EP0124684B1 - Coulée dans une atmosphère à faible densité thermiquement induite - Google Patents
Coulée dans une atmosphère à faible densité thermiquement induite Download PDFInfo
- Publication number
- EP0124684B1 EP0124684B1 EP84101165A EP84101165A EP0124684B1 EP 0124684 B1 EP0124684 B1 EP 0124684B1 EP 84101165 A EP84101165 A EP 84101165A EP 84101165 A EP84101165 A EP 84101165A EP 0124684 B1 EP0124684 B1 EP 0124684B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- strip
- gas
- casting
- atmosphere
- molten metal
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/005—Continuous casting of metals, i.e. casting in indefinite lengths of wire
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
- B22D11/0637—Accessories therefor
- B22D11/064—Accessories therefor for supplying molten metal
Definitions
- the invention relates to an apparatus and a method for casting of metal strip directly from a melt, and more particularly to the rapid solidification of metal directly from a melt to form substantially continuous metal strip according to the preamble of claim 1 and claim 5.
- U.S. Patent No. 4,142,571 issued to M. Narasimhan and forming the first part of claims 1 and 5 discloses a conventional apparatus and method for rapidly quenching a stream of molten metal to form continuous metal strip.
- the metal can be cast in an inert atmosphere or a partial vacuum.
- U.S. Patent No. 3,862,658 issued to J. Bedell and U.S. Patent No. 4,202,404 issued to C. Carlson disclose flexible belts employed to prolong contact of cast metal filament with a quench surface.
- U.S. Patent No. 4,154,283 to R. Ray et al. discloses that vacuum casting of metal strip reduces the formation of gas pocket defects.
- the vacuum casting system taught by Ray et al. requires specialized chambers and pumps to produce a low pressure casting atmosphere.
- auxiliary means are required to continuously transport the cast strip out of the vacuum chamber. Further, in such a vacuum casting system, the strip tends to weld excessively to the quench surface instead of breaking away as typically happens when casting in an ambient atmosphere.
- U.S. Patent No. 4,301,855 issued to H. Suzuki et al. discloses an apparatus for casting metal ribbon wherein the molten metal is poured from a heated nozzle onto the outer peripheral surface of a rotary roll.
- a cover encloses the roll surface upstream of the nozzle to provide a chamber, the atmosphere of which is evacuated by a vacuum pump.
- a heater in the cover heats the roll surface upstream from the nozzle to remove dew droplets and gases from the roll surface.
- the vacuum chamber lowers the density of the moving gas layer next to the casting roll surface, thereby decreasing formation of air pocket depressions in the cast ribbon. The heater helps drive off moisture and adhered gases from the roll surface to further decrease formation of air pocket depressions.
- the apparatus disclosed by Suzuki et al. does not pour metal onto the casting surface until that surface has exited the vacuum chamber. By this procedure, complications involved in removing a rapidly advancing ribbon from the vacuum chamber are avoided.
- the ribbon is actuary cast in the open atmosphere, offsetting any potential improvement in ribbon quality.
- U.S. Patent No. 3,861,450 to Mobley, et al. discloses a method and apparatus for making metal filament.
- a disk-like, heat-extracting member rotates to dip an edge surface thereof into a molten pool, and a non-oxidizing gas is introduced at a critical process region where the moving surface enters the melt.
- This non-oxidizing gas can be a reducing gas, the combustion of which in the atmosphere yields reducing or non-oxidizing combustion products at the critical process region.
- a cover composed of carbon or graphite encloses a portion of the disk and reacts with the oxygen adjacent the cover to produce non-oxidizing carbon monoxide and carbon dioxide gases which can then surround the disk portion and the entry region of the melt.
- non-oxidizing gas as taught by Mobley, et al., disrupts and replaces an adherent layer of oxidizing gas with the non-oxidizing gas.
- the controlled introduction of non-oxidizing gas also provides a barrier to prevent particulate solid materials on the melt surface from collecting at the criticial process region where the rotating disk would drag the impurities into the melt to the point of initial filament solidification.
- the exclusion of oxidizing gas and floating contaminants from the critical region increases the stability of the filament release point from the rotating disk by decreasing the adhesion therebetween and promoting spontaneous release.
- Mobley, et al. address only the problem of oxidation at the disk surface and in the melt.
- the flowing stream of non-oxidizing gas taught by Mobley, et al. is still drawn into the molten pool by the viscous drap of the rotating wheel and can separate the melt from the disk edge to momentarily disturb filament formation.
- Mobley, et al The particular advantage provided by Mobley, et al, is that the non-oxidizing gas decreaes the oxidation at the actual point of filament formation within the melt pool. Thus, Mobley, et al. fail to minimize the entrainment of gas that could separate and insulate the disk surface from the melt.
- U.S. Patent No. 4,282,921 and U.S. Patent No. 4,262,734 issued to H. Liebermann disclose an apparatus and method in which coaxial gas jets are employed to reduce edge defects in rapidly quenched amorphous strips.
- U.S. Patent No. 4,177,856 and U.S. Patent No. 4,144,926 issued to H. Liebermann disclose a method and apparatus in which a Reynolds number parameter is controlled to reduce edge defects in rapidly quenched amorphous strip. Gas densities and thus Reynolds numbers, are regulated by the use of vacuum and by employing lower molecular weight gases.
- the object of the invention is an apparatus and method for efficiently casting smooth metal strip and substantially preventing the formation of gas pocket defects therein.
- the apparatus of the invention for casting metal strip comprising:
- the method and apparatus of the invention advantageously minimize the formation and entrapment of gas pockets against the quenched surface during the casting of the strip.
- the invention avoids the needs for complex vacuum casting apparatus and can be practiced in an ambient atmosphere.
- the heated gas within the depletion region surprisingly provides better and more uniform cooling and quenching of the molten metal.
- the hot gas provides a low density atmosphere that inhibits the formation of gas pockets operating to decrease contact between the molten metal and the quench surface.
- the more uniform quenching provides improved phsyical properties in the cast strip.
- the reduction of surface defects on the quenched surface side of the strip increases the packing factor of the material and reduces localized stress concentrations that can cause premature fatigue failure.
- the smoothness of the free surface side of the cast strip is also improved by the method and apparatus of the invention. This increased smoothness further increases the packing factor of the material.
- the more uniform quenching afforded by the low density atmosphere provides a more consistent and uniform formation of the amorphous state.
- the number and size of strip surface discontinuities is reduced, improving the magnetic properties of the strip.
- the present invention effectively minimizes gas pocket defects on the strip surface which contacts the quench surface, and produces strip having a smooth surface finish and uniform physical properties.
- Complex equipment and procedures associated with vacuum casting are eliminated.
- the invention efficiently casts ultra thin as well as extra thick metal strip directly from the melt at lower cost and with higher yield. Such ultra thin and extra thick strips are especially suited for use in such applications as magnetic devices and can be substituted for conventional materials with greater effectiveness and economy.
- a strip is a slender body the transverse dimensions of which are much smaller than its length.
- a strip includes wire, ribbon, sheet and the like of regular or irregular cross-section.
- the invention is suitable for casting metal strip composed of crystalline or amorphous metal and is particularly suited for producing metal strip which is rapidly solidified and quenched at a rate of at least about 10'C/sec from a melt of molten metal.
- Such rapidly solidified strip has improved physical properties, such as improved tensile strength, ductility and magnetic properties.
- FIG. 1 shows a representative prior art device for rapidly casting continuous metal strip.
- Molten metal alloy contained in crucible 2 is heated by a heating element 3.
- Pressurization of the crucible with an inert gas forces a molten stream through a nozzle 4 at the base of the crucible and deposits the molten metal onto a moving chill body, such as rotatable casting wheel 1.
- Solidified moving strip 6, after its break-away point from the quench wheel is then routed onto a suitable winding means.
- Quench surface 5 is preferably a material having high thermal conductivity. Suitable materials include carbon steel, stainless steel and copper based alloys such as beryllium copper. To achieve the quench rates of at least about 10 4 °C per second, wheel 1 is internally cooled and rotated to provide a quench surface that advances at a speed ranging from about 100-4000 meters per minute. Preferably, the quench surface speed ranges from about 200-3000 meters per minute. Typically, the thickness of the cast strip ranges from 25-100 microns (micrometers).
- FIG. 2 shows a representative apparatus of the invention.
- a moving chill body such as endless casting belt 7, has a chilled casting quench surface 5.
- Nozzle means such as nozzle 4, deposits a stream of molten metal onto a quenching region 14 of quench surface 5 to form strip 6.
- Nozzle 4 has an orifice 22 located at exit portion 26.
- a depletion means including gas nozzle delivery means 8, heater means 10, and gas supply 12, heat a gas 24 from gas supply 12 to produce a low density atmosphere and directs the gas with gas nozzle 8 to a depletion region 13 located adjacent to and upstream from quenching region 14.
- Nozzle 8 is suitably located to direct gas 24 at and around the depletion region 13 so that the gas 24 substantially floods the depletion region 13, providing a low density atmosphere therewithin.
- Valve 16 regulates the volume and velocity through nozzle 8.
- gas nozzle 8 is located upstream of quenching region 14 and is- directed along the direction of movement of the quench surface.
- gas nozzle 8 can be located coaxial with casting nozzle 4 as representatively shown in FIG. 3.
- low density atmosphere means an atmosphere having a gas density less than 1 gram per liter and preferably, having a gas density of less than about 0.5 grams per liter.
- gas 24 is heated to at least about 800K, and more preferably, is heated to at least about 1300K.
- hotter gases are preferred because they will have lower densities and will better minimize the formation and entrapment of gas pockets between quench surface 5 and the deposited molten metal.
- Entrapped gas pockets are undesirable because they produce ribbon surface defects that degrade the surface smoothness. In extreme cases, the gas pockets will cause perforations through strip 6.
- a very smooth surface finish is particularly important when winding magnetic metal strip to form magnetic cores because surface defects reduce the packing factor of the material.
- the packing factor is the volume fraction of the actual magnetic material in the wound core (the volume of magnetic material divided by the total core volume) and is often expressed in percent.
- a smooth surface without defects is also important in optimizing the magnetic properties of strip 6 and in minimizing localized stress concentrations that would otherwise reduce the fatigue resistance of the strip.
- Gas pockets also insulate the deposit molten metal from quench surface 5 and reduce the quench rate in localized areas.
- the resultant, non-uniform quenching produces non-uniform physical properties in strip 6, such as non-uniform strength, ductility and magnetic properties.
- gas pockets can allow undesired crystallization in localized portions of the strip.
- the gas pockets and the local crystallizations produce discontinuities which inhibit mobility of magnetic domain walls, thereby degrading the magnetic properties of the material.
- the invention produces high quality metal strip with improved surface finish and improved physical properties.
- metal strip has been produced with packing factors of at least 80%, and up to about 95%.
- the mechanism by which gas pockets are reduced can be more readily explained with reference to FIG. 6.
- the gas boundary layer velocity profile near quench surface 5 and upstream of melt puddle 18 is shown schematically at 20.
- the maximum gas boundary layer velocity occurs immediately adjacent to quench surface 5 (substrate) and is equal to the velocity of the moving quench surface.
- moving quench surface 5 ordinarily draws cool air from the ambient atmosphere into depletion region 13 and into quenching region 14, the region of the quench surface upon which molten metal is deposited. Because of the drafting of relatively cool air into the quenching region, the presence of the hot casting nozzle and the molten metal do not sufficiently heat the local atmosphere to significantly reduce the density thereof.
- Melt puddle 18 wets the substrate surface to an extent determined by various factors including the metal alloy composition, the substrate composition, and the presence of surface films.
- the pressure exerted by the gas boundary layer at the melt-substrate interface acts to locally separate the melt from the substrate and form entrained gas pockets which will appear as "lift-off" areas 44 on the ribbon underside.
- the stagnation pressure of the gas boundary layer pressure if the layer hit a rigid wall
- P s gas density
- v substrate velocity. Therefore, the reduction of gas boundary layer density or substrate velocity are important in the reduction of the size and the number of gas pockets entrained under the molten metal puddle.
- a low density gas in the boundary layer could be employed.
- the selection of a low molecular weight gas is one way to reduce boundary layer gas density.
- the variety of low molecular weight gases which can be used in this fashion is quite limited.
- a preferred manner in which to reduce the boundary layer gas density is to use a heated gas; the density of the gas will diminish as the inverse of the absolute temperature.
- the heating of the gas atmosphere located proximate to quenching region 14 to decrease the density thereof does not degrade the quenching of the molten metal.
- the heating actually improves the uniformity of the quench rate by minimizing the presence of insulating, entrapped gas pockets, and thereby improves the quality of the cast strip.
- FIG. 4 shows an embodiment of the invention in which the aforesaid gases are supplied at low density by a depletion means.
- Nozzle 4 deposits molten metal onto quench surface 5 of rotating casting wheel 1 to form strip 6.
- the depletion means in this embodiment is comprised of gas supply 12, gas nozzle 8 and heater means 10.
- Valve 16 regulates the volume and velocity of gas delivered through gas nozzle 8, and a wiper brush 42 conditions quench surface 5 to help reduce oxidation thereon.
- Heater means 10 heats the gas to produce a heated, low-density atmosphere around depletion region 13 and around quenching region 14 where molten metal is deposited. As a result, a hot, low density atmosphere is located around quenching region 14 and for a distance on either side thereof.
- additional gas nozzles 32 and heater means 33 can be employed, together with gas supply 12' to provide additional atmospheres 36 along selected portions of strip 6 to further protect the strip from oxidation.
- the invention may optionally include a flexible hugger belt 38 which entrains strip 6 against quench surface 5 to prolong cooling contact therewith.
- the prolonged contact improves the quenching of strip 6 by providing a more uniform and prolonged cooling period for the strip.
- Guide wheels 40 position belt 38 in the desired hugging position along quench surface 5, and a drive means moves belt 38 such that the belt portion in hugging relation to quench surface 5 moves at a velocity substantially equal to the velocity of the quench surface.
- belt 38 overlaps the marginal portions of strip 6 to directly contact and frictionally engage quench surface 5. This frictional engagement provides the required driving means to move the belt.
- a further advantage of thin strip is that the strip experiences less bending stresses when wound to a given diameter. Excessive bending stresses will degrade the magnetic properties through the phenomenon of magnetostriction.
- the apparatus and method of the invention are particularly useful for forming very thin metal strip. Since the invention significantly reduces the size and depth of gas pocket defects, there is less chance that such a defect will be large enough to perforate the case strip. As a result, very thin strip can be cast because there is less probability that a defect large enough to perforate the strip will form.
- the invention can be adapted to cast very thin metal strip, which as-cast, is less than about 15 micrometers thick.
- the cast strip has a thickness of 12 micrometers or less. More preferably, the cast strip thickness ranges from 7 to 12 micrometers.
- the thin metal strip has a width dimension which measures at least about 1.5 millimeters, and preferably measures at least about 10 mm.
- a forced-convection-cooled, plain carbon steel substrate wheel is 38 cm (15 in.) in diameter, 5 cm (2 in.) wide.
- nickel-base ribbons of composition Ni 6a Cv,Fe 3 B, 4 Si $ (subscripts in atomic percent) are produced on the steel wheel with low circumferential surface speed (about 10 m/s or 2,000 fpm) to avoid excessive ribbon-substrate adhesion.
- the substrate wheel is conditioned continuously during the run by an idling brush wheel inclined about 10° out of the casting direction.
- the ribbons exhibit very little adhesion on the substrate surface.
- An increase in casting pressure and an increase substrate surface speed help improve ribbon substrate adhesion.
- All of the ribbons cast show significant populations of entrapped air pockets in the underside.
- a dark oxidation track which forms on the substrate surface during ribbon casting, limits the ribbon to substrate adhesion.
- a hot gas stream directed at the ribbon casting track upstream of the melt puddle, reduces oxidation and promotes ribbon-substrate adhesion. The combined actions of the hot gas stream and the conditioning brush reduce the substrate oxidation, increase adhesion and produce ribbon having good geometric uniformity.
Claims (9)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US48347483A | 1983-04-11 | 1983-04-11 | |
US483474 | 1983-04-11 |
Publications (2)
Publication Number | Publication Date |
---|---|
EP0124684A1 EP0124684A1 (fr) | 1984-11-14 |
EP0124684B1 true EP0124684B1 (fr) | 1987-05-06 |
Family
ID=23920183
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP84101165A Expired EP0124684B1 (fr) | 1983-04-11 | 1984-02-06 | Coulée dans une atmosphère à faible densité thermiquement induite |
Country Status (5)
Country | Link |
---|---|
EP (1) | EP0124684B1 (fr) |
JP (1) | JPS59209457A (fr) |
AU (1) | AU2453584A (fr) |
CA (1) | CA1241819A (fr) |
DE (1) | DE3463460D1 (fr) |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS62114747A (ja) * | 1985-11-15 | 1987-05-26 | O C C:Kk | 結晶が鋳造方向に長く伸びた一方向凝固組織を有する金属条の連続鋳造法 |
JPS62161443A (ja) * | 1986-01-09 | 1987-07-17 | Nippon Steel Corp | 金属細線の鋳造方法 |
US5103895A (en) * | 1989-07-20 | 1992-04-14 | Nippon Steel Corporation | Method and apparatus of continuously casting a metal sheet |
US6749700B2 (en) | 2001-02-14 | 2004-06-15 | Hitachi Metals Ltd. | Method for producing amorphous alloy ribbon, and method for producing nano-crystalline alloy ribbon with same |
Family Cites Families (17)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3861450A (en) * | 1973-04-06 | 1975-01-21 | Battelle Development Corp | An improved method of formation of filament directly from molten material |
US3862658A (en) * | 1973-05-16 | 1975-01-28 | Allied Chem | Extended retention of melt spun ribbon on quenching wheel |
CA1068470A (fr) * | 1975-02-24 | 1979-12-25 | Allied Chemical Corporation | Production de filaments ameliores faits d'alliage metallique |
US4142571A (en) * | 1976-10-22 | 1979-03-06 | Allied Chemical Corporation | Continuous casting method for metallic strips |
JPS5474698A (en) * | 1977-11-28 | 1979-06-14 | Univ Tohoku | Superconductive thin band and method of fabricating same |
JPS6038226B2 (ja) * | 1978-06-23 | 1985-08-30 | 株式会社日立製作所 | 金属薄帯の製造装置 |
DE2830522A1 (de) * | 1978-07-12 | 1980-01-31 | Licentia Gmbh | Verfahren und vorrichtung zur herstellung von folien, baendern oder platten aus silizium |
US4202404A (en) * | 1979-01-02 | 1980-05-13 | Allied Chemical Corporation | Chill roll casting of amorphous metal strip |
JPS55136552A (en) * | 1979-03-23 | 1980-10-24 | Tohoku Metal Ind Ltd | Production of broad amorphous metal tape and producing apparatus thereof |
JPS5911164B2 (ja) * | 1979-05-31 | 1984-03-14 | 東北大学長 | 超伝導体薄帯の製造方法および装置 |
JPS5823826B2 (ja) * | 1979-06-15 | 1983-05-17 | 松下電器産業株式会社 | 急冷合金薄板の製造方法 |
US4262734A (en) * | 1979-09-17 | 1981-04-21 | General Electric Company | Apparatus for melt puddle control and quench rate improvement in melt-spinning of metallic ribbons |
US4282921A (en) * | 1979-09-17 | 1981-08-11 | General Electric Company | Method for melt puddle control and quench rate improvement in melt-spinning of metallic ribbons |
EP0038584B1 (fr) * | 1980-04-21 | 1984-08-15 | BBC Aktiengesellschaft Brown, Boveri & Cie. | Gaine de soudage comprenant plusieurs couches et procédé pour la fabrication de cette gaine |
EP0040488A1 (fr) * | 1980-05-15 | 1981-11-25 | International Business Machines Corporation | Procédé de fabrication d'une structure de ruban |
JPS57116356U (fr) * | 1981-01-09 | 1982-07-19 | ||
JPS57137058A (en) * | 1981-02-18 | 1982-08-24 | Nippon Steel Corp | Nozzle protecting device in producing device for amorphous alloy strip |
-
1984
- 1984-02-06 DE DE8484101165T patent/DE3463460D1/de not_active Expired
- 1984-02-06 EP EP84101165A patent/EP0124684B1/fr not_active Expired
- 1984-02-13 AU AU24535/84A patent/AU2453584A/en not_active Abandoned
- 1984-03-27 CA CA000450625A patent/CA1241819A/fr not_active Expired
- 1984-04-11 JP JP59072602A patent/JPS59209457A/ja active Granted
Also Published As
Publication number | Publication date |
---|---|
JPS59209457A (ja) | 1984-11-28 |
CA1268923C (fr) | 1990-05-15 |
CA1241819A (fr) | 1988-09-13 |
EP0124684A1 (fr) | 1984-11-14 |
AU2453584A (en) | 1984-10-18 |
JPH0218665B2 (fr) | 1990-04-26 |
DE3463460D1 (en) | 1987-06-11 |
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