US2946100A - Block graphite mold for continuous casting - Google Patents

Block graphite mold for continuous casting Download PDF

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Publication number
US2946100A
US2946100A US606518A US60651856A US2946100A US 2946100 A US2946100 A US 2946100A US 606518 A US606518 A US 606518A US 60651856 A US60651856 A US 60651856A US 2946100 A US2946100 A US 2946100A
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Prior art keywords
mold
casting
tubes
graphite
copper
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US606518A
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English (en)
Inventor
Baier Richard
Jr John Stuart Smart
Albert J Phillips
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American Smelting and Refining Co
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American Smelting and Refining Co
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Priority to BE560271D priority Critical patent/BE560271A/xx
Priority to US606518A priority patent/US2946100A/en
Application filed by American Smelting and Refining Co filed Critical American Smelting and Refining Co
Priority to GB14763/57A priority patent/GB853853A/en
Priority to GB9925/59A priority patent/GB853854A/en
Priority to GB3872759A priority patent/GB853855A/en
Priority to DEA27170A priority patent/DE1217556B/de
Priority to US67537057 priority patent/US2938251A/en
Application granted granted Critical
Publication of US2946100A publication Critical patent/US2946100A/en
Priority to SE1245563A priority patent/SE303836B/xx
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/14—Plants for continuous casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/04—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
    • B22D11/041—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds for vertical casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/04—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
    • B22D11/059—Mould materials or platings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/12—Accessories for subsequent treating or working cast stock in situ
    • B22D11/124—Accessories for subsequent treating or working cast stock in situ for cooling
    • B22D11/1241—Accessories for subsequent treating or working cast stock in situ for cooling by transporting the cast stock through a liquid medium bath or a fluidized bed

Definitions

  • the invention relates to molds and to their use for casting metal, and more particularly to molds for the continuous casting of copper cakes.
  • the mold comprises a composite graphite block made up of two half sections of graphite block clamped together. Each section contains half of a rectangular mold pocket which has an open top to receive the molten metal and an open bottom from which the congealed casting emerges.
  • These copper tubes have compression fits with the graphite to promote excellent heat transfer, with special provision for preventing rupture of the graphite when the metal tube expands under casting conditions.
  • Disposed within the copper tubes are inner tubes which are supplied with cooling water. The upper ends of the inner tubes fall short of the closed upper ends of the outer tubes causing the water to return downwardly in the space between tubes and to discharge into the water tank under the mold which receives the congealed casting.
  • the graphite blocks are housed in a metal box or frame comprising side plates with half section water manifolds at the bottom on which the graphite blocks rest.
  • Each manifold has a gusset plate at each end providing a pair of end plates at each end of the graphite blocks.
  • Horizontal bolts pass through the side plates at their ends to clamp the graphite blocks together.
  • the supporting manifolds under the blocks have return bends for feeding the inner cooling tubes with water.
  • the manifolds also supply three series of water sprays at different levels for cooling the emerging casting.
  • the top level spray is located within the lower end of the mold pocket which is provided with a series of recesses separated by ribs which support the emerging casting.
  • the sprays are applied within the recesses between the ribs against the surface of the casting before it leaves the mold, thus cooling the surface of the casting to a temperature below the plastic range While so supported.
  • the angle of impingement of the sprays is less than 30 from the vertical to create a downward venturi effect to prevent movement of water up the mold wall to elevations higher than the spray locations.
  • the graphite walls of the mold pocket are specially contoured or tapered.
  • the tapers converge downwardly to. follow the shrinkage of the solidified casting.
  • General objects of the invention are to cast metals, particularly copper, at greatly increased rates; to cast cakes of larger cross section; to produce castings having superior surface and internal characteristics; to cast both oxygen-bearing coppers and coppers free of oxygen in commercial quantities in the same mold; to produce a mold for continuous casting having one or more of the above features of construction, and capable of accomplishing one or more of the aforesaid objects.
  • Fig. 1 is a vertical elevation of the casting system, with parts of theholding furnace and pouring ladle shown in section; v
  • Fig. 2 is a side elevation of the mold and funnel assembly, with parts shown in section;
  • Fig. 3 is a top plan view of the mold with parts shown in section;
  • Fig. 4 is a vertical transverse section, taken on the line 4-4 of Fig. 3;
  • Fig. 5 is an enlarged vertical section through the water manifold, taken on the line 5-5 of Fig. 4, showing the water manifold and various connections thereto;
  • Fig. 6 is a fragmentary plan view of the end of a manifold, with the graphite block removed;
  • Fig. 7 is a section, on the line 77 of Fig. 2, taken through the T-shaped pouring nozzle; 1
  • Fig. 8 is a fragmentary side elevation, partly in section, of the upper ends of the cooling tubes, taken on the line 8-8 of Fig. 9; V
  • Fig. 9 is a transverse section through the upper ends of the cooling tubes, taken on the line 9-9 of Fig. 8;
  • Fig. 10 is a fragmentary side elevation of the mold, showing how the upper spray tubes are clamped to the upper face of the manifold;
  • Fig. 11 is a diagram illustrating the position of the several spray nozzles with respect to the mold and to the cake being cast.
  • Fig. 12 is an isometric diagrammatic representation of the mold, illustrating the three levels of water sprays and the relationship of the tubes, graphite block and water manifold to each other and to the cake casting.
  • a melting furnace (not shown) supplies holding furnace 10 with the molten metal to be cast.
  • the furnace 10 supplies pouring ladle 11 which in turn supplies funnel-distributor 12; the latter supplies mold 13 which is mounted on mold platform 14 which in turn is mounted for vertical reciprocation on carriage 15.
  • Carriage 15 is movable horizontally on tracks 16 from over tank 20, to provide access to the product after it is cast, as hereinafter explained more in detail. It will be understod that a stationary working floor (not shown) is located on opposite sides of the tracks 16, at a level even with the tracks 16, on which workmen may walk during pouring.
  • a hydraulic starting and lowering mechanism is located within and under tank 20; this comprises a starting block 17 mounted on platform 18 which in turn is supported on piston 19 which has working relation with a hydraulic cylinder (not shown) located below water tank 20.
  • the platform 18, as shown in Fig. 1, is in approximately its uppermost position with the starting block 17 projected up inside the mold 13.
  • the starting block forms the bottom closure of the mold when initiating the pour.
  • the tank 20 may extend below the top, surface of the mold a distance corresponding to the denane 3 sired length of the cast product, which may be as much as 27 feet long; in such case the hydraulic cylinder arrangement must extend below the mold top more than twice this amount, or over 54 feet, to accommodate the piston 19 in its fully retracted position.
  • hydraulic lowering mechanism may be replaced by a conventional roll drive, cut-off mechanism and handling equipment.
  • the holding furnace shown is an upright low frequency Ajax furnace rotatable about horizontal axis 24-. It has removable covers 22 and 23 and pouring spout 25. It may receive molten metal through a launder or a bull ladle. In practice, it may be preferable to use a Scomet cylindrical off-center pouring furnace arranged to continuously receive and pour molten metal into a suitable pouring ladle. In other applications, two or more furnaces may be grouped so that, while one was pouring,
  • the others may be melting cold metal.
  • the pouring ladle 11 comprises a bowl 27, trough 28, and skim gate 29.
  • the ladle is arranged to tilt about an axis adjacent funnel 12, as indicated by the dot and dash lines.
  • the ladle is supported upon a carriage 47 having guide rolls which follow a fixed arcuate guide device 48.
  • a conventional adjustable device 49 supports a hydraulic mechanism 30 which is used to raise and lower the pouring ladle 11. Since the details of the particular holding furnace 10 and pouring ladle 11 form no part of the present invention, they will not be further described.
  • the funnel-distributor 12 comprises a bowl 31 having a refractory lining with an entrance notch 32 for receiving the trough 28 of ladle 11.
  • Funnel 12 has an inverted refractory T-shaped distributor 33 with a vertical passage 35 feeding a horizontal passage 36. See also Fig. 7.
  • Horizontal passage 36 has, at its bottom, a narrow slit 34. Instead of slit 34, a series of bottom holes may be provided.
  • Funnel 12 is supported by bridging plates 37 resting on the side walls of mold 13.
  • the manner of conveying molten copper from the holding furnace 19 to the mold 13 will be briefly outlined.
  • the pouring ladle 11 receives the metal stream from the holding furnace 10, accommodating any changes in position of the pouring furnace spout through its tilting arc.
  • the ladle bowl 27 is covered with charcoal and it delivers metal from a point near the bottom under the skim gate 29 in the usual manner.
  • the manner of handling the hot metal will depend on the nature of the metal.
  • the metal stream may fall through air in passing from holding furnace 10 to pouring ladle 11 and in passing from pouring ladle 11 to funnel 12. This is generally suitable also for highly deoxidized coppers.
  • the most important function of the funnel-distributor 12 is to distribute the molten metal in the mold 13 in such way as to avoid hot spots, cold shuts, local sweats and other minor surface faults.
  • the above action is accomplished by submerging the clay-graphite distributing tube 33 just below the surface of the molten metal in the mold, as indicated particularly in Fig. 2.
  • the multi-directional outlet flow through the ends of the horizontal passage 36 and through the bottom slit 34 provides the necessary distribution; the open ends provide stirring at the ends of the mold, while the narrow bottom slit restricts downward velocity component at the center so that all of the hot metal is not directed with high velocity at one point.
  • a compact stream with high velocity could result in a very localized central hot spot, which would increase the depth of the freezing zone of the metal in the mold.
  • clay-graphite is particularly advantageous for casting coppers.
  • the platform 18 may be lowered at a uniform speed which is variable at will. Accuracy may be maintained within a limit of one percent of constant speed by a special high precision hydraulic system (not shown).
  • the red hot cake casting, emerging from the mold is rapidly chilled by a series of pressurized water sprays described hereinafter, and the large volume of water is collected in tank 20. This water is removed at any desired level as by drain line 46.
  • the water may be circulated by a circulation and pumping system, through a cooling device, and back to the water manifolds as described hereinafter.
  • the mounting for mold 13 will now be described (Fig. 1).
  • the mold is supported on carriage 15 having four wheels 38 riding on two rails 16; thus the entire mold may be rolled out of the way to give access to the top of tank 20 in the casting pit and to the hydraulic mechanism for the removal of the cast product, after the pouring operation is completed.
  • the mold 13 is supported by a frame 14 which is vertically oscillated by a reciprocating mechanism.
  • a suitable prime mover (omitted for simplicity) is mounted on carriage 15, which reciprocates connecting rod 39.
  • Rod 39 is pivoted to a series of hell crank levers 40 on one side of the frame 14.
  • a series of bell crank levers 41 are pivoted to the carriage on the other side of frame 14.
  • Links 42 and 43 pivotally connect bell crank levers 40 and 41 to oscillatory frame 14.
  • a connecting rod 44 connects bell crank levers 40 and 41.
  • a series of guide posts 45 are supported on carriage 15, and slidably engage guides on frame 14 to insure vertical reciprocation of the mold in a substantialy vertical straight line.
  • any suitable means may be provided to vary stroke and frequency of vertical reciprocation of the mold.
  • the drive motor may have a crank arm whose length is adjustable.
  • motor speed may be changed. Neither frequency nor stroke is especially critical.
  • the stroke cannot be excessively long since, on the up-stroke, there is the possibility of jamming the taper on the hot and weak crater shell of the embryo casting that is forming at the top of the freezing zone, and which, at this point, is at a maximum cross dimension; or conversely, on the down-stroke there is a possibility of producing clearance between the embryonic crater shell and the mold wall and thereby seriously affecting the rate of heat transfer.
  • the mold 13 is supported in a metal frame comprising two manifolds 50 extending the width of the cake and forming the bottom of the mold frame.
  • the sides of the frame are formed by two verticalside plates 52 extending the width of the mold; and the ends of the frame are formed by two pairs of gusset plates 53, one pair at either end.
  • Within this frame is disposed two half sections of a massive graphite block 51, 51.
  • the frame is clamped together by a series of horizontal bolts 54 at either end of the mold. Nuts on the ends of bolts 54 clamp the graphite blocks 51, 51 tightly together.
  • the 'ends of the side plates 52 have steps 55 (Fig. 2)
  • the graphite blocks 51, 51 are supported in a boxlike metal structure which protects the relatively fragile graphite material.
  • the manifolds 56 which form the bottom of the mold frame, have end legs 59 which face each other but which do not abut (Fig. 3).
  • the graphite blocks 51, 51 have corresponding end extensions which do abut at 61.
  • the graphite blocks 51 are made from suitable commercial graphite and are machined to the shape indicated.
  • the abutting surfaces 61 of the two blocks are machined so as to form a tight seal to prevent escape of the molten metal.
  • the interior mold surfaces 96 are machined to provide generally flat planar vertical surfaces which vary from planes by the tapers and bulges hereinafter discussed. In horizontal cross section the mold surfaces are of generally oblong rectangular configuration with curved fillets 62 at the corners (Fig. 3). In practice, it has. been found necessary to bulge the horizontal configuration outwardly to compensate for the tendency for the casting to dish inwardly as the result of thermal warpage. The bulge is proportional to casting speed and cooling rate and the dimensions are chosen to result in a casting with substantially parallel sides.
  • the manifolds 50 are box-like structures built up of plates suitably fastened together. At the upper and inner corners of the manifolds are extension ledges 60 (Figs. l and 5) facing the interior of the mold. These ledges 60 project both from the main length of the manifold and from the endextensions thereof.
  • the manifolds 50 are each provided with an inlet passage 63 which intersects both the main part of the manifold and the extension thereof-see particularly Figs. 5 and 6. These inlets have flanges for connection with pipes which supply the manifolds with cold water.
  • inlet passages 63 for the two manifolds 50 are both located at the same end of the mold.
  • the manifolds 50 deliver water to the main cooling tubes 80 and to three levels of water sprays.
  • the manifolds have a series of top holes 64 in the main sections and offset ends; they have a series of bottom holes 65 for the cooling tubes in both the main sections and offset ends; their ledges have a series of drilled passages 66 for -the middle level sprays in both the main sections and offset end; the ledges contain holes 86 for the main cooling tubes in both main sections and ends.
  • the graphite blocks 51 have 'a series of horizontal passages in which are located cross tubes 68.
  • Each cross tube has a nozzle tip 67 having a downwardly directed discharge passage disposed at a 20 angle to the vertical.
  • the cross tubes 68 connect with elbows 69 which are connected to fittings 7tl-see Fig. 10.
  • Fittings 70 have annular recesses housing O-rings 71 which press against the adjacent face of the manifold 50 around the top openings 64.
  • the fittings 70 are clamped against the manifold by a series of clamping bars 72 and bolts 73. The bars straddle adjacent fittings and the bolts 73 are disposed between.
  • the openings for the end cross tubes 68 are made, half in one section and half in the other section ofthe-graphite; Also, see Fig. 3, the top openings 65 supplying these end cross tubes 68 are positioned in one manifold for the one end of the mold and in the other manifold for the other end of the mold, the cross tube 68 being appropriately bent to accommodate the elbows 69.
  • the graphite blocks 51 and side plates 52 have clearance spaces 75 for the elbows 69. It will be noted that the inner faces of the graphite blocks 51 have clearance bays 74 below the discharge of nozzles 67. These clearance bays 74 provide, in effect, vertical ribs which support the hot and pliable casting while the water sprays are directed between the ribs on the surface of the casting before it leaves the mold, thus cooling the surface below the plastic range while so supported. I
  • the bottom level of sprays and the cooling tubes are supplied from the bottom openings 65 in the manifolds.
  • a series of return bends 70 (Fig. 4) connect with the inner vertical tubes and have lower spray holes 82.
  • the return bends 7Q are connected to coupling members 78 which are clamped around the bottom openings 65 by a series of clamping bars 81 and bolts; these are similar to the clamping bars 72 and bolts 73 described above.
  • the middle level sprays are provided by nozzle holes 84 drilled into the ledges 60 and connecting with the passages 66.
  • the axes of the nozzle holes 84 have an angle with vertical of about 20.
  • the outer cooling tubes 85 (Fig; 4) are loosely disposed in the upper ends of openings 86 in the ledges 60, and have special fits with the drilled openings in the graphite blocks 51 through which they pass.
  • the inner tubes 80 are disposed inside of the outer tubes 85 and extend short of the top of the outer tubes (Fig. 8).
  • the outer tubes 85 have top caps 88 silver soldered thereto.
  • the outer cooling tube 85 has a normal size which is oversize with respect to the opening in the graphite 51 in which it fits.
  • the outer tube 85 is providedwith an inner longitudinal rib 87 which limits the force exerted by the copper tube on the graphite when the copper tube expands from heat under casting conditions.
  • the inner tube 80 has two longitudinal external ribs 91 and a longitudinal internal rib 92.
  • Internal rib 92 surrounds internal rib 87, and the external ribs91 space the inner tube from the outer tube to form the water passages illustrated particularly in the drawing.
  • the relationship between the cooling tubes and the graphite blocks is most important.
  • the outer copper tubes 85 are fitted oversize in the drilled and precisely reamed graphite holes at room temperature.
  • the tubes being of copper will expand more than the graphite mold block at casting temperatures and thus improve initial contact pressure during the service period.
  • the relative expansions of copper and graphite are so dissimilar that an ordinary unribbed hard drawn copper tube will fracture a graphite cylinder having a wall thickness of 7a to inch when they are assembled tightly and heated up to operating temperature range.
  • the longitudinal expansion rib 87 avoids placing undue stress on the graphite since the expansion of the tube is accommodated by elastic collapse of the rib under compression and thus the copper tube maintains the desired surface-to-surface fit with the graphite 51.
  • the graphite blocks have enlarged clearance recesses 89 and 90 at the tops of the tubes to relieve the graphite blocks of stress at these points.
  • the holes in the graphite at the lower ends of the tubes are made slightly larger than at the mid-lengths of the tubes to relieve the lower ends of the graphite block from stress where there is no need for tight fit between cooling tubes and graphite block because of the relatively small amount of heat extracted through the graphite block at the lower ends of the tubes.
  • the tubes assume a slightly larger diameter at their ends than at their middles, thus reducing any tendency of the tubes to creep longitudinally in their holes.
  • a series of protecting plates are provided-see particularly Fig. 3. These plates 94 are held in place by a series of bolts threaded into the graphite.
  • the graphite walls of the molding space are especially contoured or tapered.
  • the relatively easy machining and shaping of the graphite makes the graphite mold especially adaptable for dressing tapers;
  • the graphite block is made in two halves bolted together, but it can also be manufactured from a single solid block of graphite in one piece.
  • the multiple piece construction has certain advantages because it is easy to machine tapers and to provide water sprays.
  • the tapers converge downwardly to follow the shrinkage of the solidified casting and are related in degree to the casting dimensions. Since tapers are intended to improve cooling contact and must follow the shrinkage pattern of the cake rather closely, it follows that a slow casting rate which produces a well cooled cross section will permit the use of a steeper taper (i.e. at a larger angle to vertical) than a rapid casting rate where the shape is emerging from the mold at a higher temperature.
  • the usable speed range for any given taper is not so critical that a reasonable variation in speed cannot be permitted. Obviously, this range is greater at higher speeds where the cake always tends to clear the mold at a high temperature. For instance, tests show that at higher casting speeds a taper suitable for 13 inches per minute can be used up to at least 20 inches per minute; whereas, at slower casting speeds a taper suitable for 8 inches per minute, becomes unsuitable above about 10 inches per minute.
  • the tapers being used approximate a total of .045 inch across the 4 /2 inch direction, and .250 inch across the 25 inch direction.
  • Their aid to heat extraction can be followed readily by measuring the working temperatures down the mold wall with thermocouples. In straight sided molds, there is a sharp drop in wall temperature below the point where the cake shrinks away from contact. With proper tapers, the wall temperatures in these locations can be raised by as much as 300-700 F. with corresponding increase in heat removal.
  • Tapers are determined empirically from observations of their effect on the surface of the cake during the course of operation. Their effect on surface quality is important in all types of copper, since they provide a general smoothness that is not obtained in straight sided molds. With tough pitch copper, we doubt that a commercially acceptable cake surface can be made without them at desirably high casting rates, due to exudations of heavy CuCu O eutectic sweats which form if a clearance gap is permitted due to shrinkage of the casting from contact with the mold wall. Copper melts at 1083 C. and the CuCu O eutectic melts at 1065 C.
  • tapers are an effective aid to increasing heat transfer, and that their use permits the casting of a smoother surface on which oxide sweats can be suppressed to a remarkable degree.
  • the motion of reciprocation of the mold in the form illustrated, is simple harmonic. That is to say, from a position at rest at the upper end of its stroke the mold will gradually accelerate. to its maximum speed half way down its stroke, after which it will gradually decelerate to its position at rest at the bottom of its stroke; whereupon the mold will similarly accelerate and decelerate to its upper position of rest.
  • the above described condition of hot forming of the plastic shell will be accentuated when the maximum speed of downward motion of the mold is greater than the uniform downward motion of platform 18 and the cast product-provided the clearance between casting and mold wall, produced on the downward stroke, is not excessive.
  • the combination of direct molten metal contact with the bare graphite on one side, and that of the compressed cooling tubes on the other, provides not only an extremely efiicient heat transfer medium, but one that has exceptionally high capacity.
  • This construction results in increasing casting speed to at least 20 tons per hour while simultaneously maintaining a maximum graphite temperature of 800 F. at the freezing zone. At such casting rates, the mold and sprays are removing a B.t.u. equivalent of 4800 horsepower.
  • the heat being transferred through the graphite walls probably averages 750,000 B.t.u.s per square foot per hour.
  • the mold illustrated must employ about 1300 gallons per minute of water at approximately 35 p.s.i. Half of this quantity is distributed to each of the two rectangular headers at the bottom of the mold. Each header in turn supplies its line of cooling tubes and the three sets of high velocity sprays that impinge on the hot surface of the emerging casting. The incoming water to each main cooling tube is conducted to the top and returned down between the two tubes with a free discharge at the mold bottom into the tank 20.
  • the three sets of sprays illustrated are important participants in the total cooling.
  • the bottom of the liquid V zone or crater 97 is about even with the bottom of the mold. Therefore, the highest sprays, which are located above the bottom of the mold, are impinging on a red hot surface with a small liquid core. Consequently, the sprays as a whole, remove most of the sensible heat and a small portion of the latent heat under such conditions, and this total is well over 50% of the overall heat extraction.
  • the upper sprays have opportunity to apply cooling while the cake is still supported by the mold wall ribs between bays74, thereby preventing bulg ing.
  • this design greatly aids in keeping-the and particularly copper.- It is especially useful for cast-' ing oxygen-bearing copper such as tough pitch copper in any desired size; and for casting coppers free of oxygen such as oxygen-free or phosphorous deoxidized copper.
  • oxygen-bearing copper is intended to include tough pitch copper as well as copper containing a lesser amount of oxygen; it is intended to include any copper in which oxygen is in available form for attacking the graphite if the reaction temperature of the graphite is exceeded.
  • the term copper free of oxygen is intended to cover those coppers known as phosphorous deoxidized copper containing both high phosphorous and low residual phosphorous, any other deoxidized copper such as copper deoxidized by lithium, boron, calcium, etc., and also those coppers referred to as oxygen free; in other words, any copper in which there is no oxygen available for attacking the graphite at its reaction temperature.
  • a protective layer of discrete particles of carbonaceous material such as flake graphite, lamp black,-
  • Reciprocation using long strokes has the known advantage of presenting a progressively different cold mold surface to the incoming metal, thus integrating the zone of high heat removal over a longer length of mold wall than would be the case if it were stationary.
  • Reciprocation and the taper also have the advantage of improving the surface of the casting as pointed out above.
  • the present mold provides high heat transfer capacity in the initial construction, the maintenance of the Working contacts over the operating temperature range and the provision of great, dimensional stability despite repeated thermal cycling, which is needed if a long mold life is to be achieved.
  • Our mold is based Graphite has a very low coefiicient of expansionabout one-ninth that of copper. Thus, graphite has unusual resistance to thermal shock and will not crack when subjected to temperature extremes.
  • the above mold has many advantages. Due to the absence of lubricating film, and due to the efiicient heat transfer, it can cast at a higher rate than an all-metal mold.
  • the tapers can be applied more easily to the graphite wall than to an all metal mold.
  • the mold can be enlarged or made smaller within limits by machining off either the mold space surfaces or the meeting surfaces where the two halves meet.
  • the mold may be used for casting other shapes by changing the shape of the graphite wall defining the mold space, and by chan ing also the disposition of the cooling tubes.
  • the tube may be made oval or elliptical in cross section and slightly oversize. The tube is then forced into the graphite hole which makes the elliptical cross section more nearly a true circle. As the graphite and copper heat up during the casting operation, the expansion of the copper tube will change its shape causing it to move still further towards circular form and, at the same time, the area of contact between copper tube and graphite opening will increase and the constant pressure will also increase.
  • the major axis of the ellipse formed by the elliptical cross section may be perpendicular to the surface of the mold pocket so as to have the area of best thermal contact between tube and graphite adjacent the mold pocket.
  • a mold for casting metal comprising a block of frangible material having a mold pocket, the walls of said block having passages therein, oversize metal tubes having compression fits in said passages, said metal tubes having longitudinally extending compression ribs to limit the expansive force, exerted by the tubes against the frangible material due to temperature rise during the casting operation, to a point safely below the rupture strength of the mold material.
  • a mold according to claim 1 in which said tubes constitute outer tubes and in which the ribs on said outer tubes project inwardly, said mold further comprising inner tubes disposed within said outer tubes, said inner tubes having longitudinally extending, inwardly projecting ribs nesting the ribs on said outer tubes, and additional, longitudinally extending, outwardly projecting ribs bearing against said outer tubes to space the main portions of the inner and outer tubes to provide a flow space therebetween for coolant.
  • a mold for continuously casting metals comprising a graphite block having a mold pocket open at the top to receive molten metal and open at the bottom to discharge the congealed casting, the lower portion of said mold pocket having a series of recesses forming a series ofribs therebetween, said ribs being co-extensive with the walls of the mold pocket, means for supplying said recesses with a fluid to contact the congealed casting be fore it emerges from said mold pocket, thus cooling the 12 surface of the casting below its plastic range while the casting" is being supported by said ribs.
  • a mold according to claim' 3 comprising nozzles in said recesses, the angle of impingement of spray from said nozzles being less than 30 from the vertical for the purpose of creating a downward venturi effect, thus preventing movement of water up the mold wall to elevations higher than the spray locations.
  • the mold according to claim 4 comprising further means for directing sprays below the mold in order to further cool the emerging casting.
  • a mold having a mold pocket open at the top to receive molten metal and open at the bottom to discharge the congealed casting, opposed longitudinal profile areas in the mold pocket converging toward the bottom of the mold to provide tapers and thus maintain substantial cooling contact between the shrinking casting and mold pocket wall throughout the effective length of the mold pocket and means for vertically reciprocating said mold.
  • a mold for continuously casting metals having a mold pocket for receiving molten metal at one end and for discharging a congealed casting at the other end, the portion of the mold pocket adjacent the exit end having a plurality of recesses forming a plurality of projections therebetwcen, the tops of said projections describing surfaces coextensive with the walls of the mold pocket, and means for supplying said recesses with a fluid to contact the congealed casting before it emerges from the mold pocket, thus cooling the surface of the casting below its plastic range while the casting is being supported by said projections.
  • a mold for continuously casting metals comprising a graphite block having a mold pocket open at the top to receive molten metal and open at the bottom to dis-- charge the congealed casting, said bloc having walls with internal passages therein, ,mctal tubes in said passages, said tubes exerting elastic, expansive pressure against the walls of said passages to promote heat transfer therebetween, said tubes having longitudinally extending compression ribs to limit the expansive force exerted by the tubes against the graphite due to temperature rise during the casting operation to a point safely below the rupture strength of the mold material, and means for supplying coolant to said tubes.
  • a mold for continuously casting metals comprising a graphite block having a mold pocket open at the top to receive molten metal and open at the bottom to discharge the congealed casting, said block having walls with internal passages therein, metal tubes in said passages, said tubes exerting elastic, expansive pressure against the walls of said passages to promote heat transfer therebetween, second metal tubes disposed within said first-mentioned tubes and spaced therefrom to provide a flow space for the coolant, means for preferentially directing coolant to that part of the flow space between said first and second mentioned tubes which faces the mold pocket.
  • a mold for continuously casting metals comprising a graphite block having a mold pocket open at the top to receive molten metal and open at the bottom to discharge the congealed casting, said block having walls with internal passages therein, metal tubes in said passages, said tubes exerting elastic, expansive pressure against the walls of said passages to promote heat transfer therebetween, said internal passages being relieved at each end of the tubes, causing the tubes to assume a slightly larger diam eter at their ends than at the mid-parts thereof.
  • a mold for continuously casting metals having a mold pocket open at the top for receiving molten metal and open at the bottom for discharging a congealed casting, the portion of the mold pocket adjacent the lower end having a plurality of recesses forming a plurality of projections therebetween, the tops of said projections describing surfaces coextensive with the walls of the mold pocket, nozzles for supplying said recesses with water to contact the congealed casting before it emerges from the mold pocket, thus cooling the surface of the casting below its plastic range while the casting is being supported by said projections, said nozzles being directed downwardly and at such angle that their streams impinge against the surface of the casting at an angle of less than 30 degrees with respect to vertical, thus preventing upward movement of water products.
  • a continuous casting mold for continuously casting metal comprising a graphite block having a mold pocket open at the top to receive molten metal and open at the bottom to discharge the congealed casting, said block having walls with internal straight machined passages therein, the surfaces of said passages being smooth, straight metal tubes lining said passages, the wall of said tubes being elastic and having sufficient temper to exert pressure against said smooth surfaces to promote heat transfer therebetween, said tubes expanding more than the graphite with temperature rise, thus maintaining heat transfer contact between said tubes and block, means for permitting the walls of said tubes to move relative to said smooth surfaces to relieve pressure on the graphite block exerted by the tubes due to thermal expansion of the tubes, and means for supplying coolant to said tubes.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)
  • Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)
  • Cooling Or The Like Of Semiconductors Or Solid State Devices (AREA)
US606518A 1956-08-27 1956-08-27 Block graphite mold for continuous casting Expired - Lifetime US2946100A (en)

Priority Applications (8)

Application Number Priority Date Filing Date Title
BE560271D BE560271A (da) 1956-08-27
US606518A US2946100A (en) 1956-08-27 1956-08-27 Block graphite mold for continuous casting
GB9925/59A GB853854A (en) 1956-08-27 1957-05-09 Continuous casting apparatus and method
GB3872759A GB853855A (en) 1956-08-27 1957-05-09 Mold for continuously casting metals
GB14763/57A GB853853A (en) 1956-08-27 1957-05-09 Continuous casting
DEA27170A DE1217556B (de) 1956-08-27 1957-05-17 Durchlaufkokille zum Stranggiessen von Metallen
US67537057 US2938251A (en) 1956-08-27 1957-07-31 Metal distribution for continuous casting
SE1245563A SE303836B (da) 1956-08-27 1963-11-12

Applications Claiming Priority (1)

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US606518A US2946100A (en) 1956-08-27 1956-08-27 Block graphite mold for continuous casting

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Publication Number Publication Date
US2946100A true US2946100A (en) 1960-07-26

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US606518A Expired - Lifetime US2946100A (en) 1956-08-27 1956-08-27 Block graphite mold for continuous casting

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US (1) US2946100A (da)
BE (1) BE560271A (da)
DE (1) DE1217556B (da)
GB (3) GB853855A (da)
SE (1) SE303836B (da)

Cited By (20)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3066364A (en) * 1958-03-26 1962-12-04 American Smelting Refining Pouring technique for continuous casting
US3089209A (en) * 1960-01-06 1963-05-14 American Smelting Refining Method for continuous casting of metal
US3098269A (en) * 1960-05-09 1963-07-23 American Smelting Refining Mold for continuous casting
US3115586A (en) * 1961-10-26 1963-12-24 Rca Corp Holding circuit allowing pulse to be gated for predetermined time set by charging circuit
US3115686A (en) * 1959-10-21 1963-12-31 American Smelting Refining Pouring mechanism for continuous casting
US3124855A (en) * 1964-03-17 Baier
US3157921A (en) * 1963-05-23 1964-11-24 American Smelting Refining Cooling molds for casting metal
US3166803A (en) * 1962-08-10 1965-01-26 Olsson Erik Allan Device for centering the stream of metal to the middle of the mould during vertical continuous casting
US3167829A (en) * 1962-02-20 1965-02-02 Concast Ag Apparatus for continuous casting of metal
US3209407A (en) * 1962-01-22 1965-10-05 Reis Walter Device for facilitating the working on surfaces of molds or the like
US3329197A (en) * 1965-04-26 1967-07-04 Southwire Co Method of cooling molten copper with a coolant flow velocity to exceed steam generation
US3343592A (en) * 1965-09-22 1967-09-26 Concast Inc Reciprocating continuous casting curved mold mounting system
US3395751A (en) * 1964-12-03 1968-08-06 Schloemann Ag Means for moving the chill-mould in continuous casting plant
US3447592A (en) * 1965-05-03 1969-06-03 Alfred J Wertli Cooling apparatus for differentially cooling a continuous casting
US3463220A (en) * 1965-07-24 1969-08-26 Vaw Ver Aluminium Werke Ag Method for continuous casting of thin bands,plates
US3506063A (en) * 1967-05-18 1970-04-14 Ashmore Benson Pease & Co Ltd Continuous casting
US3515202A (en) * 1966-08-20 1970-06-02 Paderwerk Gebr Benteler Schlos Method for continuous casting of metal ingots
US3780789A (en) * 1969-10-08 1973-12-25 Alusuisse Apparatus for the vertical multiple continuous casting of aluminum and aluminum alloys
US4235279A (en) * 1977-06-28 1980-11-25 Fried. Krupp Gesellschaft Mit Beschrankter Haftung Apparatus for cooling a continuous casting mold
US5219029A (en) * 1992-03-09 1993-06-15 Gunther Behrends Oscillator for continuous casting mold

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1583592A (en) * 1977-05-19 1981-01-28 Imi Refiners Ltd Continuous casting mould
DE2847581A1 (de) * 1978-11-02 1980-05-14 Krupp Gmbh Durchlaufkokille

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US1346333A (en) * 1919-08-18 1920-07-13 Petinot Napoleon Process for producing articles of iron silicid
US1393195A (en) * 1920-03-20 1921-10-11 Bradley Ross Edward Billet-casting
US2131307A (en) * 1935-10-25 1938-09-27 Behrendt Gerhard Chill for continuous string casting
US2154234A (en) * 1936-07-28 1939-04-11 American Metal Co Ltd Adjustable mold
US2264288A (en) * 1939-04-13 1941-12-02 American Smelting Refining Apparatus for continuously casting metals
US2410837A (en) * 1944-04-17 1946-11-12 Dow Chemical Co Cast ingot
GB588618A (en) * 1944-10-05 1947-05-29 Harold Andrews Method of and means for continuous casting of solid or hollow sections in ferrous metals
US2613411A (en) * 1947-09-30 1952-10-14 Continuous Metalcast Corp Cooling system for continuous casting molds
GB718644A (en) * 1952-05-14 1954-11-17 Ici Ltd Improvements in or relating to the continuous casting of metals
US2698467A (en) * 1950-06-05 1955-01-04 Edward W Osann Jr Method and apparatus for the continuous casting of metal
CA518702A (en) * 1955-11-22 The American Metal Company Mold and method for continuous casting
US2744303A (en) * 1954-07-29 1956-05-08 Kaiser Aluminium Chem Corp Trough for transferring molten metal
US2747244A (en) * 1953-07-15 1956-05-29 Norman P Goss Porous mold for the continuous casting of metals
US2767448A (en) * 1952-06-27 1956-10-23 Babcock & Wilcox Co Continuous casting mold
US2772455A (en) * 1955-10-28 1956-12-04 Allegheny Ludlum Steel Metal pouring apparatus for continuous casting
US2835940A (en) * 1956-07-18 1958-05-27 Wieland Werke Ag Mold and method for continuously casting cakes
US2904860A (en) * 1955-12-27 1959-09-22 Hazelett Strip Casting Corp Metal casting method and apparatus

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DE209617C (da) *
US2136394A (en) * 1935-06-29 1938-11-15 Frank F Poland Casting metal
US2135465A (en) * 1935-10-26 1938-11-01 Byron E Eldred Continuous casting of metal shapes
DE846900C (de) * 1941-11-11 1952-08-18 Wieland Werke Ag Giessform fuer das stetige Giessen von Metallen

Patent Citations (17)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA518702A (en) * 1955-11-22 The American Metal Company Mold and method for continuous casting
US1346333A (en) * 1919-08-18 1920-07-13 Petinot Napoleon Process for producing articles of iron silicid
US1393195A (en) * 1920-03-20 1921-10-11 Bradley Ross Edward Billet-casting
US2131307A (en) * 1935-10-25 1938-09-27 Behrendt Gerhard Chill for continuous string casting
US2154234A (en) * 1936-07-28 1939-04-11 American Metal Co Ltd Adjustable mold
US2264288A (en) * 1939-04-13 1941-12-02 American Smelting Refining Apparatus for continuously casting metals
US2410837A (en) * 1944-04-17 1946-11-12 Dow Chemical Co Cast ingot
GB588618A (en) * 1944-10-05 1947-05-29 Harold Andrews Method of and means for continuous casting of solid or hollow sections in ferrous metals
US2613411A (en) * 1947-09-30 1952-10-14 Continuous Metalcast Corp Cooling system for continuous casting molds
US2698467A (en) * 1950-06-05 1955-01-04 Edward W Osann Jr Method and apparatus for the continuous casting of metal
GB718644A (en) * 1952-05-14 1954-11-17 Ici Ltd Improvements in or relating to the continuous casting of metals
US2767448A (en) * 1952-06-27 1956-10-23 Babcock & Wilcox Co Continuous casting mold
US2747244A (en) * 1953-07-15 1956-05-29 Norman P Goss Porous mold for the continuous casting of metals
US2744303A (en) * 1954-07-29 1956-05-08 Kaiser Aluminium Chem Corp Trough for transferring molten metal
US2772455A (en) * 1955-10-28 1956-12-04 Allegheny Ludlum Steel Metal pouring apparatus for continuous casting
US2904860A (en) * 1955-12-27 1959-09-22 Hazelett Strip Casting Corp Metal casting method and apparatus
US2835940A (en) * 1956-07-18 1958-05-27 Wieland Werke Ag Mold and method for continuously casting cakes

Cited By (20)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3124855A (en) * 1964-03-17 Baier
US3066364A (en) * 1958-03-26 1962-12-04 American Smelting Refining Pouring technique for continuous casting
US3115686A (en) * 1959-10-21 1963-12-31 American Smelting Refining Pouring mechanism for continuous casting
US3089209A (en) * 1960-01-06 1963-05-14 American Smelting Refining Method for continuous casting of metal
US3098269A (en) * 1960-05-09 1963-07-23 American Smelting Refining Mold for continuous casting
US3115586A (en) * 1961-10-26 1963-12-24 Rca Corp Holding circuit allowing pulse to be gated for predetermined time set by charging circuit
US3209407A (en) * 1962-01-22 1965-10-05 Reis Walter Device for facilitating the working on surfaces of molds or the like
US3167829A (en) * 1962-02-20 1965-02-02 Concast Ag Apparatus for continuous casting of metal
US3166803A (en) * 1962-08-10 1965-01-26 Olsson Erik Allan Device for centering the stream of metal to the middle of the mould during vertical continuous casting
US3157921A (en) * 1963-05-23 1964-11-24 American Smelting Refining Cooling molds for casting metal
US3395751A (en) * 1964-12-03 1968-08-06 Schloemann Ag Means for moving the chill-mould in continuous casting plant
US3329197A (en) * 1965-04-26 1967-07-04 Southwire Co Method of cooling molten copper with a coolant flow velocity to exceed steam generation
US3447592A (en) * 1965-05-03 1969-06-03 Alfred J Wertli Cooling apparatus for differentially cooling a continuous casting
US3463220A (en) * 1965-07-24 1969-08-26 Vaw Ver Aluminium Werke Ag Method for continuous casting of thin bands,plates
US3343592A (en) * 1965-09-22 1967-09-26 Concast Inc Reciprocating continuous casting curved mold mounting system
US3515202A (en) * 1966-08-20 1970-06-02 Paderwerk Gebr Benteler Schlos Method for continuous casting of metal ingots
US3506063A (en) * 1967-05-18 1970-04-14 Ashmore Benson Pease & Co Ltd Continuous casting
US3780789A (en) * 1969-10-08 1973-12-25 Alusuisse Apparatus for the vertical multiple continuous casting of aluminum and aluminum alloys
US4235279A (en) * 1977-06-28 1980-11-25 Fried. Krupp Gesellschaft Mit Beschrankter Haftung Apparatus for cooling a continuous casting mold
US5219029A (en) * 1992-03-09 1993-06-15 Gunther Behrends Oscillator for continuous casting mold

Also Published As

Publication number Publication date
GB853854A (en) 1960-11-09
BE560271A (da)
DE1217556B (de) 1966-05-26
GB853855A (en) 1960-11-09
GB853853A (en) 1960-11-09
SE303836B (da) 1968-09-09

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