters, it is worth and is U.S.$300,000.Utilize the DC mold that is used for the base substrate of 7 inch diameters of the present invention, it is worth and is U.S.$210, and 000, save U.S.$90,000.The component count purpose reduces in described embodiment, weares and teares and needs with respect to less parts and change.This will cause reducing spare part and the cost of the parts (for example running stores) that are consumed in use.In addition, owing to reduce the number and the surface area of mating surface, so less parts have the chance of less metal or cooling agent leakage.This will cause reducing the probability of the reaction of uncontrollable metal and cooling agent, and known, it can blast some this reaction in essence.

The embodiment of DC mold of the present invention and mould system also provides some other advantages.Traditionally, the turbulent flow of the cooling agent of interruption stream and cooling agent is owing to can not wipe out fine steam bubbles from billet surface, the generation of the steam that promotion is freely risen.But the nozzle opening 170 that the embodiment of mold water ring geometry can be by Fig. 2, angle 134 and nozzle height 172 particularly under nozzle height 172 is 0 situation, can be controlled the generation of the steam in the casting station.Because cooling agent curtain 130 can be near the laminar flow of the continual cooling agent the configuration billet surface 133, so, can be further the generation of the steam that freely rises be reduced to bottom line by the present invention.The generation of control steam is with the visibility maximization of manufactured product, the therefore security that increases operator and equipment.And then, control the generation of free rising steam, can need not to utilize expensive steam induced-draught fan system.

As in the typical practical operation, when cooling agent was recirculation water in the DC casting operation, the recirculation cooling agent was assembled a large amount of foreign particles.These foreign particles tend to block coolant channel.And then, if the poor quality of cooling medium.Then deposit or sediment may be in the back side of mold (for example, on the direction face 434 at Fig. 4) crystallizations.If periodically these deposits are not removed, deposit will reduce the pyroconductivity of mold.An example is if utilize the recirculation water with high water hardness as cooling medium, then usually to form the deposit of calcium and magnesium in the rear side of mold.

Usually, such as the inspection of the cooling duct of DC mold and cleaning be the loaded down with trivial details work of the routine of after finishing each casting, carrying out.Except the cleaning mold, only be the inspection of the cooling duct of traditional mold, itself be exactly a kind of trouble and tediously long task.Whole mold must be taken apart together with its whole sealings.Produce the used time except being used for base substrate, this will spend the considerable time.

Comparing with mould system with traditional DC mold, is unusual easy to reach for the maintenance of coolant channel of the present invention, because by pulling down the following cooling agent ring that is positioned at mold of the present invention, the workman can be easy to clear up the path in the coolant channel.Experiment shows that a DC mold of the present invention can clean out and assemble up and rework in 3 minutes.20 minutes maintenance time of a this maintenance time of the present invention and a traditional DC mold makes a sharp contrast.Therefore, this special maintenance form of the present invention can reduce total casting turnaround time, thereby, further increase productivity ratio.

The heat transfer surface of the heat absorption ring of traditional DC mould system is so to be difficult to approachingly, makes the surfaceman usually ignore and removes the calcium be blocked on the heat transfer surface.But, as can be seen from Figure 9, be positioned at surfaceman below the mould table 702 and can remove calcium on the heat transfer surface that is blocked in heat absorption ring of the present invention, and need not to unload any parts of the present invention.Coolant channel of the present invention can easily safeguard, can relax the requirement for the filtration of the strictness of the cooling agent that uses in traditional DC mould system.

User-friendly, cheap and simple embodiment of the present invention is converted into long-life DC mold.Because can utilize the identical different alloy of tool assembly casting of the present invention, so, comparing with traditional DC mold, the present invention has replacement and uses widely in the base substrate manufacture.And then, compare refining embodiment with traditional mold design, on the unit are of mould table 702, allow more DC mold.This can provide more positive management control in whole base substrate is produced.

Eco-friendly DC mold of the present invention and mould system, following advantage is provided, that is, cause the advantage of the casting speed aspect that productivity ratio is improved, cause metallurgically improved liquate band under the surface being reduced to MIN advantage, make easily, assembling easily, and cause quality and the improved versatility of productivity ratio, cause the less parts of economic worth, cause safeguarding improved cleanability, and the improvement of security.Therefore, embodiments of the invention provide a kind of DC mold assembly, and described mold assembly has a lot of improvement for operator's use, and by these improvement, base substrate production workshop can benefit.

Exemplary embodiment as described herein just furnishes an explanation to principle of the present invention, should not be construed as the restriction of the purport scope that claim of the present invention is proposed.Principle of the present invention can be used and system widely, reaching advantage as described herein, and reaches other advantage and satisfies other purpose.

Claims

1. direct chill casting mold comprises: mold body, described mold body comprise direction face and the flange that extends radially outward; Be used to keep the box-type device of cooling agent, this box-type device is attached to the upside of mold body flange; The cooling agent ring, it comprises adjusting range, described cooling agent loops is incorporated into the downside of box-type device, be used to keep cooling agent, so that make adjusting range and direction face close mutually to form nozzle, described direction mask has the position based on the position of adjusting range, wherein, and can regulate in the position of described direction face and the position of adjusting range; Mold starting head; Heat absorption ring, wherein, described heat absorption ring comprises the porous ring with certain altitude, wherein, the height of described porous ring at [3/8] inch to the scope of [7/8] inch; And the lubricant feed lines, this path, by the inside of cooling agent ring and is attached on the mold case from the downside of cooling agent ring.

2. direct chill casting mold as claimed in claim 1 is characterized in that, the heat absorption ring is limited by the span less than { mark (15/8) } inch.

3. direct chill casting mold as claimed in claim 2 is characterized in that, described span is in the scope of [7/8] inch and { mark (14/8) } inch.

4. direct chill casting mold as claimed in claim 1 is characterized in that, the heat absorption ring further comprises the mold tang with certain altitude, and wherein, the height of described mold tang arrives in the scope of { mark (6/8) } inch at { mark (2/8) } inch.

5. direct chill casting mold as claimed in claim 1 is characterized in that, the direction face is limited by an angle, and wherein, described angle is spent in the scope of 85 degree 60.

6. direct chill casting mold as claimed in claim 5 is characterized in that, described angle is spent in the scope of 75 degree 60, and this angle is angle with respect to the horizontal plane.

7. direct chill casting mold as claimed in claim 5 is characterized in that, described angle is spent in the scope of 72 degree 67.

8. direct chill casting mold as claimed in claim 1, it is characterized in that, the mold body further comprises mold case, the retaining ring with mold tang and is attached to porous ring on the mold body, the position that described porous ring combines with the mold body is near the mold tang, wherein, retaining ring is attached to the mold case in the device that is used to keep cooling agent.

9. direct chill casting mold as claimed in claim 1 is characterized in that, being used to keep the device of cooling agent is the part of mould table.

10. direct chill casting mold as claimed in claim 1 is characterized in that, further comprises: baffle ring, this baffle ring are made into to be coupled to and are used to keep in the device of cooling agent, and are held by mold body and cooling agent environmental protection.

11. direct chill casting mold as claimed in claim 1 is characterized in that, adjusting range is limited with an angle, and described angle is spent in the scope of 90 degree 0.

12. direct chill casting mold as claimed in claim 11 is characterized in that, described angle is spent in the scope of 12 degree 4.

13. direct chill casting mold as claimed in claim 12 is characterized in that, the angle ranging from 6 degree.

14. direct chill casting mold as claimed in claim 1 is characterized in that nozzle comprises nozzle opening, wherein, described nozzle opening can be regulated.

15. direct chill casting mold as claimed in claim 14 is characterized in that, nozzle opening is in 0.050 to 0.150 inch scope.

16. direct chill casting mold as claimed in claim 15 is characterized in that, nozzle opening is in 0.070 to 0.108 inch scope.

17. direct chill casting mold as claimed in claim 1 is characterized in that nozzle comprises nozzle height, wherein, nozzle height can be regulated.

18. direct chill casting mold as claimed in claim 17 is characterized in that, is 0 position with respect to nozzle height, nozzle height is in positive and negative 0.200 inch scope.

19. direct chill casting mold as claimed in claim 18 is characterized in that, is 0 position with respect to nozzle height, nozzle height is in 0 to 0.100 inch scope.

20. direct chill casting mold as claimed in claim 1 is characterized in that, nozzle height can be with 0.01 inch incremental adjustments.

21. direct chill casting mold as claimed in claim 20 is characterized in that, nozzle height is 0 inch.

22. direct chill casting mold as claimed in claim 1 is characterized in that nozzle comprises nozzle distance, wherein, described nozzle distance can be regulated.

23. direct chill casting mold as claimed in claim 22 is characterized in that nozzle distance is in 0.06 inch to 0.36 inch scope.

24. direct chill casting mold as claimed in claim 1 is characterized in that, irrelevant with used unit, nozzle distance is one a multiple at least 0.0010 and 0.0060.

25. direct chill casting mold as claimed in claim 24 is characterized in that, nozzle distance is 0.090 inch.

26. direct chill casting mold as claimed in claim 1, it is characterized in that, further comprise: at least one shim liner, described shim liner are configured between the device that is used for keeping cooling agent and the mold body and cooling agent ring and being used for keeps between the device of cooling agent at least one.

27. direct chill casting mold as claimed in claim 1 is characterized in that, further comprises: at least one gear, described gear and mold body contact with at least one rotation in the cooling agent ring.

28. direct chill casting mold as claimed in claim 1 is characterized in that, further comprises: be attached to the feed pipe on the mold body.

29. direct chill casting mold as claimed in claim 1 is characterized in that, further comprises: accessory system, described accessory system have at least one hydraulic fluid tank, cooling agent cassette for supplying, stuffing-box, lubricant case; And control system, described control system has the computer server of communicating by letter with accessory system.

30. direct chill casting mold as claimed in claim 29 is characterized in that, further comprises: at least one is attached to computer client on the computer server by network.

31. direct chill casting mold as claimed in claim 30 is characterized in that described network is the internet.

32. direct chill casting mold as claimed in claim 1 is characterized in that, owing to keep the device of cooling agent to comprise cooling fluid tank.