MXPA97002151A

MXPA97002151A - Apparatus and method for the vertical molding of a bar of me

Info

Publication number: MXPA97002151A
Application number: MXPA/A/1997/002151A
Authority: MX
Inventors: I Sartschev Adam; Joshua C Liu
Original assignee: Aluminum Company Of America
Priority date: 1994-09-20
Filing date: 1997-03-20
Publication date: 1997-06-01

Abstract

A generally vertical molding (10) for molding molded metal into metal bars. The moulder includes a pair of movable opposing bands (12, 14), each of the bands having a molding surface (12a, 14a) and a pair of movable opposing dam block means (30, 32) including a plurality of dam block having one end mounted to an orbiting or rotating support (43, 44) and a molding surface (34a, 36a) opposite the mounted end. The molding surfaces of the belts and the molding surfaces of the dam blocks define a zone (100) for molding bars to solidify the molded metal in a metal bar. The moulder also includes cooling bars (70, 72) to cool the belts while the two belts pass through the bar molding zone. An associated method and a metal bar manufactured by such method are also provided

Description

APPARATUS AND METHOD FOR THE VERTICAL MOLDING OF IMA BARRA DE METAL DESCRIPTION OF THE INVENTION This invention relates to a generally vertical moulder which produces a metal bar from molded metal. The invention also includes a method for producing a metal bar from molded metal and an associated metal bar product. The continuous molding of a metal bar is a well-known process. An example of such a process is the molding of aluminum bars using a wheel-type moulder. The aluminum bar is used as an initial product to produce aluminum rods and aluminum wire. The advantage of a continuous molding process compared to conventional processes for producing aluminum rods and wire from large extruded cylindrical pieces (38 cm diameter) (15 inches) is that the process of continuous molding or collapsing certain stages of the manufacturing process which results in the elimination of certain equipment and work stations. This in turn significantly reduces capital, labor, maintenance and energy consumption. REF: 24382 The known wheel type continuous bar moulder involves providing a rotating wheel having a trapezoidal groove into which molded aluminum is molded or molded. The groove is covered by a steel or copper band as the wheel and cast molded aluminum rotate. The groove and band form a mold to mold the aluminum bar. The molten aluminum solidifies the groove and then exits the wheel of the moulder. The solidification process is carried out by introducing a cooler on the back side of the belt and on the sides of the mold. After solidification, the aluminum rod is introduced into a rotary mill in which the bar fits into an aluminum rod. The aluminum rod is then cooled, lubricated and rolled into a wire. As is well known to those skilled in the art, the quality of molded aluminum bar depends mainly on the thermal conditions during the solidification process. The rate of heat extraction must be controlled in order to resist (i) surface liquefaction; (ii) the accumulation of residual stresses during solidification which may cause the fracture of the bar and the rupture of the bar during subsequent molding or processing; and (iii) the segregation of the central line of alloying elements.

Although. Many process improvements have been made to the wheel-type moulder, the above problems are present, especially in the molding of certain alloys such as aluminum alloys 2XXX, 5XXX, 6XXX and 7XXX. The lucidity of surfaces is caused by the formation of gaseous air between the solidifying aluminum bar and the mold which causes the melting of the cover surface of the bar again. This problem can be solved by maintaining contact between the mold and the aluminum bar that solidifies through the length of the molding process. However, to the extent that the wheel-type moulder has a rigid mold on three sides, it is difficult, if not impossible, to maintain a mold / bar contact through the solidification process. In addition, the mold and the band will be distorted in an unpredictable manner and therefore also make it difficult to maintain the mold / bar contact. Therefore, there is a need for a bar molding process and an apparatus that provides good mold / bar contact to resist surface liquefaction and improve the overall surface quality of the molded product. The partially solidified bar that bends in the rounded wheel mold causes the fracture of the side bar and the decomposition or breakage of the bar during melting and rolling. The different alloys show different capacities of propensity to the accumulation of residual tensions. This problem is related to the mass transfer speeds with respect to the length of the solidification zone and can be controlled by careful manipulation of the application. of cooler in strategic positions in the process of melting or molding. This requires a molding process with flexibility to vary heat transfer rates over the solidification zone, so that different alloys can be melted or cast successfully. Although improvements have been made in the handling of the cooler application in the wheel-type moulder, there is still a need for a bar molding process and apparatus that Provide flexibility to vary heat transfer rates over the length of the solidification zone. In addition, for longer cooling interval alloys (ie 2XXX, 4XXX, 6XXX and 7XXX) must: have a very efficient cooler application apparatus in order to rapidly remove heat from the solidified metal. The wheel-type moulder does not provide the type of high cooling rates that are needed to efficiently solidify the molten or molded bar. The inefficiency in the cooling causes the segregation of the central line of the alloy elements ... which is a universally undesirable result. Therefore, there is still a need for a bar moulder having a cooling system which efficiently removes heat from the molten molten metal in order to form a high quality aluminum bar. The bar moulder of the invention has satisfied the needs mentioned above as well as others. The generally vertical moulder for molding molten metal into metal bars comprises a pair of movable opposing strips each of the strips has a molding surface and a cooling surface opposite the molding surface and a pair of dam block means mobile opposites, the dam block means include a plurality of dam blocks having a mounted end and a rotating support, and a molding surface opposite the mounted end. The molding surfaces of the dam blocks define a bar molding area for solidifying the molded metal in a metal bar. The moulder additionally comprises cooling bar means for cooling the webs as they pass through the bar molding zone. A method is also provided for molding metal furid in metal bars. The method comprises providing a generally vertical bar moulder as described above having a pair of movable belts, a pair of dam block means and a cooling bar means for cooling the belts. The method further comprises solidifying the molten metal in a bar molding zone defined by the molding surfaces of the bands and the molding surfaces ie the dam blocks to form the metal bar. A metallic bar made by the method of the invention is also provided. A full understanding of the invention can be obtained from the following description of the preferred embodiment when read in conjunction with the accompanying drawings, in which: Figure 1 is a perspective view of a generally vertical bar moulder which encompasses the present invention. Figure 2 is a view taken along line 2-2 of Figure 1. Figure 3 is a view taken along line 3-3 of Figure 1. Figure 4 is a view taken at along line 4-4 of figure 3.

Figure 5 is a cross-sectional view taken at a. "or along line 5-5 of Figure 4. Figure 6 is a horizontal section through the bar molding area. Figure 7 is a partially schematic vertical section of the bar molding area showing the bands y. 'a bar that solidifies. Figure 7A is a cross-sectional view taken at a. or along the line 7A-7A of Figure 7. Figure 7B is a cross-sectional view taken along the line 7B-7B of Figure 7. Figure 7C is a sectional view. cross section taken along the length of line 7C-7C of Figure 7. Figure 7D is a cross-sectional view taken along line 7D-7D of Figure 7. Figure 8 is a cross-sectional view. front elevation of one of the bar cooling means. Figure 9 is a cross-sectional view taken along the line 9-9 of Figure 8 and also shows the band as it is positioned in relation to the cooling bar means. Figure 10 is a detailed, elevated cross-sectional view of the nozzles in the upper portion of the cooling bar means.

Figure 11 is an enlarged, detailed cross-sectional view of the nozzles in the middle portion of the fortification baTra medium. Figure 12 is an enlarged, detailed cross-sectional view of the nozzles in the lower portion of the cooling bar means. Now, with reference to Figures 1-3, a mode of the generally vertical bar moulder 10 is shown. In general, the moulder 10 consists of a pair of opposed movable bands 12 and 14 which are driven and supported by the rollers 20, 22 and 24 and 26, respectively. It is preferred that the rollers 20 and 24 are free rollers and that the rollers 22, 26 are drive rollers, although it will be appreciated that, less preferably, this arrangement may be reversed, and the rollers 22, 26 may be the rollers. of drive and rollers 20, 24 can be free rollers. The rollers are of conventional construction and preferably are approximately 51 to 127 cm (20 to 50 inches) in diameter, based on the thickness of the web. The rollers are mounted on a frame (not shown) and are adapted to move the belts at a speed of at least 12 m / min (40 feet per minute). Preferably, bands 12 and 14 are endless bands, although such bands, such as those shown in U.S. Patent No. 4,823,860, which is expressly incorporated herein by reference, may also be used. Bands 12 and 14 can be made of copper and steel and are approximately 30.5-46 cm (12 to 18 inches) wide and approximately 0.03-0.13 mm (0.010 to 0.050 inches) thick. Bands 12 and 14 provide excellent heat transfer means for cooling the molten metal. The band 12 has a molding surface 12a and a cooling surface 12b, and the band 14 has a molding surface 14a and a cooling surface 14b. It will be appreciated that the molding surfaces 12a, 14a make contact with the molten metal to be cooled and the cooling surfaces 12b, 14b are cooled by a coolant from the cooling bar means, as will be explained in more detail below. A pair of mobile opposing dam block means 30, 32 is also provided, each including a plurality of dam blocks, such as the dam block 34 on the dam block means 30 and the dam block 36 on the dam. 32 block of dam. Each of the dam blocks is mounted on respective rotating means which consist of chains 43, 44, to which the dam blocks are mounted, and the frame members 45, 46, respectively, in relation to which they move. the chains J "*, 44. The chains 43, 44 are rotated by a motor (not shown) so that the dam block means 30 and 32 are driven by themselves., 32 of the dam block are supported by support members (not shown) which extend from the frame members 45, 46 to the support members which are in contact with the floor of the construction holding the moulder 10. Dam blocks are preferably made of copper and each has a molding surface, for example the molding surface 34a in the dam block 34, and a molding surface 36a on the dam block 36. It will be appreciated that the molding surfaces 34a and 36a of the dam blocks will contact the molten metal to be cooled and: the moulder 10 as will be explained in detail in the following. Although the moved movable dam block means 30, 32 are shown, it will be appreciated that other arrangements can be used for the side dams. For example, stationary side dams which are supported by the moulder frame and placed to form the bar molding zone can be used. Another embodiment involves mounting a plurality of side dams on both edges of one of the rotating bands.

The side dams are constructed and positioned so that when they are in the molding zone, they join to form a continuous side wall to define the molten metal in the bar molding zone and when the side dams leave the molding zone of the mold. bar, the side dams, similar to a bicycle chain, are separated so that they can advance around the drive pulley. Referring now to Figures 4 and 5, it will be appreciated that the molding surface 34a of the dam block 34 includes a pair of slots 34b, 34c, which are oriented generally perpendicular to one another. The slots 34b, 34c have a depth D, which is shown in Figure 5. The objective of this arrangement is to maintain a flat block surface and at the same time facilitate thermal expansion and contraction of the dam block 34 when used in the molding operation. Care must be taken in the configuration of the slots 34b, 34c, however, in order to resist the molten metal entering the slots 34b, 34c. This is done by limiting the thickness of the grooves to prevent the penetration of metal. The bar moulder 10 additionally includes a refractory trough 60 for introducing molten metal 64, for example molten aluminum, into the moulder 10. The molten metal 64 is supplied from a passage (not shown) guided from a maintenance furnace ( shown) and can be treated or flowed before reaching the refractory trough 60. The molten metal 64 then passes through the refractory tundish and into the nozzle 66 for delivery in the molding zone of the bar (described in detail below ). A pair of cooling means of the bar 70 and 72 (the cooling means of the bar 70 are only shown in FIG. 1), are arranged behind the bands 12 and 14 respectively. The cooling means of the bar 70 and 72 are mounted on the supports (not shown) which support the rollers and the bands. The cooling means of the bar supplies refrigerant, such as water, from a source of refrigerant through a • multiple, such as the manifold 74 for the bar cooling means 70 (Figure 1), which is directed to the cooling surface 12b of the strip 12 as will be explained in detail in the following Figures 7-10. Multiple manifolds such as the manifolds 74a and 74b may be provided in the cooling means of the bar 70. As best seen in FIG. 2, a spring-loaded band seal 80 for the band 12 and a loaded band seal with spring 82 for band 14 are provided. These band seals 80 and 82 help resist the escape of molten metal from the bar molding zone and also maintain intimate band / mold contact. The band seals may be of design and operation similar to those shown in U.S. Patent No. 4,785,873, which is expressly incorporated herein by reference. As can also be better seen in FIG. 2, band support shoes 90, 91 are also provided for the band 12, and 92, 93 for the band 14. The band support shoes increase the separation of the rolls between if and therefore in turn generate a larger space between the bands. This allows adjustment of the initial pressure from the refractory trough 60 because a greater number of vertical positions for the refractory trough 60 are possible. In addition, this allows the bar cooling means 70 and 72 to be placed close to the nozzle 66 so that the cooling of the bands 12 and 14 can begin as soon as the molten metal comes into contact with the bands 12 and 14. Finally, additional space can be used to adjust the induction heaters 94 and 95 near the point at which the molten metal makes contact with the bands 12 and 14. It will be appreciated that the band shoes 91 and 93 can be eliminated and that the diameter of the rollers 22 and 26 can be increased to suit the use of shoes 90 and 92 of band. Now with reference to figure 6, a horizontal section of the bar moulder 10 is shown showing a cross section of the bar molding zone 100. The bar molding zone 100 is defined by the molded surfaces 34a, 36a of the dam chutes 34, 36 and the molding surfaces 12a, 14a of the belts 12 and 14. The belts 12 and 14 have a width that is greater than the width of >; the molding zone 100, as can be seen in figure 6, in order that the dam block means 30 and 32 form a mold for molding the metal bar. The bar molding area is generally in the form of a rectangle and typical dimensions of the cross-sectional area of the bar molding zone 100 shown in Figure 6 can be 5 x 7.6 cm (2"x 3"); 5 x 10 cm (2"x 4"), 7.6 x 10 cm (3"x 4") or 7.6 x 7.6 cm (3"x 3"). Preferably, the bar molding area has contoured corners, as shown in Figure 6, which are formed by dam blocks 34 and 36 formed in a complementary manner. Contoured corners for bar installations as molded decreases tension during rolling and prevents splinters and fractures from the bar. More generally, and as used herein, the bar molding zone 100 is defined to have a cross-sectional shape generally in the form of a rectangle consisting of a first dimension Fl and a second dimension F2 that is about 50% to 400% of the first dimension Figure 7 and Figures 7A, 7B, 7C and 7D show the solidification of molten metal 64 in the molded bar. The molten metal 64 is introduced into the bar molding zone 100 through the refractory tundish 60 and the nozzle 66. Upon entering the bar molding zone 100, the molten metal 64 melts completely but rapidly a cover 102 solidifies on the outer edges of the molten metal to begin forming the metal bar. The heat is transferred from the molten metal which solidifies through the bands 12 and 14, which are cooled by the cooling bands 70 and 72. As it occurs, the molten metal solidifies from the outside in the form of a solid cover portion 102, and a porous zone 104 and a molten central zone 106. As the bar moves through the bar molding zone 100, it continuously extracts heat from the molten metal, and the bar continues to solidify. The characteristic V shape (or sump) is formed in the bar molding zone by the boundaries between the solid deck portion 102, the porous zone 104 and the liquid center zone 106. The bar 110 becomes completely solid and then leaves the bar moulder 10 for further processing, for example forming by rolling or cutting into straight pieces. Preferably, the outlet temperature is in the range of 427-538 ° C (800 ° -1000 ° F). Molten aluminum can be molded into aluminum bars by using a molder of the invention Although any aluminum alloy can be molded, the most probable alloys for bar molders come from the following designations of the aluminum association (Aluminum Asdociation) : 2XXX, 3XXX, 4XXX, 5X2X, 6XXX and 7XXX. The bar moulder 10 is especially effective for so-called "hard alloys" (2XXX, 4XXX, 6XXX and 7XXX alloys) which simply can not be molded using the continuous bar molding apparatus and methods of the prior art due to its range of very prolonged cooling. The generally vertical bar moulder provides a metal head which facilitates excellent contact of molten metal to the band and excellent feeding of the molten metal over the entire cross section during initial solidification. This facilitates a short porous area. The generally vertical bar moulder inherently has an equal solidification on all sides. In addition, due to the design of the cooling nozzles, excellent contact of the band with the bar is maintained. All this results in an excellent molded bar product which minimizes the problems associated with other molded bar products, such as surface liquefaction and centerline segregation. In the proper formation of the bar there are several critical elements which must be controlled. First, the bands must be resistant to distortion upon first contact with the molten metal from the nozzle 66. If waves or other distortions (known in the art as "curly") occur, this may adversely affect the quality of the surface. Second, as the band solidifies, the band must maintain intimate contact with it in order to resist air spaces generated between the band and the bar. This will avoid having to remelter the partially solidified cover. This recast causes a defect called surface liquefactions. In addition, there must be efficient mass transfer from the bar that solidifies through the band. This improves the metallurgical qualities of the bar and minimizes defects such as centerline segregation.

The design of the cooling bar 70, 72 resists the distortion of the bands 12, 14 when the molten metal enters the bar molding zone 100 and also maintains intimate contact on the solidifying bar. With reference to Figures 8 and 9, the cooling bar means 70 (which is similar to the cooling bar means 72, so that only one will be explained in detail) is a hollow structure having a cooling wall 200 which is oriented to the cooling surface 12b of the band 12. A coolant is introduced (such as water) from a coolant source (not shown) to the manifold 74. The manifold 72 is shown centrally positioned in the cooling bar means 70, although it will be appreciated that it can be placed in different positions. The refrigerant is supplied at approximately 2.8-4.2 kg / cm2 (40-60 psi) and fills the hollow cavity 208 formed by the walls of the cooling bar means 70. The cooling wall 200 has a plurality of generally circular nozzles such as the nozzle 218, as best seen in Figure 8. As can be seen in Figure 9, each of the nozzles defines a conduit 223 located centrally in the same and ending in a hole 223a which produces a jet of water directed to the cooling surface 12b of the band 12. The refrigerant exits the cooling bar means when moving within the channels 230 (figures 6 and 9) defined by the nozzles and then it is extracted by gravity and also by means of a vacuum means 240 which is shown in figure 9. The vacuum means 240 consists of a housing mounted on the rear side of the bar cooling means 70. The vacuum of a vacuum supply source (not shown) draws the refrigerant away from the rod cooling means 70 through the outlet tubes 242, 244 by generating vacuum within the vacuum means 240 through the tubes 242 and 244 exit. In order to resist the band distortion near the upper portion of the bar molding zone 100, the. nozzles in the upper portion are configured as shown in figure 10. The nozzles have a concave guide surface 250 and a flat flange 252. The distance between the flat shoulder 252 and the cooling surface of the band 12b must be less than the distance between the hole 223a and the cooling surface of the band 12b. The preferred distance between the flange 252 and the cooling side of the band 12b is 1.6 mm (1/16") or less.A jet of water 254 travels through the conduit 223 and leaves the orifice 223a and swirls as it does. shown in Figure 10 to generate a liquid film 260 on which the band 12 moves. It will be appreciated that the refrigerant should also be maintained in the area above the nozzle 250 shown in Figure 10 so as to have a vacuum V generated by the nozzle 250. Due to the depth of the concave guide surface, the diameter of the hole 250, the distance between the flange of the flange 252 and the cooling surface 12b of the band and the level of water that is it maintains around the nozzles, a vacuum is generated between the band and the nozzle 250 so that it pulls the band towards the nozzles, as shown by the arrow V. The vacuum pressure keeps the band in a flat position, so that minimizes the disto band mission. The vacuum arrow V is also shown in Figure 7A. To the extent that the bar moves through the molding area, less vacuum pressure is required, and therefore the concave guide surfaces are not as deep. This can be demonstrated in Figure 11, which shows the nozzles in the middle portion of the cooling bar means. The reference numbers in Figure 11 point to similar characteristics as shown in Figure 10 with only a subscript "a". Just before the metal solidifies completely in the bar molding area, the vacuum is not required at all, and in fact, a positive pressure is needed to maintain the contact of the band in the bar that solidifies in order to maintain contact with the bar due to the fact that there is a contraction of conformal size. solidifies. Therefore, as shown in Fig. 12 (in which the similar characteristics shown in Fig. 10 are indicated by a subscript "b") which shows the nozzles in the lower portion of the bar cooling medium. , the guide surfaces are generally flat and therefore a positive pressure P is exerted from the water jet on the cooling surface of the band in order to move the band and bring it into contact with the solid bar. The diameter of the hole, although shown unchanged from the hole diameter in the upper section, can also decrease to generate higher pressure. In FIG. 7D, the pressure arrow P is also shown. It will be appreciated that by changing the depth of the guide surfaces and the diameter of the holes, the vacuum and the pressing force on the bands can be altered. Therefore, the vertical bar moulder 10 can be used successfully to mold different alloys having different solidification rates. In addition, heat transfer in the moulder can also be controlled more effectively to obtain a higher quality molded bar. The method of the invention comprises providing a vertical bar moulder as shown in Figs. 1-12 and solidifying the molten metal supplied in the bar moulder, in a bar molding zone defined by the molding surfaces of the bars. gangs and dam blocks and 'dike. The generally vertical bar moulder provides several benefits over continuous bar molding machines of the prior art. Because the molding process is vertical, an metallostatic head is used. The metal head provides excellent molten metal at the contact pressure of the band and excellent molten metal fed during initial solidification. This helps to make a porous area as short as possible (see figure 7). The bar solidifies equally on both sides and due to the cooling bar design, excellent metal contact with the strip is maintained throughout the bar molding area. This allows the elaboration of an excellent molding product in which superficial liquefactions and central line segregation are minimized. The bands provide an excellent heat transfer mechanism and do not need to be coated, preheated or lubricated. It will be appreciated that while the emphasis on the entire specification has been focused on molten molten aluminum, other molten metals such as, for example, dye, zinc, steel and lead can be molded by using the bar moulder of the invention and the method of the invention. The invention also contemplates a molded metal rod manufactured by the method of the invention and a molded aluminum rod manufactured by the method of the invention. It will be appreciated that a vertical bar moulder and associated method have been provided in which the vertical bar moulder produces a metal bar from molten metal and an associated metal bar product. Although specific embodiments of the invention have been described, it will be appreciated by those skilled in the art that various modifications and alterations to these details may be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements described are only illustrative and not limiting of the scope of the invention which should be considered in all its breadth with respect to the appended claims and to any and all equivalents thereof. It is noted that in relation to this date, the best method known by the applicant to carry out the aforementioned invention, is the conventional one for the manufacture of the objects to which it refers. Having described the invention as above, the content of the following is claimed as property:

Claims

1. A vertical bar moulder or smelter for casting molten metal into a metal bar in a mold zone, the vertical bar moulder has an upper portion and a lower portion with the molten metal that is introduced into the upper portion, and the metallic product out in the lower portion, the vertical bar moulder further includes (i) a pair of movable opposing strips, each having a molding surface and a cooling surface; (ii) a pair of mobile dam or dam opposing block means including a plurality of dam blocks having an end mounted to a rotating support and a molding surface attached to the mounting end, the molding surface of the belts and the molding surfaces of the dam blocks define a bar molding area to solidify the molten metal in the metal bar; and (iii) a plurality of nozzles placed in a cooling wall to cool the bar means to direct a jet of coolant to the cooling surface of the strip, the nozzles in the upper portion each include a concave guide surface that has a first depth so that the coolant jet generates a vacuum to draw the bands towards the nozzles so that distortion is prevented, and the nozzles at the bottom portion each include a guide surface that is (x) concave and having a second depth, the second depth is less than the first depth of the concave guide surfaces of the nozzles in the upper portion, or (y) are substantially flat so that the jet of coolant generates a pressure to push the band moving it away from the nozzles so that intimate contact surface to surface is maintained between the molding surfaces of the band and the metal to the melt that solidifies.

2. The moulder according to claim 1, characterized in that the nozzles are separated from one another so as to define channels for draining the refrigerant from the cooling wall; and the drained coolant is removed from the bar moulder by means of vacuum.

3. The moulder according to claim 2, characterized in that at least part of the nozzles have a concave guide surface which faces the cooling surface of the strip, the duct is generally positioned centrally on the guide surface , wherein the refrigerant forms a liquid film on which the web travels while the web moves through the bar molding zone.

4. The moulder according to claim 3, characterized in that the guide surface includes a flange having a generally flat surface, the flat surface generally being parallel to the cooling surface of the belt.

5. The moulder according to claim 1, characterized in that the bar molding area is generally rectangular in cross section and has a first dimension and a second dimension, the second dimension being between approximately 50% and 400% of the first dimension.

6. The moulder according to claim 5, characterized in that the bar molding area is formed by a portion of the molding surface of the band and the dam blocks; and the dimension of the molding area formed by the portion of the molding surface of the web is greater than the direction of the molding zone of the bar formed by the dam block.

7. The moulder according to claim 1, characterized in that the molding surface of the dam block has at least one slot to adapt to the thermal expansion of the dam block.

8. The moulder according to claim 1, characterized in that it includes: separate means for moving each of the bands in the bar molding area, each of the means of movement comprises: a first roller placed above the molding zone bar; a second roller placed below the bar molding area; A web support shoe for guiding and holding the web after the web travels over the first web but before the web reaches the top portion ie the bar molding area, the web support shoe defines a web. space generated above the bar molding area which is greater than the distance between the bands, so that: (i) the pressure of molten m head for the molten m, which is supplied within the zone Molding can be adjusted; (ii) an auxiliary apparatus can be adjusted in the (...), and (iii) the cooling bar means can be placed more closely adjacent to the point where the molten m enters the molding zone for the first time. from the bar

9. The moulder according to claim 8, characterized in that the bands are endless bands.

10. The moulder according to claim 9, characterized in that the auxiliary apparatus includes the induction of imitation means placed in the space to heat the bands before the bands enter the bar molding zone.

11. The moulder according to claim 10, characterized in that it includes: a refractory tundish having a feed tip for feeding molten metal into the bar molding zone, the feed tip having a portion that is placed in the molding zone bar and a sealing means, spring biased, to deflect the web and bring it into intimate surface-to-surface contact with the feed tip so that the molten metal does not leak from the bar molding zone.

12. The moulder according to claim 1, characterized in that the nozzles have a circular cross-sectional shape. IQH A generally vertical molding (10) for molding molded metal into metal bars. The moulder includes a pair of movable opposing bands (12, 14), each of the bands having a molding surface (12a, 14a) and a pair of movable opposing dam block means (30, 32) including a plurality of dam blocks having one end mounted to an orbiting or rotating support (43, 44) and a molding surface (34a, 36a) opposite the mounted end. The molding surfaces of the belts and the molding surfaces of the dam blocks define a zone (100) for molding bars to solidify the molded metal in a metal bar. The moulder also includes cooling bars (70, 72) to cool the belts while the two belts pass through the bar molding zone. It also provides an associated method and a metallic bar :: abricated by such method.