EP1870182B1 - Procede de moulage d un alliage fondu - Google Patents

Procede de moulage d un alliage fondu Download PDF

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Publication number
EP1870182B1
EP1870182B1 EP06731431.0A EP06731431A EP1870182B1 EP 1870182 B1 EP1870182 B1 EP 1870182B1 EP 06731431 A EP06731431 A EP 06731431A EP 1870182 B1 EP1870182 B1 EP 1870182B1
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EP
European Patent Office
Prior art keywords
slag
molten alloy
ingot
casting
water
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EP06731431.0A
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German (de)
English (en)
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EP1870182A1 (fr
EP1870182A4 (fr
Inventor
Setsuo Mishima
Yasushi Ishimoto
Takanori Aikawa
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Proterial Ltd
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Hitachi Metals Ltd
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Publication of EP1870182A1 publication Critical patent/EP1870182A1/fr
Publication of EP1870182A4 publication Critical patent/EP1870182A4/fr
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    • 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
    • B22D11/04—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
    • B22D11/059—Mould materials or platings
    • 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
    • B22D11/04—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
    • B22D11/0401—Moulds provided with a feed head

Definitions

  • the present invention relates to a process for casting a molten alloy, which can prevent segregation such as centerline segregation and/or inverse V segregation, and form a fine structure.
  • VAR vacuum arc remelting process
  • ESR electroslag remelting process
  • the stacking solidification can decrease generation of segregation, such as centerline segregation or inverse V segregation, caused in casting into an ingot by virtue of a small solidification space. There is also an advantage that fine and homogenous structure is obtained, since the cooling rate can be increased by the use of a water-cooled mold.
  • Patent Document 1 discloses, as a process for solution of such problem, a technology based on the ESR process in which the effect of refinement can be expected by slag reaction.
  • the process includes producing fine droplets of molten alloy without the use of an electrode, adding a heated and melted slag layer to the molten alloy, and drawing an ingot from a bottom of a refined layer.
  • Patent Document 1 JP-A-62-4840
  • JP 2004 098092 A discloses a casting process with the features of the preamble of claim 1. A similar casting process is also suggested in JP 10 328 792 A .
  • EP-A-0 448 773 the inner walls of the mold are lined with heat-conductive ceramic tiles.
  • JP 11 300 448 A shows a heat insulator provided inside or at the outer surface of the wall of the mold.
  • the specific process described in the Patent Document 1 is a continuous casting process of holding a molten steel in a refining tank and drawing the molten steel from a water-cooled mold provided separately. Although this is referred to as stacking solidification in the Patent Document 1, stacking solidification in the technical field of the ESR and VAR processes is one solidified in a stacking manner as described above, and is different from that in the process disclosed in the Patent Document 1.
  • Patent Document 1 employs the continuous casting process, which is effective in producing the effect of refinement by slag which is one of the effects in application of ESR, but in which the ingot is forced to be drawn only with its surface solidified, the Patent Document 1 involves a problem that there is a possibility of generation of such deficiency as centerline segregation or center porosity, especially in high alloy. It also involves a problem that it is not possible to produce a small solidification space to provide a fine and homogeneous structure, which is an important advantage of ESR.
  • the inventors of the invention have found that a small molten alloy pool, which is approximate to that in ESR, can be formed in a solidification space, when the molten alloy is supplied to the solidification space, in which slag is held, under the condition of a very low casting rate of not more than 0.3 m/min. It has been also found that an ingot having a fine and homogeneous structure can be obtained by slag having the effects of thermal insulation and shielding of a molten alloy pool surface from outside air.
  • the inventors have reached the invention ascertaining that the direct cause for roughening the surface texture of the steel ingot, when stacking solidification like ESR is performed by supplying a molten alloy toward a water-cooled mold made of metal such as copper, iron, etc. through slag at a very low rate, resides in that the extraction of heat in the vicinity of a boundary between a solidified shell and slag, that is, in the vicinity of a meniscus position of the molten alloy pool is excessively large to lead to solidification of slag in a wide range, and drawing is made while a heat insulating layer is formed, or the cause resides in breakage of an initially solidified shell. They find that a steel ingot is considerably improved in surface texture, without inhibiting cooling, by arranging a heat insulator in the vicinity of the boundary.
  • the invention provides a process for casting a molten alloy as defined in claim 1, the process comprising pouring the molten alloy into a solidification space enclosed by an inside wall of a water-cooled mold and holding slag therein from a container holding the molten alloy therein to solidify the molten alloy while forming a molten alloy pool, and drawing an ingot vertically from a lower section of the water-cooled mold depending on the pouring rate of the molten alloy, wherein a heat insulator for suppressing an extraction of heat from slag is arranged in an upper section of the mold, the insulator having an inside wall shaped to be contiguous to the inside wall of the water-cooled mold.
  • an upper surface position of a meniscus in the molten alloy pool is controlled to come within a range where the heat insulator is arranged, in a steady state of casting.
  • the inside wall of the heat insulator in the invention is contiguous to the inside wall of the water-cooled mold on a downstream side.
  • the heat insulator is made of a graphite material.
  • the casting rate of the molten alloy in the invention is 0.01 to 0.1 m/min, more preferably at most 0.08 m/min, and still more preferably at most 0.05 m/min.
  • Slag applied in the invention is one having a low melting point of 500 to 1400°C and a thickness of 20 to 100 mm.
  • such an alloy can be applied as are especially difficult in obtaining fine grains and decreasing component segregation, such as tool steel such as cold die steel, hot die steel, or high-speed tool steel, other high alloy steel, or alloy steel applied to ESR.
  • the invention is desirably applied to the casting of a molten alloy which contains, by mass%, Fe as a main component, not more than 3.0% of C, and not less than 5% of other metallic elements than Fe, and more desirably the molten alloy contains 0.1 to 3.0 % of C, by mass%.
  • the invention since a stackingly solidified ingot can be obtained directly from a molten alloy, it is possible to ensure low cost and high productivity.
  • the invention is especially made effective because of a considerable decrease in processes when it is applied to the manufacture of a high alloy which is liable to generate segregation and deterioration in surface texture.
  • the invention has an important feature in a casting process for feeding a molten alloy into a solidification space, in which slag is held, at a very low rate while the extraction of heat from slag is suppressed by a heat insulator arranged on an upper portion of a water-cooled mold.
  • a molten alloy is poured into the solidification space which is enclosed by the inside wall of a water-cooled mold and in which slag is held, from a container, such as tundish, which holds the molten alloy therein.
  • a molten alloy is poured at a very low rate of not higher than 0.3 m/min and the molten alloy as fed is rapidly solidified while forming a molten alloy pool. Therefore, a solidification space is enclosed by the inside wall of a water-cooled mold.
  • an ingot is vertically drawn from the lower portion of the water-cooled mold depending on the pouring rate of the molten alloy (so that upper surface position of a meniscus be maintained substantially in a predetermined position).
  • the meniscus having a predetermined shape can be formed to obtain a stacked solidified ingot having a fine and homogeneous structure similar to that by ESR.
  • the roughened surface of an ingot cannot be improved only by the above method, and thus the invention employs an approach, in which casting is made while the extraction of heat from slag is suppressed by a heat insulator arranged on the upper portion of a water-cooled mold and having an inside wall contiguous to the inside wall of the water-cooled mold.
  • the heat insulator enables suppressing slag from being excessively solidified at a boundary between the slag and a solidified shell, and drawing of an ingot is inhibited from causing simultaneous descent of a solid slag and breakage of a solidified slag.
  • it is possible to prevent effusion of a molten steel caused by inadvertent crack of slag or crack of an underdeveloped solidified shell, enabling not only an improvement in ingot surface but also an improvement in ingot cooling.
  • an inside wall shaped to be continuous to the inside wall of a water-cooled mold is provided in the invention is that in case where the inside wall forms a large, discontinuous step or a clearance, a surplus stress acts on a solidified shell as formed when it slides on a mold wall surface, and thus the solidified shell is broken to lead to degradation of an ingot surface.
  • the heat insulator be shaped to have an inside wall having a substantially the same shape as that of the inside wall of the water-cooled mold on the downstream side in a cross section perpendicular to a direction in which an ingot is drawn.
  • the heat insulator according to the invention is positioned within that range, which is effective in restricting the extraction of heat from slag.
  • the solidification of slag has a most adverse effect on the boundary between slag in the vicinity of the mold and the meniscus of a molten alloy pool, that is, in a position where a solidified shell is formed.
  • the invention relates to dynamic casting and thus is effective to demonstrate the effect of suppressing the extraction of heat from slag by the heat insulator especially in a position where a solidified shell is formed, in the steady state of casting.
  • the position where the solidified shell is formed is close to an upper surface position of a meniscus of the molten alloy pool. Since the upper surface position of the meniscus is easily detected as an object to be controlled, it is desired to control the upper surface position of the meniscus in the molten alloy pool to be within the range where the heat insulator is arranged, in the steady state of casting.
  • a lower end position of the heat insulator arranged in the vicinity of a boundary between a solidified shell and slag preferably comes within the range of 100 mm downward from a controlled position of the molten alloy surface (upper surface position of the meniscus), since the original cooling function is degraded when the heat insulator excessively covers the water-cooled mold.
  • the lower end position of the heat insulator preferably comes out of the range of 10 mm downward from the upper surface position of the meniscus.
  • an upper end position of the heat insulator is preferably arranged above an upper surface of the slag. This is for the sake of handling in mounting of the heat insulator and thermal insulation over a slag region.
  • a heat insulator in the invention is a material which has excellent resistance to slag errosion and slidability in addition to heat resistance. While ceramics, etc. can be used, ceramics containing graphite is effective with respect to slidability. Furthermore, a graphite material having excellent resistance to slag errosion, moldability, and slidability is arranged.
  • a container for holding a molten alloy in the invention comprises any one as well as one called tundish.
  • it may be a container having heating means according to need.
  • a casting mold formed by a water-cooled mold preferably has a circular shape from the viewpoint of uniformity in a configuration of solidification, it may have elliptical or rectangular shape taking into consideration a shape of an ingot, manufacturability, etc. It is desired, in order to make a small solidification space, that a water-cooled mold be made of a metal having excellent heat conductivity, such as iron or copper.
  • slag is important to insulation of heat and shielding of a surface of the molten alloy pool from outside air, as well as to the refining action such as trapping of inclusion, or desulfurizing of a molten alloy.
  • a method of feeding a molten alloy is not limited in the invention. It is expected that the refining effect is improved owing to slag reaction when the molten alloy is poured so as to pass through the slag. In this case, however, there is a possibility that flow of a molten alloy at the time of pouring agitates slag to trap the slag, which becomes an inclusion in the ingot.
  • the refining effect owing to slag reaction cannot be expected much, but generation of an inclusion due to agitation of slag can be prevented. Accordingly, it is desirable to appropriately select the method of feeding a molten alloy, according to the invention, depending on a required quality and taking into consideration the relationship with slag.
  • heating means for the purpose of temperature control on slag. It is simple and effective as heating means to use Joule heat obtained by carrying current through slag.
  • an electrode for current-carrying is arranged so that current flows concentratedly on the outer periphery of slag. Heating of slag enables suppressing generation of an abnormal structure on a surface layer and mitigating the detrimental quality of slag having a high melting point.
  • Slag temperature is preferably below the casting temperature.
  • Slag having such a low melting point forms, together with the effect of a heat insulator, an appropriate slag solidified layer on the side of the heat insulator, and permits little slag to enter between an ingot and a water-cooled mold, so that generation of crack is suppressed on a solidified shell.
  • slag is preferable since direct contact between a molten alloy and the water-cooled mold is avoided, and an ingot having a favorable casting surface can be drawn along the water-cooled mold.
  • Slag having a melting point below 500°C is not practical. Rather, slag having a low melting point of 500 to 1400°C is used.
  • a slag layer preferably has a thickness of 20 mm to 100 mm.
  • a casting rate of the molten alloy is not higher than 0.3 m/min in the invention is that, when the casting rate is too large, it is hard to obtain a structure which is homogeneous and less in segregation which stacking solidification aims, and there is a possibility that slag may be trapped in the molten alloy.
  • the casting rate is not higher than 0.1 m/min, and preferably, it is not higher than 0.05 m/min. Taking into consideration productivity, the casting rate is not lower than 0.01 m/min.
  • Fig. 1 shows an example of a casting process, according to the invention, in which an apparatus embodying the invention is used.
  • Fig. 1 shows a cross section of the apparatus comprising a tundish 10 which holds a molten alloy 11, a water-cooled mold 2 made of iron, and an elevator 20 which draws an ingot.
  • a graphite sleeve 3 serving as a heat insulator is arranged on an upper portion of the water-cooled mold.
  • the water-cooled mold is shaped to have a length of 400 mm, and the upper portion having a length of 200 mm on which the graphite sleeve is arranged has an inside diameter of 471 mm, while a lower portion has an inside diameter of 450 mm.
  • the graphite sleeve having a length of 200 mm, an inside diameter of 450 mm, and an outside diameter of 470 mm is mounted inside the upper portion of the water-cooled mold.
  • a secondary cooling zone 30 is arranged below the water-cooled mold.
  • a shield 14 serving to shut off the molten alloy from an outside air and an electrode 15 for carrying current to slag is arranged as additional means.
  • flow 13 of a molten alloy is poured from a nozzle 12 on a bottom of the tundish 10, which holds the molten alloy 11, into the water-cooled mold 2, which defines a solidification space including slag 1 therein. Slag are melted beforehand and introduced into the mold in the early stage of casting.
  • a molten alloy pool 4 is controlled to be formed having a meniscus upper surface position "A" distant by 50 mm from a lower end "B" of the graphite sleeve 3 mounted inside the water-cooled mold 2 and serving as a heat insulator. Thereby, it is possible to form a solidified shell on an inside wall of the heat insulator.
  • an elevator 20 is lowered to draw an ingot 5 according to a poured quantity of the molten alloy 11, and thus it is possible to advance stacking solidification while maintaining a meniscus position constant.
  • the ingot drawn out of the water-cooled mold is mist-cooled in the secondary cooling zone 30.
  • a molten alloy was held in the tundish and cast into the water-cooled mold in which slag having the composition and the melting point shown in Fig. 1 was held so as to have a thickness of 50 mm.
  • Two types of steel corresponding to JIS SKD11 and SKH51 by mass% were used as the molten alloy.
  • TABLE 2 indicates compositions of the molten alloy.
  • Temperature of the molten alloy was 1500°C and the casting rate was approximately 0.02m/ min (20 mm/min), and a length of up to 3m was cast.
  • TABLE 3 indicates thicknesses of skin slags of thus obtained ingots.
  • TABLE 4 indicates results of measurements of a secondary dendrite arm spacing DAS II in positions of D/8, D/4 and D/2 (where D indicates a diameter of an ingot) from a surface of a sectioned specimen at a longitudinal position of 1/2 of an ingot length.
  • the ingot as obtained was subjected to hot forging at 1100°C until it was made 115 mm square. After surfaces of the 115 mm square ingot were ground by 2 mm, the ingot was subjected to die marking and the presence of any cracks was examined. TABLE 5 indicates the results.
  • Example 2 An experiment of casting was made with the apparatus shown in Example 1 added with an electrode 15 for carrying current to slag.
  • a cylindrical-shaped graphite electrode was used as the electrode 15.
  • the electrode 15 for carrying current to slag was immersed into slag having the composition in TABLE 1. Electric current was carried to the slag to heat the slag. Temperature was simultaneously measured in an intermediate position between the graphite electrode and a molten alloy surface, and slag temperature was controlled at 1400°C by a current value.
  • the slag had a thickness of 50 mm and the molten alloy have a composition of SKD11 indicated in TABLE 2.
  • Example 2 Other conditions are same as those in Example 1. Temperature of the molten alloy was 1500°C and the casting rate is approximately 0.02 m/min (20 mm/min). A length of up to 3m was cast.
  • TABLE 6 indicates depths of bad structures in a surface layer
  • TABLE 7 indicates DAS II measured values in positions of D/8, D/4 and D/2 from a surface thereof (where D indicates a diameter of the ingot).
  • a metal structure can be made fine and a steel, which is low in cost and excellent in steel product performance, can be supplied by performing such rapid solidification, so that a wide demand is expected from the viewpoint of source saving and energy saving.
  • FIG. 1 is a conceptional view showing an example of an apparatus suitable to carry out the process of the invention.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Continuous Casting (AREA)
  • Forging (AREA)

Claims (5)

  1. Procédé de coulée d'un alliage fondu, comprenant :
    le versement de l'alliage fondu d'une cuve contenant l'alliage fondu dans un espace de solidification entouré par une paroi interne d'un moule refroidi à l'eau avec le laitier qu'il contient pour solidifier l'alliage fondu tout en formant un bain d'alliage fondu ; et
    l'étirement d'un lingot, de manière verticale, à partir d'une section inférieure du moule refroidi à l'eau,
    caractérisé en ce que
    l'alliage fondu est versé à un débit de coulée de 0,01 à 0,1 m/min ;
    un isolant thermique constitué d'un matériau de type graphite pour supprimer une extraction de chaleur du laitier est agencé dans une section supérieure du moule, l'isolant ayant une paroi interne façonnée pour être continue avec la paroi interne du moule refroidi à l'eau ; et
    le laitier est chauffé sur sa périphérie par une électrode, le laitier ayant un point de fusion de 500 à 1400 °C et une épaisseur de 20 à 100 mm à partir de l'alliage fondu.
  2. Procédé selon la revendication 1, dans lequel la position de surface supérieure d'un ménisque du bain d'alliage fondu est réglée, dans un état permanent de coulée, pour se situer dans une plage dans laquelle l'isolant thermique est agencé.
  3. Procédé selon la revendication 1 ou 2, dans lequel l'isolant thermique a la paroi interne qui a la même forme en coupe transversale perpendiculairement à la direction dans laquelle le lingot est étiré que celle de la paroi interne du moule refroidi à l'eau d'un côté aval.
  4. Procédé selon l'une quelconque des revendications 1 à 3, dans lequel le débit de coulée de l'alliage fondu est de 0,01 à 0,05 m/min.
  5. Procédé selon l'une quelconque des revendications 1 à 4, dans lequel l'alliage fondu contient du Fe comme composant principal, pas plus de 3 % de C et pas moins de 5 % de tout élément métallique autre que Fe, en % en masse.
EP06731431.0A 2005-04-11 2006-04-07 Procede de moulage d un alliage fondu Active EP1870182B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2005113298 2005-04-11
PCT/JP2006/307484 WO2006109739A1 (fr) 2005-04-11 2006-04-07 Procede de moulage d’un alliage fondu

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EP1870182A1 EP1870182A1 (fr) 2007-12-26
EP1870182A4 EP1870182A4 (fr) 2009-01-14
EP1870182B1 true EP1870182B1 (fr) 2016-10-19

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EP (1) EP1870182B1 (fr)
JP (1) JP4548483B2 (fr)
CN (1) CN101155653B (fr)
WO (1) WO2006109739A1 (fr)

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JP6435810B2 (ja) * 2014-03-04 2018-12-12 日立金属株式会社 鋳造方法および鋳造用鋳型
EP3255165B1 (fr) * 2015-02-04 2020-03-11 Hitachi Metals, Ltd. Matériau pour outil de travail à froid, outil de travail à froid et procédé pour le fabriquer
CN104624990B (zh) * 2015-02-26 2023-08-25 周嘉平 一种均匀冷却结晶器铜管及其制造方法
KR102166604B1 (ko) * 2018-09-18 2020-10-16 현대제철 주식회사 턴디쉬용 슬래그 배출장치
CN113458352B (zh) * 2020-03-30 2023-11-24 日本碍子株式会社 Cu-Ni-Sn合金的制造方法及用于其的冷却器

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JPS5370037A (en) * 1976-12-03 1978-06-22 Kobe Steel Ltd Casting method
JPS5468724A (en) * 1977-11-11 1979-06-02 Hitachi Ltd Electroslag casting apparatus
DE3340844C1 (de) * 1983-11-11 1984-12-20 Mannesmann AG, 4000 Düsseldorf Stranggiesskokille mit Kuehleinrichtung fuer das Vergiessen von Metall,insbesondere von Stahl
JPS624840A (ja) * 1985-06-29 1987-01-10 Daido Steel Co Ltd 金属の精錬方法
JPS6340664A (ja) * 1986-08-05 1988-02-22 Chuetsu Gokin Chuko Kk 金属溶解精錬用水冷鋳型
DE69029467T2 (de) * 1990-03-30 1997-07-10 Nippon Steel Corp Stranggussform und Stranggussverfahren
JPH10328792A (ja) 1997-06-04 1998-12-15 Nippon Steel Corp 連続鋳造方法
JPH11300448A (ja) 1998-04-20 1999-11-02 Nippon Steel Corp 連続鋳造用鋳型
US6192970B1 (en) * 1999-04-28 2001-02-27 Rivindra V. Tilak Independently positioned graphite inserts in annular metal casting molds
JP3772111B2 (ja) * 2001-12-12 2006-05-10 日鐵建材工業株式会社 高Ａｌ・Ｙ・ＲＥＭ含有鋼連続鋳造用モールドフラックス
JP3891078B2 (ja) * 2002-09-06 2007-03-07 住友金属工業株式会社 過包晶中炭素鋼溶鋼の連続鋳造方法
CN2617499Y (zh) * 2003-05-14 2004-05-26 中国科学院金属研究所 一种偏晶型合金薄板连铸设备
CN1276811C (zh) * 2004-07-28 2006-09-27 东北大学 水缝－分瓣体内水冷式软接触电磁连铸结晶器
JP4505811B2 (ja) * 2005-04-11 2010-07-21 日立金属株式会社 合金溶湯の鋳造方法

Also Published As

Publication number Publication date
EP1870182A1 (fr) 2007-12-26
EP1870182A4 (fr) 2009-01-14
CN101155653B (zh) 2011-11-16
JPWO2006109739A1 (ja) 2008-11-20
JP4548483B2 (ja) 2010-09-22
CN101155653A (zh) 2008-04-02
WO2006109739A1 (fr) 2006-10-19

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