EP4185419A1 - Système de moule de coulée semi-continue - Google Patents

Système de moule de coulée semi-continue

Info

Publication number
EP4185419A1
EP4185419A1 EP21752417.2A EP21752417A EP4185419A1 EP 4185419 A1 EP4185419 A1 EP 4185419A1 EP 21752417 A EP21752417 A EP 21752417A EP 4185419 A1 EP4185419 A1 EP 4185419A1
Authority
EP
European Patent Office
Prior art keywords
coolant
casting
nozzles
mold
bar
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.)
Pending
Application number
EP21752417.2A
Other languages
German (de)
English (en)
Inventor
Randal Guy Womack
Ravindra Tarachand PARDESHI
Paul SISK
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.)
Novelis Inc Canada
Original Assignee
Novelis Inc Canada
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Novelis Inc Canada filed Critical Novelis Inc Canada
Publication of EP4185419A1 publication Critical patent/EP4185419A1/fr
Pending legal-status Critical Current

Links

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
    • B22D11/04—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
    • B22D11/049—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds for direct chill casting, e.g. electromagnetic casting
    • 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
    • B22D11/05—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds into moulds having adjustable walls
    • 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
    • B22D11/055—Cooling the moulds
    • 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
    • B22D11/12—Accessories for subsequent treating or working cast stock in situ
    • B22D11/124—Accessories for subsequent treating or working cast stock in situ for cooling
    • 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
    • B22D11/12—Accessories for subsequent treating or working cast stock in situ
    • B22D11/124—Accessories for subsequent treating or working cast stock in situ for cooling
    • B22D11/1243—Accessories for subsequent treating or working cast stock in situ for cooling by using cooling grids or cooling plates
    • 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
    • B22D11/12—Accessories for subsequent treating or working cast stock in situ
    • B22D11/124—Accessories for subsequent treating or working cast stock in situ for cooling
    • B22D11/1246—Nozzles; Spray heads

Definitions

  • a direct chill (DC) casting process is a semi-continuous process for producing solid metal ingots (e.g., aluminum alloy ingots) from liquid melt.
  • liquid melt is initially cooled in a shallow bottomless mold whose cavity shape is based on the desired cross-section of the ingot. Initially a bottom block seals the mold cavity from the lower side.
  • the liquid melt is poured from the upper side into the mold, and the bottom block is lowered into a curtain of coolant (e.g., cooling water), which further cools the metal in the periphery, resulting in a solidified shell that holds a liquid sump.
  • coolant e.g., cooling water
  • the casting progresses in steady state during which the thermal and solidification profiles do not vary with time.
  • the initial cooling at the periphery of the ingot in the mold is known as the primary region.
  • the primary cooling region the heat extraction rate from the melt is very high at the first point of contact because the melt is in direct contact with the water cooled mold. But, after the formation of this initially solidified shell, an air gap is formed at the mold/ingot interface due to solidification shrinkage.
  • a direct chill casting mold system includes a mold and a coolant bar.
  • the mold defines a casting cavity having a casting axis.
  • the coolant bar includes a plurality of nozzles and is configured to dispense a coolant via the plurality of nozzles onto a periphery of a metal product after the metal product has passed through the mold.
  • the coolant bar is movable relative to the casting axis (e.g., linearly, rotationally, etc.).
  • a direct chill casting mold system includes a mold defining a casting cavity having a casting axis.
  • the direct chill casting mold system also includes a coolant bar having a plurality of nozzles.
  • the coolant bar is configured to dispense a coolant via the plurality of nozzles onto a periphery of a metal product after the metal product has passed through the mold.
  • a direct chill casting mold system includes a mold, a first coolant bar, and a second coolant bar.
  • the mold defines a casting cavity having a casting axis.
  • the first coolant bar is downstream from the mold and includes a plurality of first nozzles.
  • the first coolant bar is configured to dispense a coolant via the plurality of first nozzles onto a periphery of a metal product after the metal product has passed through the mold.
  • the second coolant bar is downstream from the mold and includes a plurality of second nozzles.
  • a direct chill casting mold system includes a mold and a coolant bar.
  • the mold defines a casting cavity having a casting axis, and the mold is adjustable in the direction substantially perpendicular to the casting axis such that a dimension of the casting cavity in the direction substantially perpendicular to the casting axis is adjustable.
  • the coolant bar includes a plurality of nozzles, and the coolant bar is configured to dispense a coolant via the plurality of nozzles onto a periphery of a metal product after the metal product has passed through the mold.
  • the coolant bar is movable relative to the casting axis.
  • FIG.1 is a schematic of a metal casting system according to embodiments.
  • FIG.2 is a side view of a portion of a casting mold system according to embodiments.
  • FIG.3 is a bottom perspective view of a portion of a coolant bar of the casting mold system of FIG.2.
  • FIG.4 is a sectional view of the coolant bar of FIG.2 taken along line 4 – 4 in FIG.3.
  • FIG.5 is a sectional view of the coolant bar of FIG.2 taken along line 5 – 5 in FIG.3.
  • FIG. 6A is a sectional view of a portion of a casting mold system according to embodiments in a start position.
  • FIG.6B is a sectional view of the portion of the casting mold system of FIG.6A in a transition position.
  • FIG.6C is a sectional view of the portion of the casting mold system of FIG.6A in a run position.
  • FIG. 7 is a top view of a casting mold system for a casting system according to embodiments during a start of casting.
  • FIG.8 is a top view of the casting mold system of FIG.7 during steady state casting.
  • FIG. 9 is a top perspective view of a casting mold system for a casting system according to embodiments.
  • FIG.10 is a bottom perspective view of the casting mold system of FIG.9.
  • FIG.11 is a perspective view of a portion of the casting mold system of FIG.9.
  • FIG.12 is a sectional view of a portion of the casting mold system of FIG.9.
  • FIG.13 is another sectional view of a portion of the casting mold system of FIG.9.
  • casting mold systems for DC casting systems. While the casting mold systems described herein can be used with any metal, they may be especially useful with aluminum.
  • the casting mold systems described herein each include a mold and at least one coolant bar.
  • the mold defines a casting cavity having a casting axis along which metal is moved as it is cast into a solidified product. In some cases, the mold may be internally cooled.
  • the mold is adjustable in one or more directions that are not parallel to the casting axis (hereinafter referred to as “adjustment directions”).
  • one or more adjustment directions are substantially perpendicular to the casting axis such that a dimension of the mold (and as such a dimension of the cast product) can be adjusted as desired.
  • the mold in a vertical casting system, may be adjustable in a horizontal direction.
  • the at least one coolant bar is downstream from the mold and includes a plurality of nozzles.
  • the at least one coolant bar dispenses a coolant, including but not limited to water, via the plurality of nozzles onto a periphery of the metal product after the metal product has passed through the mold.
  • a coolant including but not limited to water
  • at least one of the plurality of nozzles is arranged at an oblique or otherwise non-zero (or non-parallel) angle relative to an axis of the coolant bar, although it need not be in other examples.
  • the axis of at least one of the plurality of nozzles may be adjustable relative to the axis of the coolant bar.
  • a “non-zero” angle is one that is not parallel with respect to a particular axis.
  • the at least one coolant bar is movable relative to the casting axis.
  • the at least one coolant bar is adjustable linearly.
  • the at least one coolant bar is pivotable or rotatable about a pivot axis that is not parallel to the casting axis.
  • the pivot axis may be substantially perpendicular to the casting axis, although it need not be in other examples.
  • the at least one coolant bar may be movable relative to the casting axis via additional or alternative movements as desired.
  • the at least one coolant bar is adjustable relative to the casting axis such that the axis of at least one of the plurality of nozzles is adjustable.
  • the at least one coolant bar is movable between a start position, a transition position, and a run position.
  • at least one nozzle of the plurality of nozzles in the start position, at least one nozzle of the plurality of nozzles is a first distance from the casting axis; in the transition position, the at least one nozzle of the plurality of nozzles is a second distance from the casting axis that is less than the first distance; and in the run position, the at least one nozzle of the plurality of nozzles is a third distance from the casting axis that is less than the second distance.
  • more than one coolant bar such as two coolant bars, may be utilized with casting mold system.
  • the coolant bars may be arranged in various positions relative to each other and relative to the mold along the casting axis as desired (e.g., a coolant bar may be downstream from the mold and upstream from another coolant bar, may be downstream from the mold and another coolant bar, etc.). In certain embodiments with more than one coolant bar, at least one characteristic of one coolant bar optionally may be different from the other coolant bar.
  • the at least one characteristic may include, but is not limited to, a number of nozzles, a pattern or arrangement of nozzles, a pressure at which the nozzles dispense the coolant, an angle of one or more of the nozzles relative to the axis of the coolant bar and/or the casting axis, movement relative to the casting axis, a surface profile facing the casting axis, combinations thereof, or other various characteristics as desired.
  • one coolant bar may be adjustable in the adjustment direction while the other coolant bar is fixed (not adjustable) in the adjustment direction.
  • one coolant bar may have a plurality of nozzles where each nozzle is arranged substantially perpendicular to the casting axis while the other coolant bar may have a plurality of nozzles where each nozzle is arranged at an oblique (or otherwise non-zero or non-parallel) angle relative to the casting axis.
  • one coolant bar may have a substantially planar surface profile facing the casting axis while the other coolant bar may have a non-planar surface profile facing the casting axis.
  • one coolant bar may dispense the coolant at a first pressure, and the other coolant bar may dispense the coolant at a second pressure that is less than the first pressure.
  • one coolant bar may dispense the coolant with a gas and/or a supercritical fluid, while the other coolant bar may dispense just the coolant.
  • Various other characteristics may be varied between two or more coolant bars as desired. In other embodiments, the characteristics need not be varied between two or more coolant bars.
  • the casting mold system described herein may provide improved cooling compared to existing mold systems, and the improved cooling may allow for the overall casting system to cast at a faster speed compared to existing casting systems without bleed-out and/or other defects in the ingot. The improved speed may allow for more metal to be cast in a given time period compared to existing casting systems and/or a shorter overall processing time for a given amount of metal compared to existing casting systems.
  • the casting mold system may optionally allow for faster casting speeds by providing two or more layers of coolant jets, which may ensure nucleate cooling by providing a better cooling capacity without a breakdown to film cooling.
  • the casting mold system may allow for casting speeds of at least 60 mm/min., such as at least 70 mm/min., such as at least 75 mm/min., such as at least 80 mm/min., such as at least 85 mm/min.
  • the casting mold system described herein may also provide ingots having improved properties.
  • the casting mold system described herein may provide an ingot having an improved shape because the casting mold system can adjust the ingot’s shape during the casting process as desired, which may reduce the amount of metal that would otherwise have to be scrapped in existing casting systems.
  • the casting mold system may also allow for multiple alloys to be cast on the same mold system because the shape of the mold can be adjusted as desired for each alloy.
  • the casting mold system may also allow for ingots having different thicknesses to be cast with the same mold because the shape of the mold is adjustable as desired.
  • the casting mold system described herein may provide an ingot having a reduced shell zone or no detectable shell zone.
  • the DC casting system 100 generally includes a casting mold system 102 having an open-ended mold 104.
  • Molten metal 103 may be introduced into a mold cavity 105 of the mold 104 through a mold inlet 106 and emerge as an ingot 110 from a mold outlet 108.
  • the ingot 110 being cast can include metal in various stages of solidification including solidified metal 112, transitional metal 114, and molten metal 116.
  • the upper part of the ingot 110 may have the molten metal 116 that forms an inwardly tapering sump within the region of solidified metal 112 of the ingot 110.
  • the mold 104 which may be internally cooled with a coolant such that the mold has cooled casting surfaces, provides initial primary cooling of the molten metal and peripherally confines and cools the molten metal to start formation of the region of solidified metal 112 of the ingot 110.
  • the cooling metal moves out and away from the mold 104 through the mold outlet 108 along a casting axis 120.
  • FIGS. 2-5 illustrate an example of a casting mold system 202 according to various embodiments.
  • the casting mold system 202 may be used in a DC casting system, such as the DC casting system 100 and in place of the casting mold system 102.
  • the casting mold system 202 generally includes a mold 204 and at least one coolant bar 226.
  • the mold 204 includes a mold inlet 206 and a mold outlet 208 and defines a casting axis 220 along which metal may move during a casting process. While only a portion of the casting mold system 202 is illustrated in FIGS.2-5, similar to the mold 104, the mold 204 defines a mold cavity 205 that initially receives the molten metal during casting and such that casting surfaces 225 of the mold 204 can provide primary cooling to the periphery of the ingot. In certain examples, the mold 204 is a continuous structure, although in other examples, the mold 204 may include one or more mold sub-sections. The mold 204 may be constructed from various suitable materials including, but not limited to, aluminum and/or copper.
  • the mold 204 may be hollow or define an inner chamber such that the mold 204 can be internally cooled with a coolant and provide cooling to the casting surfaces 225 of the mold 204.
  • the coolant may be various suitable coolants for the casting process, including but not limited to water.
  • the coolant used for cooling of the mold 204 is recirculated back to the mold 204 without being utilized for secondary cooling. In such examples, because the coolant of the mold 204 is not used for secondary cooling, the mold 204 may have a reduced coolant requirement compared to existing systems, and the mold 204 may be thinner and/or have any shape as desired.
  • the mold 204 is adjustable in one or more adjustment directions 231. FIG.
  • FIG. 2 illustrates an example of one adjustment direction 231 that is substantially perpendicular to the casting axis 220 such that the mold 204 is movable in a plane towards or away from the casting axis 220.
  • the mold 204 is adjustable such that a dimension of the mold cavity 205 (and as such a dimension of the ingot) can be adjusted as desired. While a single adjustment direction is illustrated in FIG.2, the number and/or direction of the adjustment directions relative to the casting axis 220 (or relative to each other when there are more than one adjustment directions 231) should not be considered limiting.
  • a mold segment may be adjusted independently from or in conjunction with at least one other mold segment.
  • the mold 204 is adjustable between a start configuration (FIG.7) and a steady state configuration (FIG.8) such that a shape of the mold cavity 205 in the start configuration is different from the shape of the mold cavity 205 in the steady state configuration.
  • the mold 204 may be adjustable through various suitable actuator mechanisms or devices, including, but not limited to, electric motors, solenoids, hydraulic actuators, pneumatic actuators, combinations thereof, or other suitable actuators as desired.
  • the casting mold system 202 includes a single coolant bar 226. However, the number of coolant bars 226 should not be considered limiting.
  • FIGS. 9-13 illustrate an embodiment of a casting mold system 304 with two coolant bars.
  • each coolant bar may be substantially the same as another coolant bar or at least one coolant bar may have at least one characteristic that is different from another coolant bar.
  • the coolant bar 226 is at least partially downstream from the mold outlet 208 and is configured to dispense a coolant via a plurality of nozzles 236 onto a periphery of a metal product after the metal product has passed through the mold 204.
  • the coolant bar 226 is positioned relative to the mold 204 such that at least one of the nozzles 236 is downstream from the mold 204.
  • the coolant bar 226 may be constructed from various suitable materials as desired and may be a continuous structure or may include one or more bar sub-sections.
  • the coolant bar 226 generally includes a top end 228 and a bottom end 230 opposite from the top end 228, and a bar axis 232 extends from the top end 228 to the bottom end 230.
  • a face 234 of the coolant bar 226 includes the plurality of nozzles 236 that are configured to dispense a coolant onto a periphery of an ingot during casting. As best illustrated in FIGS.
  • the coolant bar 226 includes a coolant chamber 240 that is in fluid communication with each of the nozzles 236 and is configured to store a supply of coolant.
  • the coolant of the coolant bar 226 may be the same as or different from the coolant used to provide cooling to the mold 204.
  • the face 234 has a double stepped profile; however, the face 234 may have various shapes or profiles as desired.
  • FIGS. 6A-C illustrate another example of a face having a double stepped profile
  • FIGS.9-13 illustrate coolant bars where the face may be planar or single stepped.
  • FIGS.9-13 illustrate other arrangements of nozzles on a coolant bar.
  • all of the nozzles 236 may be substantially the same (e.g., substantially the same orientation relative to the bar axis 232, configured to dispense the coolant at substantially the same pressure, etc.).
  • the plurality of nozzles 236 may include one or more subsets 238 of nozzles 236 that differ from each other in at least one characteristic.
  • the coolant bar 226 includes four subsets 238A-D of nozzles 236, and the nozzles of each subset 238A-D differ from those of other subsets 238 by location on the face 234 relative to the bar axis 232 and by angle at which they extend relative to the bar axis 232.
  • the nozzles 236 of the first subset 238A are provided at a first location on the face 234 relative to the bar axis 232 and extend at a first oblique (or otherwise non-zero) angle relative to the bar axis 232
  • the nozzles 236 of the second subset 238B are provided at a second location on the face 234 relative to the bar axis 232 and extend at a second oblique (or otherwise non-zero) angle relative to the bar axis 232
  • the nozzles 236 of the third subset 238C are provided at a third location on the face 234 relative to the bar axis 232 and extend at a third oblique (or otherwise non-zero) angle relative to the bar axis 232
  • the nozzles 236 of the fourth subset 238D are provided at a fourth location on the face 234 relative to the bar axis 232 and extend at a fourth oblique (or otherwise non-zero) angle relative to the bar
  • the coolant bar 226 is movable relative to the casting axis 220 such that an angle and/or position of the nozzles 236 relative to the casting axis 220 can be adjusted as desired.
  • the coolant bar 226 includes one or more bar sections, one bar section may be movable independently from or in conjunction with another bar section.
  • the coolant bar 226 may be adjustable via the same actuator mechanisms or different mechanisms as those used to control the mold 204.
  • a controller or controllers may be provided to control the coolant bar.
  • the controller or controllers may be various suitable computing devices as desired with a processor and/or a memory.
  • the controller or controllers may be operably connected to the actuator mechanisms or as otherwise desired such that the coolant bar is controlled as desired.
  • the controller or controllers may be operably connected to one or more sensors, and the controller may control the coolant bar based on information detected by the sensor(s). Additionally or alternatively, the controller may be used to control other aspects of the casting mold system. As some non- limiting examples, the controller may control a bottom block of the system, an angle of the coolant bar, a position of the coolant bar, a shape of the mold, a water flow rate, and/or as otherwise desired.
  • the coolant bar 226 is adjustable in the same adjustment direction(s) 231 as the mold 204, although it need not be in other examples.
  • the coolant bar 226 may have various other movement patterns as desired.
  • the coolant bar 226 is pivotable about a pivot axis 242 (FIG.3) such that both the position and the angle of the nozzles 236 relative to the casting axis 220 can be adjusted as desired.
  • the coolant bar 226 may be movable between a start position (FIG. 6A), a transition position (FIG. 6B), and a run position (FIG. 6C).
  • the coolant bar 226 may be laterally adjustable, pivotable, both laterally adjustable and pivotable, and/or otherwise movable as desired.
  • molten metal is introduced into the mold cavity 205 via the mold inlet 206.
  • the casting surface 225 of the mold 204 provides primary cooling of the molten metal, and the metal exits the mold outlet 208 as a solidifying ingot.
  • the coolant bar 226 provides secondary cooling by directing the coolant from the coolant chamber 240 to the nozzles 236 such that the nozzles 236 dispense the coolant on the periphery of the ingot.
  • FIGS.6A-C illustrate an example of a casting mold system 302 according to various embodiments during a casting process.
  • the casting mold system 302 is substantially similar to the casting mold system 202 except that a profile of the face 234 of the coolant bar 326 is modified compared to that illustrated in FIGS.2-5.
  • the relative positioning of the coolant bar 326 relative to the mold 204 has been adjusted such that the mold 204 overlaps more of the coolant bar 326 compared to the casting mold system 202.
  • the coolant bar 326 is pivotable relative to the casting axis 220 such that the position and angle of the nozzles 236 relative to the casting axis 220 can be adjusted as desired during casting.
  • the coolant bar 326 delivers coolant in a way that can start the casting process with a reduced coolant flow, and the coolant bar can increase coolant in a controlled manner via increased coolant flow and added nozzles 236 directing coolant onto the ingot.
  • FIG.6A illustrates the casting mold system 302 in a start position.
  • the coolant bar 326 is pivoted on the pivot axis 242 such that the coolant bar 326 is tilted away from the casting axis 220, and a single jet 346A of coolant from the nozzle 236 of the subset 238A is directed to contact a surface 344 of an ingot 310.
  • more than one nozzle but less than all nozzles may direct jets of coolant to contact the surface 344 in the start position.
  • the nozzle 236 from another subset may provide the single jet of coolant in the start position.
  • the coolant bar 326 directing coolant in the start position may reduce butt curl in the ingot at the start of the casting process. In some cases, the reduced coolant pressure and/or volume of coolant may reduce the butt curl in this phase.
  • FIG.6B illustrates the casting mold system 302 in a transition position, which is any position of the casting mold system 302 between the start position (FIG. 6A) and the run position (FIG.6C). In general, during in the transition position, more coolant is added as the ingot 310 lengthens and casting speed is increased.
  • the coolant bar 326 is progressively pivoted on the pivot axis (coming out of the page in FIGS. 6A-C) such that the coolant bar 326 is pivoted towards the casting axis 220 (and reducing the distance between the nozzles 236 and the casting axis 220).
  • the coolant bar 326 may be pivoted continuously or at predetermined intervals as desired. As the pivot angle increases, the distance between the casting axis 220 and each nozzle 236 progressively decreases.
  • the jet 346A contacts the surface 344 higher on the ingot 310 and allows another jet 346B of coolant from the nozzle 236 of the subset 238B to contact the surface 344 of the ingot 310 and thereby extract more heat from the ingot 310.
  • the coolant bar 326 may continue to pivot such that the jets 346 continue to climb higher on the surface 344 and additional jets 346C-D (from the nozzles 236 of the subsets 238C-D, respectively) contact the surface 344 and provide additional heat extraction.
  • the order or sequence of jets 346 contacting the ingot 310 should not be considered limiting as the order may depend on location of a particular nozzle 236 on the face 234 of the coolant bar 326 and/or the angle of a particular nozzle 236 relative to the bar axis 232.
  • the coolant pressure and/or volume of coolant is increased.
  • increasing the coolant pressure and/or volume may include activating valves or other flow control mechanisms such that additional nozzles 236 are activated.
  • the pivot angle of the coolant bar 326 continues to increase until the casting mold system 302 is in the run position. [0049]
  • FIG.6C illustrates the casting mold system 302 in the run position.
  • the jets 346C-D of coolant may contact the ingot 310 at an angle that minimizes coolant bounce off and encourages the coolant to sheet 345 down the surface 344 of the ingot 310.
  • the jets 346A-B of coolant are able to run at a higher position on the ingot 310 and at a higher angle because coolant bounce off is not a concern.
  • the casting speed may be up to 100 mm per minute and/or up to 120 mm per minute. In other examples, the speed may be greater than 120 mm per minute.
  • FIGS. 7 and 8 illustrate another example of a casting mold system 702.
  • FIG. 7 illustrates the casting mold system 702 in a start position
  • FIG. 8 illustrates the casting mold system 702 in a steady cast position.
  • the casting mold system 702 includes a mold 704 and a coolant bar 726, which may be similar to the mold 204 and the coolant bar 326, respectively.
  • the mold 704 includes a plurality of mold segments 752 and the coolant bar 726 includes a plurality of bar segments 754.
  • the number, shape, or size of the mold segments 752 and the bar segments 754 should not be considered limiting on the disclosure.
  • the spacing between the mold segments 752 and the spacing between the bar segments 754 has been exaggerated for purposes of illustrating movement of the mold segments 752 and the bar segments 754 in a plane 755 substantially perpendicular to the casting axis (coming out of the page in FIGS.7 and 8) and does not infer any particular arrangement.
  • the mold 704 and/or the coolant bar 726 may be adjustable between the start position (FIG.
  • FIGS. 9-13 illustrate another example of a casting mold system 902 according to embodiments.
  • various support structures and/or devices 956 may be utilized to support the casting mold system 902 in an overall casting system.
  • the casting mold system 902 includes two coolant bars 926A-B, both of which are positioned downstream from the mold 204.
  • at least one characteristic of the coolant bar 926A is different from a corresponding characteristic of the coolant bar 926B, although it need not be in other examples.
  • a shape or profile of a face 234A of the coolant bar 926A is different from the shape or profile of a face 234B of the coolant bar 926B.
  • an arrangement or pattern of nozzles 236A of the coolant bar 926A is different from the arrangement or pattern of nozzles 236B of the coolant bar 926B.
  • an angle of each nozzle 236A relative to the bar axis 232A of the coolant bar 926A is different from an angle of each nozzle 236B relative to the bar axis 232B of the coolant bar 926B.
  • the bar axis 232B of the coolant bar 926B may be, but does not have to be, aligned with the bar axis 232A of the coolant bar 926A.
  • each nozzle 236A is substantially perpendicular to the bar axis 232A of the coolant bar 926A while each nozzle 236B is at an oblique angle relative to the bar axis 232B of the coolant bar 926B.
  • a coolant chamber 240B of the coolant bar 926B may be different from the coolant chamber 240A of the coolant bar 926A. In the embodiment illustrated in FIGS.
  • the coolant chamber 240A is a single chamber while the coolant chamber 240B is divided into sub-chambers 941 that are in fluid communication with each other.
  • the nozzles 236A are configured to dispense the coolant at a first pressure
  • the nozzles 236B are configured to dispense the coolant at a second pressure that is different from the first pressure.
  • the first pressure and the second pressure may be from about 250 psi to about 750 psi, although they may be outside of this range in other embodiments.
  • the first pressure is greater than the second pressure such that the coolant bar 926A is a high pressure coolant bar and the coolant bar 926B is a low pressure coolant bar.
  • one of the coolant bars e.g., coolant bar 926A
  • a gas and/or supercritical fluid including but not limited to nitrogen or compressed air, and is configured to dispense the coolant with the gas and/or supercritical fluid.
  • one of the coolant bars is fixed relative to the casting axis 220, and the other coolant bar is movable relative to the casting axis 220.
  • the high pressure coolant bar 926A is fixed relative to the casting axis 220, and the low pressure coolant bar 926B is movable relative to the casting axis 220 (e.g., pivotably, in a plane perpendicular to the casting axis 220, etc.).
  • the high pressure coolant bar 926A may be movable and/or the low pressure coolant bar 926B may be fixed.
  • the arrangement of the high pressure coolant bar 926A and the low pressure coolant bar 926B relative to the mold 204 should not be considered limiting.
  • the multiple coolant bars 926A-B may help align nozzle positions appropriately relative to the casting axis 220 and relative to movement of the mold 204 relative to the casting axis 220. In some embodiments, the multiple coolant bars 926A-B may help maintain the distance between the high pressure nozzles 236A of the coolant bar 926A with the ingot. The coolant bar 926B with the low pressure nozzles 236B may minimize or reduce bounce-off of coolant from the ingot, and the movement of the low pressure coolant bar 926B relative to the ingot (linearly, rotationally, etc.) may allow for nozzle positions and/or angles to change relative to the ingot, thereby providing a desired heat transfer at various stages of casting.
  • a direct chill casting mold system comprising: a mold defining a casting cavity comprising a casting axis; and a coolant bar comprising a plurality of nozzles, wherein the coolant bar is configured to dispense a coolant via the plurality of nozzles onto a periphery of a metal product after the metal product has passed through the mold, and wherein the coolant bar is movable relative to the casting axis.
  • the coolant bar comprises a coolant bar axis
  • the plurality of nozzles comprises a first set of nozzles and a second set of nozzles, wherein each nozzle of the first set of nozzles extends at a first non-zero angle relative to the coolant bar axis, and wherein each nozzle of the second set of nozzles extends at a second non-zero angle relative to the coolant bar axis that is different from the first non-zero angle.
  • the direct chill casting mold system of any preceding or subsequent illustrations or combination of illustrations wherein the mold and the coolant bar are each movable relative to the casting axis in a direction substantially perpendicular to the casting axis.
  • Illustration 5 The direct chill casting mold system of any preceding or subsequent illustrations or combination of illustrations, wherein the coolant bar is a first coolant bar and the plurality of nozzles are a first plurality of nozzles, wherein the direct chill casting mold system further comprises a second coolant bar comprising a second plurality of nozzles, and wherein the second coolant bar is between the mold and the first coolant bar along the casting axis.
  • a direct chill casting mold system comprising: a mold defining a casting cavity comprising a casting axis; and a coolant bar comprising a plurality of nozzles, wherein the coolant bar is configured to dispense a coolant via the plurality of nozzles onto a periphery of a metal product after the metal product has passed through the mold, and wherein an angle of at least one nozzle of the plurality of nozzles is adjustable relative to the casting axis.
  • the coolant bar comprises a coolant bar axis
  • the plurality of nozzles comprises a first set of nozzles and a second set of nozzles, wherein each nozzle of the first set of nozzles extends at a first non-zero angle relative to the coolant bar axis, and wherein each nozzle of the second set of nozzles extends at a second non-zero angle relative to the coolant bar axis that is different from the first non-zero angle.
  • the direct chill casting mold system of any preceding or subsequent illustrations or combination of illustrations wherein the coolant bar is a first coolant bar and the plurality of nozzles are a first plurality of nozzles, wherein the direct chill casting mold system further comprises a second coolant bar comprising a second plurality of nozzles, wherein the second coolant bar is configured to direct the coolant via the second plurality of nozzles onto the periphery of the metal product after the metal product has pass through the mold.
  • a direct chill casting mold system comprising: a mold defining a casting cavity comprising a casting axis; a first coolant bar downstream from the mold, the first coolant bar comprising a plurality of first nozzles, wherein the first coolant bar is configured to dispense a coolant via the plurality of first nozzles onto a periphery of a metal product after the metal product has passed through the mold; and a second coolant bar downstream from the mold, the second coolant bar comprising a plurality of second nozzles, wherein the second coolant bar is configured to dispense the coolant via the plurality of second nozzles onto the periphery of the metal product after the metal product has passed through the mold, wherein the first coolant bar is fixed in a direction substantially perpendicular to the casting axis, and wherein the second coolant bar is adjustable in the direction substantially perpendicular to the casting axis.
  • Illustration 16 The direct chill casting mold system of any preceding or subsequent illustrations or combination of illustrations, wherein the mold is adjustable in the direction substantially perpendicular to the casting axis such that a dimension of the casting cavity in the direction substantially perpendicular to the casting axis is adjustable.
  • Illustration 17 The direct chill casting mold system of any preceding or subsequent illustrations or combination of illustrations, wherein the first coolant bar is configured to dispense the coolant at a first pressure, wherein the second coolant bar is configured to dispense the coolant at a second pressure that is less than the first pressure, and wherein the first coolant bar is between the mold and the second coolant bar.
  • a direct chill casting mold system comprising: a mold defining a casting cavity comprising a casting axis, wherein the mold is adjustable in the direction substantially perpendicular to the casting axis such that a dimension of the casting cavity in the direction substantially perpendicular to the casting axis is adjustable; and a coolant bar comprising a plurality of nozzles, wherein the coolant bar is configured to dispense a coolant via the plurality of nozzles onto a periphery of a metal product after the metal product has passed through the mold, and wherein the coolant bar is movable relative to the casting axis.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Abstract

Un système de moule de coulée semi-continue comprend un moule et au moins une barre de refroidissement. Le moule délimite une cavité de coulée ayant un axe de coulée le long duquel se déplace un produit métallique pendant un processus de coulée. Ladite barre de refroidissement comprend une pluralité de buses, et ladite barre de refroidissement est conçue pour distribuer un fluide de refroidissement par l'intermédiaire de la pluralité de buses sur une périphérie du produit métallique après que le produit métallique a traversé le moule. Selon divers aspects, ladite barre de refroidissement est mobile par rapport à l'axe de coulée.
EP21752417.2A 2020-07-22 2021-07-19 Système de moule de coulée semi-continue Pending EP4185419A1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US202062705915P 2020-07-22 2020-07-22
US202163200798P 2021-03-30 2021-03-30
PCT/US2021/042209 WO2022020248A1 (fr) 2020-07-22 2021-07-19 Système de moule de coulée semi-continue

Publications (1)

Publication Number Publication Date
EP4185419A1 true EP4185419A1 (fr) 2023-05-31

Family

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Application Number Title Priority Date Filing Date
EP21752417.2A Pending EP4185419A1 (fr) 2020-07-22 2021-07-19 Système de moule de coulée semi-continue

Country Status (10)

Country Link
US (1) US20230219130A1 (fr)
EP (1) EP4185419A1 (fr)
JP (1) JP2023535184A (fr)
KR (1) KR20230004813A (fr)
CN (1) CN115697585A (fr)
BR (1) BR112022022196A2 (fr)
CA (1) CA3183892A1 (fr)
DE (1) DE212021000422U1 (fr)
MX (1) MX2023000885A (fr)
WO (1) WO2022020248A1 (fr)

Family Cites Families (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2705353A (en) * 1952-04-04 1955-04-05 Kaiser Aluminium Chem Corp Method of continuous casting
FR1072748A (fr) * 1953-01-23 1954-09-15 Cie Francaise Des Metaux Perfectionnements à la coulée continue ou semi-continue des métaux et alliages
FR71375E (fr) * 1956-11-28 1959-12-22 Pechiney Coulée des métaux
US3877510A (en) * 1973-01-16 1975-04-15 Concast Inc Apparatus for cooling a continuously cast strand incorporating coolant spray nozzles providing controlled spray pattern
NO790471L (no) * 1978-02-18 1979-08-21 British Aluminium Co Ltd Stoepemetaller.
US4415017A (en) * 1981-06-26 1983-11-15 Olin Corporation Control of liquid-solid interface in electromagnetic casting
CH670779A5 (fr) * 1986-04-15 1989-07-14 Concast Standard Ag
JPH06205Y2 (ja) * 1989-03-17 1994-01-05 吉田工業株式会社 水平連続鋳造装置における二次冷却装置
EP0812638A1 (fr) * 1996-06-14 1997-12-17 Alusuisse Technology & Management AG Lingotière réglable pour la coulée continue
CN102083569A (zh) * 2008-06-06 2011-06-01 诺维尔里斯公司 通过水喷射从铸锭去除冷却水的方法和装置
US11331715B2 (en) * 2017-06-12 2022-05-17 Wagstaff, Inc. Dynamic mold shape control for direct chill casting

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Publication number Publication date
KR20230004813A (ko) 2023-01-06
WO2022020248A1 (fr) 2022-01-27
CA3183892A1 (fr) 2022-01-27
US20230219130A1 (en) 2023-07-13
CN115697585A (zh) 2023-02-03
MX2023000885A (es) 2023-02-22
BR112022022196A2 (pt) 2023-01-31
JP2023535184A (ja) 2023-08-16
DE212021000422U1 (de) 2023-03-28

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