KR20240049305A - System and method for producing textured casting molds on a continuous belt caster - Google Patents

Abstract

A method of texturing a casting mold of a continuous belt casting system includes providing at least one endless belt having an elongated belt surface. The stretched belt surface includes at least a first region and at least a second region adjacent the first region across the width of the stretched belt surface, the stretched belt surface at least partially defining a casting cavity of the continuous belt casting system. It is configured to do so. The method includes texturing the stretched belt surface by applying a predetermined texture to the first area.

Description

System and method for producing textured casting molds on a continuous belt caster

REFERENCES TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 63/260,937, entitled “System and Method for Producing Textured Casting Molds in a Continuous Belt Caster,” filed September 7, 2021, the contents of which are incorporated in their entirety. Incorporated herein by reference.

field of invention

This application relates to continuous belt casters, and more particularly to systems and methods for producing textured casting molds for continuous belt casters.

Continuous belt casting machines, such as twin belt casters, single belt casters, and recirculating block casters, are commonly used to produce cast metal articles from molten metals, including but not limited to aluminum and aluminum alloys. In continuous belt casting machines, casting cavities are formed between continuously moving casting surfaces. During the casting process, molten metal flows into the casting cavity (usually in a continuous manner). Heat is removed from the metal by the stretched belt surface and the metal solidifies into a metal article, which is continuously discharged from the casting cavity by the moving casting surface.

The texture of the stretched belt surface, such as a steel belt surface or a copper belt surface, can at least partially affect the heat flux through the stretched belt surface. For steel belts, the traditional procedure for texturing the belt surface is that steel shot (or other medium) is mixed with air, pressurized using a cyclone, and the shot is fired onto the belt surface through a gun. This is accomplished by a controlled shot-blasting process that induces a texture in which the edges are interconnected dimples. The final texture depends on shot size distribution, pressure, traversing speed, belt rotation speed, distance between gun and belt, and angle of incidence of the gun. Although shot-blasting is relatively economical and fast, the resulting texture is randomized and difficult to repeat or precisely control to provide a specific texture, which can lead to metallurgical and mechanical surface defects in as-cast metal articles. Structural anisotropy can be tolerated.

Embodiments protected by this patent are defined by the claims below and not by this Summary. This summary is a high-level overview of various embodiments and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used separately to determine the scope of the claimed subject matter. The subject matter should be understood by reference to the appropriate portions of the entire specification, some or all drawings, and each claim of this patent.

According to some embodiments, a method of texturing a casting mold of a continuous belt casting system includes providing an elongated belt surface to at least one endless belt. The stretched belt surface includes at least a first region and a second region adjacent the first region across the width of the stretched belt surface, the stretched belt surface at least partially defining a casting cavity of the continuous belt casting system. It is composed. The method includes applying a predetermined texture to a first area and texturing the stretched belt surface such that the second area does not include the predetermined texture.

According to a particular embodiment, a method of texturing a casting mold of a continuous belt casting system includes providing at least one endless belt having an elongated belt surface. The stretched belt surface includes a first region and a second region adjacent the first region across the width of the stretched belt surface, the stretched belt surface configured to at least partially define a casting cavity of the continuous belt casting system. do. The method includes locally texturing the stretched belt surface such that the first region includes the predetermined texture and the second region does not include the predetermined texture.

According to various embodiments, a method of texturing a casting mold of a continuous belt casting system includes providing an elongated belt surface to at least one endless belt. The elongated belt surface includes a plurality of first regions and a plurality of second regions, with adjacent first regions separated by one of the plurality of second regions. The stretched belt surface is configured to at least partially define a casting cavity of the continuous belt casting system. The method includes applying a predetermined texture only to first regions and texturing the stretched belt surface such that the distance between adjacent first regions is between 0.01 mm and 1.0 mm, or any actual distance useful for casting purposes.

According to some embodiments, a continuous belt casting system includes an endless belt having an elongated belt surface, wherein the elongated belt surface includes a predetermined textured pattern defined on the elongated belt surface. The stretched belt surface at least partially defines the casting cavity of the continuous belt casting system.

According to certain embodiments, a method of casting a metal slab includes introducing molten metal into a casting cavity defined by two endless belts, at least one of the endless belts comprising a belt surface having a predetermined textured pattern. do. The method includes advancing molten metal through a casting cavity by advancing an endless belt to solidify the molten metal, and causing the solidified molten metal to emerge from the outlet of the casting cavity as a metal slab, the cast metal slab texturing the belt surface. It includes a step of including a surface texture pattern corresponding to the pattern.

According to some embodiments, the cast metal slab is formed by a continuous belt caster and includes a slab surface having a surface texture pattern that corresponds to a predetermined textured pattern on a belt surface of an endless belt of the continuous belt caster.

According to various embodiments, a method of texturing a casting mold of a continuous belt casting system includes providing at least one endless belt comprising an elongated belt surface. The method includes texturing the stretched belt surface by applying a predetermined texture pattern to the stretched casting, the predetermined texture pattern comprising a non-random pattern of grooves or ridges.

The various embodiments described herein may include additional systems, methods, features and advantages that may not necessarily be explicitly disclosed herein but will become apparent to those skilled in the art upon review of the following detailed description and accompanying drawings. will be. It is intended that all such systems, methods, features and advantages be included within this disclosure and protected by the appended claims.

This specification refers to the following attached drawings, and use of the same reference numerals in different drawings is intended to illustrate the same or similar components.
1 illustrates a continuous belt casting system according to an embodiment.
Figure 2 is a flow diagram of a method of manufacturing a casting surface for a continuous belt casting system according to an embodiment.
3 is a top view of an endless cast belt of a belt casting system prior to texturing according to an embodiment.
4A-C illustrate steps in a method of texturing a casting surface for a continuous belt casting system according to an embodiment.
5A-C illustrate steps in a method of texturing a casting surface for a continuous belt casting system according to an embodiment.
6A-B illustrate steps in a method of texturing a casting surface for a continuous belt casting system according to an embodiment.
7A-B illustrate steps in a method of texturing a casting surface for a continuous belt casting system according to an embodiment.
8A-C illustrate a texturing device configured to texturize a casting surface for a continuous belt casting system according to an embodiment of the present disclosure.
9A-B illustrate a portion of a cast belt with a textured belt surface according to an embodiment.
10A-B illustrate a portion of a cast belt with a textured belt surface according to an embodiment.
11 illustrates a portion of a cast belt with a textured belt surface according to an embodiment.
12A-B illustrate examples of surface topography of a cast metal slab according to embodiments.
13A-B are scanning electron microscopy images of a portion of a cast metal slab according to an embodiment compared to a traditional cast metal slab.
14A-B are photographs showing the porosity of a portion of a cast metal slab according to an embodiment compared to a traditional cast metal slab.
15A to 15B are photographs showing the grain structure of a portion of a cast metal slab according to an embodiment compared to a traditional cast metal slab.

Described herein are systems and methods for texturing the casting surface of a continuous belt casting system, as well as continuous belt casting systems and methods comprising a textured casting surface. Cast articles with textured surfaces are also described. The systems and methods described herein can be utilized to texturize casting surfaces in various types of belt casting systems that include at least one endless metal belt having a belt surface forming the casting surface. In some examples, the systems and methods may be utilized to texturize the casting surface of a twin belt casting system.

Texturing the casting surface may optionally include providing the endless metal belt before the endless metal belt is installed within the belt casting system and applying a predetermined texture to the second region of the endless metal belt, without applying the predetermined texture to the first region of the endless metal belt. It involves applying a predetermined texture to. In other words, the method involves applying a texturizing force or technique to individual areas of the casting surface such that the individual areas are textured to have a desired texture. The predetermined texture may be a non-random pattern of features (such as, but not limited to, a non-random pattern of grooves or ridges). Compared to traditional shot blasting or linishing techniques, which are applied to the entire casting surface, the method described herein combines the surface features of the texture (e.g. depth, diameter, shape, size, etc.) as well as the casting surface. Provides improved control over the overall distribution of textures. As a non-limiting example, the systems and methods described herein can be used to reduce surface and subsurface defects (e.g., extrudates, open dendrites, meniscus marks, porosity, cracks, shrinkage marks, etc.) to acceptable levels. A metal slab can be created that is minimized and/or eliminated.

Improved control minimizes metallurgical and mechanical surface defects such as extrudates, intermetallic compounds, ripples, etc., while minimizing the structural anisotropy of cast metal products formed by cast surfaces compared to shot blasted or lined surfaces. Provides an improved casting surface. For example, a casting surface with a texture provided by the methods described herein can provide improved control of heat flux from the molten metal and improved stabilization of the contact points between the molten metal and the casting surface, which It can reduce or eliminate casting defects in metal products and eliminate or reduce thermal deformation in endless belts. Various other advantages and advantages may be realized with the devices and methods provided herein, and the foregoing advantages should not be considered limiting.

1 illustrates an example of a continuous belt casting system 100. The specific arrangements or components illustrated in Figure 1 should not be considered limiting. Continuous belt casting system 100 generally includes a molten metal source 102 and endless casting belts 104A-B. Each of the endless casting belts 104A-B has a casting surface 106 that at least partially forms a casting cavity 108. Although not shown, edge dams are provided on each side of the system to complete the enclosure of the casting cavity 108 at its edges. The endless casting belt 104A-B is rotated (indicated by arrow 111) and molten metal 112 is introduced from the molten metal source 102 at the inlet 116 of the casting cavity 108 and in the casting direction ( 110 advances through the endless casting belt 104A-B and through the casting cavity 108. The endless cast belts 104A-B may be arranged substantially parallel, but in other instances need not be parallel. In some examples, endless casting belts 104A-B may converge toward exit 114 of casting cavity 108. In various cases, the endless casting belts 104A-B are operated at substantially the same speed so that the casting cavity 108 forms a static moving mold for the metal as it passes through the casting cavity 108. As the metal advances through the casting cavity 108, heat from the metal is transferred through the belt and the molten metal gradually solidifies. The molten metal may completely solidify before reaching outlet 114 and emerge from outlet 114 as a continuous solid cast metal substrate 118.

Endless cast belt 104A-B may be supported on pulleys or other suitable support structures and driven by a variety of suitable drive mechanisms. For simplicity, the support structure and drive mechanism are omitted in Figure 1. Cast belts 104A-B may be comprised of a variety of suitable materials, and in some cases may be comprised of suitable metals that can be sufficiently tensioned. In some examples, cast belts 104A-B may be comprised of steel, iron, iron alloys, copper, copper alloys, aluminum, aluminum alloys, and/or various other suitable metallic or non-metallic materials for belt casting. In various aspects, the casting surfaces 106 are provided with a texture on at least one of the casting surfaces 106 , and in some cases both casting surfaces 106 . The texture can control the heat flux from the molten metal and stabilize the contact point between the molten metal and the casting belt, which can minimize metallurgical and mechanical surface defects while minimizing structural anisotropy. Texture on the casting surface(s) 106 can also improve the usable life of the cast belt by minimizing or eliminating thermal distortion of the cast belt.

2 generally illustrates a method 200 of texturing a casting surface of at least one casting belt for a belt casting system. For example, endless cast belts 104A-B of continuous belt casting system 100 may be textured by method 200. In various aspects, method 200 is performed prior to installing the cast belt into the belt casting system, but in other instances this need not be the case.

At block 202 , referring to FIG. 3 , method 200 includes receiving an endless casting belt 304 . Endless cast belt 304 is substantially similar to endless cast belt 104A-B and includes an elongated belt surface 106. In certain optional examples, method 200 may receive endless cast belt 304 after forming endless cast belt 304 through various forming techniques. Techniques for forming endless cast belt 304 may include, but are not limited to, laser welding or other suitable joining techniques.

3 , in various instances, across the width of casting surface 106, casting surface 106 has at least one first region 320 configured to receive a texture and at least one first region 320 configured not to receive texture. It may include at least one second area 322. A first region 320 and/or a second region 322 may also be provided along the length of the casting surface 106 but are omitted from FIG. 3 for simplicity. When there are a plurality of first areas 320, a second area 322 may be provided between adjacent first areas 320. The number of first regions 320 and second regions 322 and the arrangement of these regions on the casting surface should not be considered limiting. Additionally, the relative regions 320 and 322 illustrated in Figure 3 are exaggerated for illustrative purposes and are not intended to infer the specific size, distribution, pattern or area of the region receiving the texture. For example, as discussed in more detail below, regions 320, 322 may have surface features provided in micrometers or millimeters.

At block 204, the method 200 sets the first region (or regions) such that the first region (320) has a predetermined texture and the second region (or regions) 322 does not include the predetermined texture. and texturing 320. In various aspects, the predetermined texture may be based on the type of metal being cast, and the predetermined texture for one type of metal may be the same or different than the predetermined texture for another type of metal. As a non-limiting example, the predetermined texture for the 5xxx series aluminum alloy, 6xxx series aluminum alloy, and 7xxx series aluminum alloy may be the predetermined texture for the 1xxx series aluminum alloy and 3xxx series aluminum alloy, 8xxx series aluminum alloy, or castable aluminum alloy. It may be different, but in other examples it is not necessary. To understand the numbering system most commonly used to name and identify aluminum and its alloys, such as AA numbers and other related designations such as "series" or "7xxx", see "For Forged Aluminum and Forged Aluminum Alloys" See “International Alloy Designations and Chemical Composition Limits” or “Aluminum Association Alloy Designations and Chemical Composition Limits Registration Records for Aluminum Alloys in Cast and Ingot Form,” both published by the Aluminum Institute.

In some cases, the predetermined texture is based on the desired surface quality of the metal being cast. In various cases, the predetermined texture is based on the desired solidification rate of the metal during continuous casting. The predetermined texture may include, but is not limited to, a predetermined depth, a predetermined diameter or other dimension, a predetermined shape, and/or a predetermined pattern or distribution of texture on the casting surface 106. In certain embodiments, the predetermined texture is a non-random texture pattern. In some embodiments, and as previously mentioned, the texture may be based on the type of metal being cast. As a non-limiting example, the texture (e.g., crosshatch texture) used in 5xxx series aluminum alloys may be different from the texture (e.g., ridge texture) used in 6xxx series aluminum alloys.

In one non-limiting example, the predetermined texture includes a depth of 20 μm to 1000 μm, such as 200 μm to 250 μm. In one alternative example, the depth may be 20 μm to 25 μm. In another non-limiting example, the distance between adjacent first areas 320 (or, conversely, the dimension of the intervening second area 322) is preset to be 0.01 mm to 1.0 mm, for example 0.1 mm to 0.3 mm. The determined texture includes a pattern or distribution of the first area 320.

As a further non-limiting example, predetermined textures include, but are not limited to, providing texture as a pattern such as grooves, ridges, diamonds, etc. In one non-limiting example, the pattern may be individual grooves in first region 320 extending along the length and/or width of casting surface 106 . In such examples, the grooves may be parallel to casting direction 110 or may extend at an angle non-parallel to casting direction 110. As one example, the groove may be a diagonal groove. Other textural patterns include ridges extending parallel, perpendicular and/or at an angle to the casting direction; grooves extending parallel, perpendicular and/or at an angle to the casting direction; and cross-hatching formed by a first set of grooves and a second set of grooves, wherein the first set of grooves is parallel, perpendicular, and/or at an oblique angle to the casting direction. 2 The groove sets are parallel, perpendicular and/or angled to the casting direction. In one non-limiting example, the pattern may be cross-hatching, with both the first set of grooves and the second set of grooves being at an oblique angle relative to the casting direction (e.g., 45° or other) such that the cross-hatching forms a diamond pattern. angle). Other patterns may be utilized as desired.

As another non-limiting example, the predetermined texture includes craters having a particular geometric or non-geometric shape. In these examples, the shape may include, but is not limited to, a triangular shape, a square shape, an angled shape, a concave shape, or any other suitable shape as desired. 4A-C, 5A-C, 6A-B, 7A-B, and 8A-C illustrate non-limiting examples of various techniques and/or devices that may be utilized in block 202 and are discussed in more detail below. .

Referring back to FIG. 2 , at block 204 the method may include installing a textured casting belt 304 in a belt casting system. Installing the textured endless cast belt 304 may include supporting the cast belt 304 on pulleys or other suitable supports such that the casting surface 106 at least partially defines the casting cavity 108. It is not limited to this.

4A-C illustrate an example of texturing the casting surface 106 that may be utilized in block 202. 4A , the method includes masking a second region 322 of the casting surface 106 such that a masking agent 424 is present in the second region 322 but not in the first region 320. The step of applying clause 424 may be included. In some cases, masking agent 424 may be a chemical resistant masking agent, although a variety of suitable types of masking agent may be utilized. In various aspects, masking agent 424 may be a polymer masking agent, a ceramic masking agent, and/or a composite masking agent. In a particular example, applying the masking agent 424 to the second region 322 includes rolling the masking agent 424 on the second region 322, applying the masking agent 424 to the second region 322. ), painting the masking agent 424 on the second area 322, inkjet printing the masking agent 424 on the second area 322, or various other suitable application techniques as desired. You can, but are not limited to this.

Referring to FIG. 4B , after the masking agent 424 is applied, the first area(s) 320 (exposed because it does not include the masking agent 424) are on the first area(s) 320. It may be etched by applying an etchant 426 to provide a predetermined texture to the first region(s) 320 . The etchant 426 may be a variety of suitable types of etchants, including but not limited to chemical etchants, electrochemical etchants, gas etchants, and/or liquid etchants. As some non-limiting examples, the etchant 426 may include picral, nital, ferric chloride, ammonium hydroxide, hydrogen peroxide, mixtures thereof, or other suitable etchants or combinations of etchants as desired. . In various examples, applying the etchant 426 may include at least one of an etch duration, an etch temperature, an etch rate, or other suitable etch details such that the first region(s) 320 are provided with a predetermined texture. It may include a control step. In Figure 4C, after etching is complete, a predetermined texture 428 is provided to the first region(s) 320 but not the second region 322. Casting surface 106 may be rinsed, dried and/or otherwise prepared prior to using casting belt 304 with a belt casting system.

5A-C illustrate another example of texturing a casting surface 106 that may be utilized in block 202 of method 200. Referring to FIG. 5A , the method may include applying a masking agent 424 to both first region(s) 320 and second region 322 using masking agent 424 . In some cases, applying masking agent 424 may include applying masking agent 424 to the entire surface area of casting surface 106. The method applies a laser 530 (e.g., from a laser head 532) to the first area 320 to laser texturize the first area(s) 320 and ) to expose the casting surface 106 of the first region(s) 320 by removing the masking agent 424 from the masking agent 424 . The illustrated laser head 532 should not be considered limiting. In various aspects, applying the laser 530 may include controlling a laser control feature while applying the laser 530. Laser control features include the mode of application of the laser (e.g., pulsed, continuous, etc.), the number of passes of the laser 530 over the first area(s) 320, and the number of passes of the laser 530 over the first area(s) 320. This may include, but is not limited to, the speed of movement of the head 532, laser energy level, pulse duration, angle of incidence of the laser with respect to the casting surface 106, combinations thereof, or other suitable laser control features.

As illustrated in Figure 5B, similar to Figure 4B, after applying the laser 530, the method includes applying an etchant 426 to the first region(s) 320 to provide a predetermined texture. may include. As illustrated in FIG. 5C , similar to FIG. 4C , after etching is completed, a predetermined texture 428 is provided to the first region(s) 320 but not the second region 322 . Casting surface 106 may be rinsed, dried and/or otherwise prepared prior to using casting belt 304 with a belt casting system.

6A-B show another example of texturing a casting surface 106 that may be utilized in block 202 of method 200. As illustrated in FIG. 6A , the method involves applying a laser 630 (e.g., from a laser head 632) to the first area(s) 320 and not to the second area 322. Includes steps. Laser 630 and/or laser head 632 may be the same or different from laser 530 and/or laser head 532. In certain aspects, applying the laser 630 includes moving the laser head 632 relative to the casting surface 106, moving the casting surface 106 relative to the laser head 632, or moving the laser head It may include moving both 632) and casting surface 106. In various aspects, applying the laser 630 may include controlling a laser control feature such that a predetermined texture 428 is provided on the first area(s) 320 . The laser control features include the application mode (e.g., pulsed, continuous, etc.), the number of passes of the laser 630 over the first area 320, the speed of movement of the laser head 632 over the first area 320, This may include, but is not limited to, laser energy level, pulse duration, angle of incidence of the laser relative to the casting surface 106, combinations thereof, or other suitable laser control features. As a non-limiting example, applying the laser 630 may include applying the laser 630 in pulsed mode. As another non-limiting example, applying the laser 630 may include applying the laser 630 on the first area(s) 320 in one pass or more than one pass. .

As shown in Figure 6B, after applying the laser 630, the predetermined texture 428 is provided to the first area(s) 320 but not to the second area 322. Optionally, after applying the laser 630, an etchant (such as etchant 426) may further texturize the first region(s) 320 so that the first region(s) 322 have a predetermined texture or It can be applied to the first area(s) 320 to have different predetermined textures.

7A-B illustrate another example of texturing a casting surface 106 that may be utilized in block 202 of method 200. 7A-B is similar to the method illustrated in FIGS. 6A-B except that the method illustrated in FIGS. 6A-B includes applying a bonding layer 734 on the casting surface 106 prior to applying the laser 630. Substantially similar. Applying the bonding layer 734 may include applying the bonding layer 734 to both the first region(s) 320 and the second region 322 or only the first region(s) 320. You can. Bonding layer 734 can be a variety of suitable materials that improve the bond between the laser and casting surface 106 to improve the shape of predetermined texture 428. In one non-limiting example, bonding layer 734 is a water layer.

8A-C illustrate an example of a texturing tool 836 that can be used to mechanically texturize the casting surface 106 in block 202 of method 200. In some non-limiting examples, texturing tool 836 may induce grooves in casting surface 106 along a direction of movement with a predetermined texture. Referring to FIG. 8A, the texturing tool 836 may include a holder 838 and a roller 840 rotatably supported on the holder 838. As best illustrated in Figures 8B-C, which show a portion of roller 840 in more detail, roller 840 has a roller surface 842, where roller surface 842 includes one or more ribs 844. do. In the example of FIGS. 8A-C , the roller surface 842 includes a plurality of ribs 844, each rib 844 having a corresponding first surface such that the plurality of first regions 320 are provided with a predetermined texture. It is configured to engage with the area 320. In this example, the portion of the roller surface 842 without the ribs 844 is configured to contact the corresponding second region 322 of the casting surface 106, such that the second region 320 is textured while the first region 320 is textured. A predetermined texture is not provided in the area 322. The number, shape, profile or size of ribs 844 should not be considered limiting, and these features may be controlled as desired to allow texturing tool 836 to provide a predetermined texture to first region 320. . As some non-limiting examples, referring to FIG. 8C , the height 846 of one or more ribs 844, the maximum distance 848 between adjacent ribs 844, and/or the minimum distance between adjacent ribs 844. 850 can be controlled such that texturing tool 836 provides a predetermined texture.

During a texturing process using texturing tool 836 , roller 840 contacts casting surface 106 such that at least one rib 844 contacts first region 320 of casting surface 106 . The method may include contacting the roller 840 with the casting surface 106 such that a portion of the roller surface 842 without at least one rib 844 contacts the second area 322 . The method includes moving the roller 840 along the casting surface 106 such that at least one rib 844 forms a predetermined texture in the first region 320 but not in the second region 322. do. In some examples, the method may include controlling an application force while moving the roller 840 along the casting surface 106.

A variety of other suitable techniques may be utilized to apply a predetermined texture to the first area 320 of the casting surface 106 and ensure that the second area 322 does not include the predetermined texture.

9A-B illustrate a portion of a casting belt 904 that is substantially similar to the casting belt 104. As illustrated in FIGS. 9A-B , cast belt 904 includes a belt surface 952 textured with a textured pattern 954. In the illustrated embodiment, the texture pattern 954 is a cross formed by a first groove 956 extending in a first direction and a second groove 958 extending in a second direction and intersecting the first groove 956. It is a hatching pattern. Optionally, the first or second direction may be a casting direction, although in other embodiments this need not be the case. For example, since both the first direction and the second direction form an inclined angle with respect to the casting direction, the crosshatching pattern may become a diamond pattern in the casting direction.

10A-B illustrate a portion of a cast belt 1004 that is substantially similar to the cast belts 104 and 904 and includes a belt surface 952 textured with a textured pattern 1054. Texture pattern 1054 is similar to texture pattern 954 and is a crosshatching pattern; Compared to the texture pattern 954, the spacing between adjacent first grooves 956 and between adjacent second grooves 958 is increased in the texture pattern 1054.

11 illustrates a portion of a cast belt 1104 that is substantially similar to the cast belts 104, 904, 1004 and includes a belt surface textured with a textured pattern 1154. Compared to texture patterns 954 and 1054, texture pattern 1154 is a ridge pattern formed by parallel grooves 1156. Groove 1156 may extend in the casting direction, perpendicular to the casting direction, and/or in a direction at an angle to the casting direction.

Cast belts 104, 904, 1004, 1104 are for illustrative purposes only and should not be considered limiting of the present disclosure. As mentioned, in other embodiments, other textures and/or texture patterns may be provided on the belt surface of the cast belt as desired.

Referring back to FIG. 1 , a method of forming a metal slab having a textured slab surface includes providing casting belts 104A-B such that at least one of the casting belts 104A-B includes a textured belt surface. It can be included. Optionally, both cast belts 104A-B may be provided with a textured belt surface. The method involves introducing molten metal 112 into a casting cavity 108 and advancing the metal 112 through the casting cavity 108 with a casting belt 104A-B so that heat from the metal 112 is transferred through the belt. and allowing the molten metal 112 to gradually solidify. Molten metal 112 may completely solidify before reaching outlet 114 and emerge from outlet 114 as a continuous slab of solid cast metal. One or both of the slab surfaces of the cast metal slab may include texture from the cast belt 104A-B.

12A-B illustrate non-limiting examples of cast metal slabs according to embodiments. As illustrated in Figures 12A-B, the pattern of the cast belt generally corresponds to the texture pattern of the cast slab surface. As used herein, the surface texture of a metal slab generally corresponds to the textured pattern of a cast belt in that the surface texture of a metal slab may have the same shape and/or pattern, but may have dimensions (e.g. depth, height, etc.) do not necessarily have to be the same. For example, during casting, the molten metal may penetrate only part of the depth of the grooves and/or other parts of the textured pattern, so that the surface texture of the metal slab generally corresponds to the textured pattern of the casting belt due to partial penetration. .

FIG. 12A illustrates the surface topography of a cast metal slab 1260A formed using a cast belt with a ridge texture pattern. As illustrated in FIG. 12A, slab 1260A formed with a ridge texture pattern had a relatively uniform casting surface. FIG. 12B illustrates the surface topography of a cast metal slab 1260B formed using a casting belt with a crosshatching textured pattern, where slab 1260B had a relatively uniform casting surface.

As previously mentioned, metal slabs formed from the textured belt surfaces described herein can have improved surface properties, sub-surface properties, and performance compared to metal slabs formed using traditional techniques. As a non-limiting example, compared to conventional cast metal slabs, metal slabs formed using the systems and methods described herein have minimized or eliminated extrudates, homogeneously or more evenly distributed, while maintaining internal quality and performance. have minimized or eliminated intermetallic compounds, minimized or eliminated voids, minimized or eliminated cracks, minimized or eliminated open dendritic structures, minimized or eliminated meniscus marks, etc. Metal slabs with the improved surface and subsurface properties described herein may have improved performance and/or uses as a result. As a non-limiting example, the metal slabs described herein may have improved adhesive durability compared to traditional metal slabs.

Figures 13a-b, 14a-b, and 15a-b illustrate non-limiting examples comparing a metal slab 1360 formed from a textured cast belt with a metal slab 1361 formed using traditional techniques. Casting parameters for slabs 1360 and 1361 were identical except for the cast belt - metal slab 1360 was formed from a cast belt with a cross-hatched texture on the belt surface, and metal slab 1361 was formed from a traditional belt with a smooth surface. It was formed from a cast belt.

13A to 13B are scanning electron micrographs of portions of metal slabs 1360 and 1361. As illustrated in FIG. 13A , the surface of metal slab 1360 was generally free of extrudates, but as shown in FIG. 13B , the surface of metal slab 1361 contained extrudates.

14A-B illustrate the porosity of portions of metal slabs 1360 and 1361. As illustrated by comparing Figure 14A to Figure 14B, the porosity of metal slab 1360 was minimal and had a uniform subsurface porosity, while metal slab 1361 had a relatively increased porosity that was less uniform.

15A to 15B illustrate the crystal structure of portions of the metal slabs 1360 and 1361. As illustrated in these figures, the crystal structures of metal slabs 1360 and 1361 were generally identical.

Overall, FIGS. 13a-b, 14a-b, and 15a-b illustrate how the metal slab 1360 described herein has improved surface properties compared to a traditional slab 1361 while maintaining the internal properties and performance of the slab. Illustrate.

A set of example embodiments, including at least some explicitly listed as “Examples,” are provided below that provide further illustration of various example embodiments in accordance with the concepts described herein. These examples are not mutually exclusive, exhaustive, or limiting; The present disclosure is not limited to this exemplary description, but includes all possible modifications and variations within the scope of the issued claims and their equivalents.

Example 1. A method of texturing a casting mold of a continuous belt casting system, the method comprising: providing at least one endless belt comprising an elongated belt surface, wherein the elongated belt surface comprises at least a first region; comprising at least a second region adjacent the first region across the width of the stretched belt surface, the stretched belt surface being configured to at least partially define a casting cavity of the continuous belt casting system; and texturing the stretched belt surface by applying a predetermined texture to a first area and ensuring that the second area does not include the predetermined texture.

Example 2. A method of any preceding or subsequent example or combination of examples, wherein providing at least one generous belt includes a copper-based endless belt, an iron-based endless belt, an aluminum-based endless belt, a steel-based endless belt, or any desired A method comprising providing at least one of any other suitable texturable belt.

Example 3. A method of any preceding or subsequent example or combination of examples, wherein the at least one endless belt is a first endless belt, the stretched belt surface is a first stretched belt surface, and the method is: a second stretched belt surface. providing a second endless metal belt comprising a belt surface, wherein the second elongated belt surface is configured to at least partially define a casting cavity, and the second elongated belt surface defines a first region and a second region. Contains-; and texturing the second stretched belt surface by applying a predetermined texture to a first region of the second stretched belt surface and ensuring that the second region of the second stretched belt surface does not include the predetermined texture. How to.

Example 4. A method of any preceding or subsequent example or combination of examples, wherein texturing the stretched belt surface comprises: applying a masking agent to at least a second region of the stretched belt surface; etching a first region of the stretched belt surface with an etchant to form a predetermined texture; and removing the masking agent from the second region of the stretched belt surface.

Example 5. The method of any preceding or subsequent example or combination of examples, wherein applying the masking agent comprises applying a chemically resistant masking agent.

Example 6. The method of any preceding or subsequent example or combination of examples, wherein applying the masking agent includes applying the masking agent only to the second area and not applying the masking agent to the first area, and The method of claim 1, wherein etching the first region includes etching the first region without a masking agent. In some embodiments, etching or texture may be provided on both sides of the belt. In certain embodiments, the etching or texture provided on one side of the belt (e.g., the water side of the belt during casting) is the same as the etching or texture provided on the other side of the belt (e.g., the molten metal side of the belt during casting). can be different.

Example 7. A method of any preceding or subsequent example or combination of examples, wherein applying the masking agent comprises: applying the masking agent to both a first region and a second region of the stretched belt surface; and laser texturing the first region of the stretched belt surface such that the masking agent is removed from the first region, and etching the first region comprises etching the first region without masking agent. . In various embodiments, etching or texture may be provided on both sides of the belt. In certain embodiments, the etching or texture provided on one side of the belt (e.g., the water side of the belt during casting) is the same as the etching or texture provided on the other side of the belt (e.g., the molten metal side of the belt during casting). can be different.

Example 8. The method of any preceding or subsequent example or combination of examples, wherein applying the masking agent comprises applying the masking agent by at least one of rolling, spraying, painting, or inkjet printing.

Example 9. The method of any preceding or subsequent example or combination of examples, wherein the etching step includes applying at least one of a chemical etchant, a liquid etchant, or a gas etchant.

Example 10. The method of any preceding or subsequent example or combination of examples, wherein the etching step includes controlling at least one of an etch duration or an etch temperature to form a predetermined texture.

Example 11. The method of any preceding or subsequent example or combination of examples, wherein texturing the stretched belt surface comprises laser texturing a first region of the stretched belt surface.

Example 12. The method of any preceding or subsequent example or combination of examples, wherein the laser texturing step includes moving the laser relative to the stretched belt surface or moving the stretched belt surface relative to the laser. .

Example 13. A method of any preceding or subsequent example or combination of examples, wherein the laser texturing step includes laser mode, speed of the laser head relative to the stretched belt surface, laser energy level, laser pulse duration, and A method comprising controlling at least one of the angle of incidence of the laser relative to the plane, or the number of laser passes over the first region of the stretched belt surface.

Example 14. The method of any preceding or subsequent example or combination of examples, wherein the laser texturing step comprises applying a layer of water on at least a first region of the stretched belt surface and laser texturing the first region with a layer of water. A method comprising steps.

Example 15. A method of any preceding or subsequent example or combination of examples, further comprising etching a first region of the stretched belt surface after laser texturing.

Example 16. A method of any preceding or subsequent example or combination of examples, wherein the texturing step includes a mechanical texturing step, wherein the mechanical texturing step includes: providing a texturing tool comprising a roller, wherein the roller is a roller surface. wherein the roller surface includes at least one rib; contacting the roller with the stretched belt surface such that at least one rib contacts a first region of the stretched belt surface; and moving the roller along the stretched belt surface such that the at least one rib forms a predetermined texture only in a first region of the stretched belt surface.

Example 17. The method of any preceding or subsequent example or combination of examples, wherein the mechanical texturing step further comprises controlling the application force while moving the roller along the stretched belt surface.

Example 18. The method of any preceding or subsequent example or combination of examples, wherein the stretched belt surface includes a plurality of first regions, wherein the second regions are between adjacent first regions across the width of the stretched belt surface. , the method further comprising: texturing the stretched belt surface by applying a predetermined texture to the plurality of first regions.

Example 19. A method of any preceding or subsequent example or combination of examples, wherein applying a predetermined texture to the plurality of first regions comprises a distance between adjacent first regions where the dimensions of the second regions are from 0.01 mm to 1.0 mm. A method comprising applying a predetermined texture to be mm.

Example 20. The method of any preceding or subsequent example or combination of examples, wherein applying a predetermined texture to the plurality of first regions includes predetermined the distance between adjacent first regions such that the distance between adjacent first regions is 0.1 mm to 0.3 mm. A method comprising applying the determined texture.

Example 21. The method of any preceding or subsequent example or combination of examples, wherein applying the predetermined texture to the first region includes forming a crater having a depth of 20 μm to 1000 μm.

Example 22. The method of any preceding or subsequent example or combination of examples, wherein applying the predetermined texture to the first region includes forming a crater having a depth of between 200 μm and 250 μm.

Example 23. The method of any preceding or subsequent example or combination of examples, wherein applying the predetermined texture to the first region includes forming grooves elongated craters in the casting direction.

Example 24. A method of any preceding or subsequent example or combination of examples, further comprising installing at least one endless belt such that the stretched belt surface at least partially forms a casting cavity.

Example 25. Endless metal belt, for a continuous belt casting system, comprising a casting surface manufactured by a method of preceding or subsequent examples or a combination of examples.

Example 26. A method of texturing a casting mold of a continuous belt casting system, the method comprising: providing at least one endless belt comprising an elongated belt surface, wherein the elongated belt surface is the width of the elongated belt surface. comprising at least a first region and a second region across, the second region being adjacent the first region, the elongated belt surface being configured to at least partially define a casting cavity of the continuous belt casting system; and locally texturing the stretched belt surface such that the first region includes the predetermined texture and the second region does not include the predetermined texture.

Example 27. A method of texturing a casting mold of a continuous belt casting system, the method comprising: providing at least one endless belt comprising an elongated belt surface, wherein the elongated belt surface has a plurality of first regions and comprising a plurality of second regions, wherein an adjacent first region of the plurality of first regions is separated by one of the plurality of second regions, and the elongated belt surface at least partially defines a casting cavity of the continuous belt casting system. configured-; and applying the predetermined texture only to the plurality of first regions and texturing the stretched belt surface such that the distance between adjacent first regions of the plurality of first regions is between 0.01 mm and 1.0 mm, or any suitable dimension. How to.

Example 28. The method of any preceding or subsequent example or combination of examples, wherein applying a predetermined texture only to the plurality of first regions comprises a distance between adjacent first regions of the plurality of first regions of 0.1 mm to 0.3 mm. A method comprising applying a predetermined texture to mm, or any suitable distance.

Example 29. A method of any preceding or subsequent example or combination of examples, wherein applying a predetermined texture only to the plurality of first regions comprises: applying a predetermined texture to each first region of the plurality of first regions at a depth of 20 μm to 1000 μm; or forming a crater having any suitable depth.

Example 30. A method of any preceding or subsequent example or combination of examples, wherein applying a predetermined texture only to the plurality of first regions comprises: applying a predetermined texture to each first region of the plurality of first regions to a depth of 200 μm to 250 μm; or forming a crater having any suitable depth.

Example 31. The method of any preceding or subsequent example or combination of examples, wherein applying a predetermined texture only to the plurality of first regions includes extending in the casting direction to a first region of each of the plurality of first regions and having a thickness of 20 μm to 20 μm. A method comprising forming a groove having a depth of 1000 μm.

Example 32. A continuous belt casting system comprising an endless belt comprising an elongated belt surface, wherein the elongated belt surface comprises a predetermined textured pattern defined on the elongated belt surface, and the elongated belt surface comprises a continuous belt surface. A continuous belt casting system that at least partially defines a casting cavity of the casting system.

Example 33. A continuous belt casting system of any preceding or subsequent example or combination of examples, wherein the predetermined textured pattern includes a ridge pattern, a groove pattern, a crosshatching pattern, or a diamond pattern formed on the stretched belt surface. , continuous belt casting system.

Example 34. A continuous belt casting system of any preceding or subsequent example or combination of examples, wherein the endless belt is a first endless belt and the stretched belt surface is a first stretched belt surface, and the continuous belt casting system has a casting cavity. A continuous belt casting system comprising a second endless belt comprising a second elongated belt surface at least partially defining the second elongated belt surface, the second elongated belt surface comprising a predetermined textured pattern.

Example 35. A continuous belt casting system of any preceding or subsequent example or combination of examples, wherein the predetermined textured pattern of the second stretched belt surface is the same as the predetermined textured pattern of the first stretched belt surface. Belt casting system.

Example 36. A method of casting a metal slab, comprising: introducing molten metal into a casting cavity defined by two endless belts, wherein at least one of the endless belts comprises a predetermined textured pattern. Includes surfaces -; advancing the molten metal through the casting cavity by advancing an endless belt to cause the molten metal to solidify; and causing the solidified molten metal to emerge from the outlet of the casting cavity as a metal slab, the cast metal slab comprising a surface textured pattern corresponding to the textured pattern of the belt surface.

Example 37. The method of any preceding or subsequent example or combination of examples, wherein the predetermined textured pattern on the belt surface comprises a ridge pattern, a groove pattern, a crosshatching pattern, or a diamond pattern.

Example 38. A method of any preceding or subsequent example or combination of examples, further comprising changing the predetermined textured pattern from a first pattern to a second pattern based on the type of metal being cast.

Example 39. Cast metal slab formed by a method of a preceding or subsequent example or a combination of examples.

Example 40. A cast metal slab formed by a continuous belt caster, wherein the cast metal slab includes a slab surface, the slab surface having a surface texture corresponding to a predetermined textured pattern on the belt surface of an endless belt of the continuous belt caster. A cast metal slab containing a pattern.

Example 41. The cast metal slab of the preceding or subsequent examples or combination of examples, wherein the surface texture pattern comprises a groove pattern, a crosshatching pattern, or a diamond pattern.

Example 42. A method of texturing a casting mold of a continuous belt casting system, comprising: providing at least one endless belt comprising an elongated belt surface; and texturing the stretched belt surface by applying a predetermined texture pattern to the stretched casting, wherein the predetermined texture pattern comprises a repeatable pattern of grooves or ridges.

Although the subject matter of the embodiments is specifically described herein to satisfy legal requirements, such description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be implemented in different ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. These descriptions should not be construed as implying any particular order or arrangement among or between the various steps or elements, except where the order of individual steps or arrangement of elements is explicitly described. Directional references such as "top", "bottom", "top", "bottom", "left", "right", "front", "back", etc. are exemplified in the drawing (or drawings) in which the component and orientation are referenced. and is intended to refer to the directions described.

The foregoing embodiments are merely examples of possible implementations and are presented merely for a clear understanding of the principles of the present disclosure. Many variations and modifications may be made to the embodiment(s) described above without departing substantially from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included within the scope of this disclosure, and all possible claims for individual aspects or combinations of elements or steps are intended to be supported by this disclosure. Moreover, although specific terms are used in this specification and the following claims, they are used in a general and descriptive sense only and are not intended to limit the described embodiments or the following claims.

Claims (42)

1. A method of texturizing a casting mold of a continuous belt casting system, comprising:
Providing at least one endless belt comprising an elongated belt surface, wherein the elongated belt surface has at least a first region and extends across a width of the elongated belt surface to the first region. comprising at least a second region adjacent, wherein the elongated belt surface is configured to at least partially define a casting cavity of the continuous belt casting system; and
A method comprising texturing the stretched belt surface by applying a predetermined texture to a first area and ensuring that the second area does not include the predetermined texture. The method of claim 1, wherein providing at least one endless belt includes providing at least one of a copper-based endless belt, an iron-based endless belt, an aluminum-based endless belt, or a steel-based endless belt. 2. The method of claim 1, wherein the at least one endless belt is a first endless belt, the elongated belt surface is a first elongated belt surface, and the method comprises:
Providing a second endless metal belt comprising a second elongated belt surface, wherein the second elongated belt surface is configured to at least partially define the casting cavity, and wherein the second elongated belt surface is configured to at least partially define the casting cavity. Includes area 1 and area 2 -; and
The second stretched belt surface by applying the predetermined texture to the first region of the second stretched belt surface, and ensuring that the second region of the second stretched belt surface does not include the predetermined texture. A method comprising texturing. 2. The method of claim 1, wherein texturing the stretched belt surface comprises:
applying a masking agent to at least the second region of the stretched belt surface;
etching the first region of the stretched belt surface with an etchant to form the predetermined texture; and
and removing the masking agent from the second region of the stretched belt surface. 5. The method of claim 4, wherein applying the masking agent comprises applying a chemically resistant masking agent. The method of claim 4, wherein applying the masking agent includes applying the masking agent only to the second region and not applying the masking agent to the first region, and etching the first region. and etching the first region without the masking agent. The method of claim 4, wherein applying the masking agent comprises:
applying a masking agent to both the first region and the second region of the stretched belt surface; and
laser texturing the first region of the stretched belt surface such that the masking agent is removed from the first region, and
Wherein etching the first region includes etching the first region without the masking agent. The method of claim 4, wherein applying the masking agent comprises applying the masking agent by at least one of rolling, spraying, painting, or inkjet printing. 5. The method of claim 4, wherein the etching step includes applying at least one of a chemical etchant, a liquid etchant, or a gas etchant. 5. The method of claim 4, wherein the etching step includes controlling at least one of an etch duration or an etch temperature to form the predetermined texture. The method of claim 1, wherein texturing the stretched belt surface comprises laser texturing the first region of the constantly stretched belt surface. 12. The method of claim 11, wherein laser texturing comprises moving a laser relative to the stretched belt surface or moving the stretched belt surface relative to the laser. 12. The method of claim 11, wherein the step of laser texturing comprises a laser mode, a speed of the laser head relative to the stretched belt surface, a laser energy level, a laser pulse duration, an angle of incidence of the laser relative to the plane of the stretched belt surface, or Controlling at least one of the number of passes of the laser over the first region of the stretched belt surface. 12. The method of claim 11, wherein the laser texturing step includes applying a layer of water on at least the first region of the stretched belt surface and laser texturing the first region with the layer of water. 12. The method of claim 11 further comprising etching the first region of the stretched belt surface after laser texturing. The method of claim 1, wherein the texturing step comprises a mechanical texturing step:
Providing a texturing tool comprising a roller, wherein the roller comprises a roller surface, the roller surface comprising at least one rib;
contacting the roller with the stretched belt surface such that the at least one rib contacts the first region of the stretched belt surface; and
and moving the roller along the stretched belt surface such that the at least one rib forms the predetermined texture only in the first region of the stretched belt surface. 17. The method of claim 16, wherein the mechanical texturing step further comprises controlling an application force while moving the roller along the stretched belt surface. 2. The method of claim 1, wherein the elongated belt surface comprises a plurality of first regions, the second regions being between adjacent first regions across the width of the elongated belt surface, and the method comprising:
The method further comprising texturing the stretched belt surface by applying the predetermined texture to the plurality of first regions. 19. The method of claim 18, wherein applying the predetermined texture to the plurality of first regions comprises applying the predetermined texture such that a distance between adjacent first regions, the dimension of the second regions, is between 0.01 mm and 1.0 mm. A method comprising applying a. The method of claim 19, wherein applying the predetermined texture to the plurality of first regions includes applying the predetermined texture such that a distance between adjacent first regions is 0.1 mm to 0.3 mm. method. The method of claim 1, wherein applying the predetermined texture to the first region includes forming a crater having a depth of between 20 μm and 1000 μm. 22. The method of claim 21, wherein applying the predetermined texture to the first region includes forming a crater having a depth of between 200 μm and 250 μm. 22. The method of claim 21, wherein applying the predetermined texture to the first region includes forming craters extending in the casting direction into grooves. The method of claim 1 further comprising installing the at least one endless belt such that the elongated belt surface at least partially defines the casting cavity. An endless metal belt for a continuous belt casting system comprising a casting surface produced by the method of claim 1. A method of texturing a casting mold in a continuous belt casting system comprising:
Providing at least one endless belt comprising an elongated belt surface, wherein the elongated belt surface includes at least a first region and a second region across a width of the elongated belt surface, wherein the elongated belt surface comprises at least a first region and a second region. an area adjacent the first area, wherein the elongated belt surface is configured to at least partially define a casting cavity of the continuous belt casting system; and
Locally texturing the stretched belt surface such that the first region includes a predetermined texture and the second region does not include the predetermined texture. A method of texturing a casting mold in a continuous belt casting system comprising:
Providing at least one endless belt comprising an elongated belt surface, wherein the elongated belt surface includes a plurality of first regions and a plurality of second regions, and an adjacent first of the plurality of first regions. regions are separated by one of the plurality of second regions, the elongated belt surface being configured to at least partially define a casting cavity of the continuous belt casting system; and
Texturing the stretched belt surface by applying a predetermined texture only to the plurality of first regions and ensuring that the distance between adjacent first regions of the plurality of first regions is 0.01 mm to 1.0 mm. . The method of claim 27, wherein the step of applying the predetermined texture only to the plurality of first regions includes applying the predetermined texture such that the distance between the adjacent first regions among the plurality of first regions is 0.1 μm to 0.3 μm. A method comprising the step of applying. 28. The method of claim 27, wherein applying the predetermined texture only to the plurality of first regions comprises forming a crater with a depth of 20 μm to 1000 μm in each first region of the plurality of first regions. , method. The method of claim 29, wherein applying the predetermined texture only to the plurality of first regions comprises forming a crater with a depth of 200 μm to 250 μm in each first region of the plurality of first regions. , method. 28. The method of claim 27, wherein applying a predetermined texture only to the plurality of first regions comprises forming a groove extending in the casting direction and having a depth of 20 μm to 1000 μm in each first region of the plurality of first regions. A method comprising steps. 1. A continuous belt casting system comprising an endless belt comprising an elongated belt surface, wherein the elongated belt surface comprises a predetermined textured pattern defined on the elongated belt surface, and the elongated belt surface comprises an elongated belt surface. A continuous belt casting system, which at least partially defines a casting cavity of the belt casting system. 33. A continuous belt casting system according to claim 32, wherein the predetermined textured pattern comprises a ridge pattern, a groove pattern, a crosshatching pattern, or a diamond pattern formed on the stretched belt surface. 33. The method of claim 32, wherein the endless belt is a first endless belt and the elongated belt surface is a first elongated belt surface, and the continuous belt casting system is characterized by a second elongated belt surface at least partially defining the casting cavity. A continuous belt casting system comprising a second endless belt comprising: wherein the second elongated belt surface comprises a predetermined textured pattern. 35. A continuous belt casting system according to claim 34, wherein the predetermined textured pattern of the second stretched belt surface is the same as the predetermined textured pattern of the first stretched belt surface. In the casting method of a metal slab, the method includes:
introducing molten metal into a casting cavity defined by two endless belts, wherein at least one of the endless belts includes a belt surface comprising a predetermined textured pattern;
advancing the molten metal through the casting cavity by advancing the endless belt and allowing the molten metal to solidify; and
causing the solidified molten metal to emerge from the outlet of the casting cavity as a metal slab, wherein the cast metal slab includes a surface textured pattern corresponding to a textured pattern of the belt surface. 37. The method of claim 36, wherein the predetermined textured pattern on the belt surface comprises a ridge pattern, a groove pattern, a crosshatching pattern, or a diamond pattern. 37. The method of claim 36, further comprising changing the predetermined textured pattern from a first pattern to a second pattern based on the type of metal being cast. A cast metal slab formed by the method of claim 36. A cast metal slab formed by a continuous belt caster, wherein the cast metal slab includes a slab surface, the slab surface having a surface textured pattern corresponding to a predetermined textured pattern on a belt surface of an endless belt of the continuous belt caster. A cast metal slab comprising: 41. The cast metal slab of claim 40, wherein the surface texture pattern comprises a groove pattern, a crosshatching pattern, or a diamond pattern. A method of texturing a casting mold in a continuous belt casting system comprising:
providing at least one endless belt comprising an elongated belt surface; and
A method comprising texturing the stretched belt surface by applying a predetermined textured pattern comprising a non-random pattern of grooves or ridges to the stretched casting.