US3123877A - Apparatus for and method of casting metal members - Google Patents

Apparatus for and method of casting metal members Download PDF

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US3123877A
US3123877A US3123877DA US3123877A US 3123877 A US3123877 A US 3123877A US 3123877D A US3123877D A US 3123877DA US 3123877 A US3123877 A US 3123877A
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cavity
metal
mold
passageway
molten metal
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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
    • B22D18/00—Pressure casting; Vacuum casting
    • B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D7/00—Casting ingots, e.g. from ferrous metals

Definitions

  • This invention relates to a method of casting metal slabs, blooms and billets, and has for its principal object the provision of a new and improved method of this kind.
  • a metal member such as a slab, a bloom or a billet
  • Another object of the invention is to provide a method of casting rollable metal members, which method results in the production of a minimum of scrap and hence results in a high percentage of recovery from a supply of molten metal.
  • Another object of the invention is to provide a method of casting metal members that are capable of being rolled into various products, which method involves causing the member to cool rapidly initially so as to freeze inwardly from its sides and ends and thereby produce in the surface areas of the metal a crystalline structure capable of being rolled upon being heated to a proper temperature and without other further treatment.
  • Another object of the invention is to provide a method of casting metal members which are capable of being rolled into various shapes, which method includes hermetic sealing of the center or core of the member while the metal therein is still molten, thereby to prevent oxidation of the surfaces defining fissures or voids formed by shrinkage of the core metal upon cooling.
  • Another object of the invention is to provide a method of eliminating sprues and risers such as have been employed heretofore in the casting of metals.
  • FIG. 1 is a diagrammatic elevational View of a pouring ladle, spout and pressure bell;
  • FIG. 2. is a plan View of FIG. 1, with a part of the pressure bell broken away;
  • FIG. 3 is a fragmentary elevation-a1 view partly in cross section, showing the pouring spout with molds registered therewith in pouring position;
  • FIG. 4 is a cross sectional view through a filled mold.
  • the ingots are then rolled into slabs which are of rectangular cross section, having a Width many times their thickness.
  • Surface imperfections in the slabs produced by rolling must be removed as by scarfing 3,l23,877, Patented Mar. 10, 1396 or grinding, and the slabs re heated to prepare them for rolling into plate stock.
  • Blooms which are rectangular or substantially rectangulai' members, are rolled from ingots after the surface imperfections thereon have been removed and the ingot heated to proper rolling temperature. Surface imperfections in the blooms produced by rolling must also be removed and the bloom rte-heated preparatory to rolling it into the desired shapes.
  • Billets which are of smaller cross sectional area than blooms, have heretofore been produced by rolling blooms to the desired dimensions of the billet after the bloom has been prepared for rolling as above.
  • the present invention seeks to eliminate this plurality of preliminary' steps.
  • molten metal :from the steel producing furnace is placed in a ladle that is equipped with a pouring spout that communicates with the bottom of the ladle and extends upwardly exteriorly thereof, terminating above the maximum height to which metal is placed in the ladle.
  • the ladle and spout are preferably pre-heated, prior to receiving the metal, to minimize the cooling of the metal therein.
  • a pressure bell fits over the ladle and is secured thereto in. such manner as to form a hermetic seal between the bell and the ladle.
  • the external pouring spout terminates in nozzles with which the gates of the molds are registered to connect the cavity therein to the spout.
  • the cavity in the mold may be positioned vertically; however, when long members such as billets are being cast, the cavity should be inclined slightly from horizontal so as to reduce the static head of the metal in the cavity.
  • Pressure is then built up in the pressure bell acting on the surface of the molten metal therein to force that metal upwardly through the pouring spout and nozzle into the mold cavity.
  • the rate of flow of the metal is maintained sufilciently rapid to prevent undue cooling of the metal, but at a rate insufficient to cause turbulence in the cavity.
  • the mold cavities are open at both ends and the lower end of the cavity registered with the nozzle of the pouring spout.
  • a ram or piston which forces air out of the cavity through the open upper end thereof. Since there is no turbulence of the metal, air is not entrapped in it and the formation of blow holes is prevented.
  • this open upper end is closed to arrest the flow of metal in the cavity and thereafter a gate valve, incorporated in the gate structure of the mold, is close-d to confine the metal in the mold.
  • Pressure built up in the pressure bell is then partially relieved and the molten metal in the spout and nozzle falls away from the closed gate valve, permitting the filled mold to be disengaged from the nozzle and an empty mold registered therewith in readiness for filling.
  • the molds of the present invention are composed of a material such as graphite that has high thermal con ductivity and high thermal shock resistance, and is unaffected by exposure to high temperature, and the mold structure includes a sufficient quantity of graphite to result in rapid dissipation of heat from the sides of the cavity, causing the metal therein to freeze rapidly.
  • the plug by which the upper end of the cavity was closed, and the gate valve, are likewise preferably composed of material having high heat conductivity, such as brass,
  • the mold may be opened and the member removed therefrom and cooled more slowly than the initial cooling.
  • the surfaces of the member upon cooling contain a relatively fine crystalline structure suitable for rolling and the surfaces are free from imperfections.
  • Bringing the molten metal into contact with the graphite or other material of high thermal conductivity, thereby causing a rapid rate of initial cooling has the desirable result of creating an outer cast surface comprised of as-cast "rains or dendrites of minimal size. Additionally, such grains or dendrites have undergone only a slight degree of chemical segregation which is a definite advantage in subsequent rolling or extruding operations.
  • Voids, internal fissures, and the like, formed in the center region of the member as the molten metal thereat freezes, are effectively sealed off from external air, and as a consequence are not oxidized and thus capable of being welded together in the subsequent rolling operation which takes place at an elevated temperature which is above the welding temperature.
  • billets formed in accordance with the teachings of the present invention upon being cropped to remove small sections from the ends thereof and then heated to proper rolling temperature, can be rolled or extruded into bars, rods, or wires, without additional preparation.
  • the present invention Since the number of preliminary operations eliminated in the formation of billets, in accordance with the teachings of the present invention, is greater than the number of such operations eliminated in the formation of slabs and blooms, the present invention, therefore, has maximum utility in connection with billet formation.
  • the ladle used in connection with the practice of the present invention will have capacity sufiicient to receive the entire quantity of steel produced in a heat of the steel making furnace and will be preferably preheated before receiving the molten metal. It is further intended that the casting of members such as billets be carried out with sufficient rapidity to permit so casting the entire quantity of the metal in the heat before the temperature thereof falls too low for eflicient casting. Since the mold cavities are closed off immediately adjacent their ends, and since no risers or sprues are employed, the percentage of conversion of the steel in the heat into cast members such as billets is higher than has been possible heretofore.
  • FIGS. 1 and 2 wherein there is diagrammatically illustrated a ladle 1, from the bottom of which a pouring spout 2 is extended.
  • This ladle which may be of the type shown in my copending application Serial No. 708,558, filed January 13, 1958, preferably consists of a metal shell 3 containing a refractory lining 4 capable of withstanding the heat of the molten metal.
  • the spout 2 like-wise consists of a metal casing and refractory lining.
  • the present invention may also be practiced in conjunction with a ladle equipped with an immersed pouring spout, such a ladle being shown in my prior Patent 2,847,739, issued August 19, 1958.
  • a pressure bell 5 Fitted over and secured to the ladle is a pressure bell 5 which is hermetically sealed onto the ladle, as indicated by the gaskets 6. Fluid pressure is admitted to the pressure bell through a suitable fitting 7 from a source not shown.
  • the pouring spout 2 terminates in generally frusto-conical nozzles 8 into which the refractory lining of the spout is extended.
  • the nozzles 8 are located above the maximum height to which molten metal may be placed in the ladle 1.
  • molds indicated generally at 10, each of which consists of a gate portion 11 having a socket which registers in seal forming engagement with a nozzle 8.
  • the molds are supported upon suitable supports 12 which are shown inclined at an angle of approximately 10 with respect to the horizontal, which is preferable when the cavities are of considerable length, as shown.
  • the mold proper consists of the usual cope and drag formed of a material of high thermal conductivity such as graphite, as indicated at 13. Within the mold is a cavity 14 to be filled with a molten metal.
  • the parting line 15 between the cope and drag sections of the mold is positioned so that the axis of the nozzle 8 coincides with the plane of the parting line 15.
  • the cavity 14 will be of shape and size depending upon the member to be cast, If the product to be cast is a billet, the mold may contain more than one cavity 14 within the teachings of the invention.
  • the gate structure 11 contains a gate valve 16 having a refractory lined opening 17 registered with the cavity 14 and the opening in the nozzle 8 when the mold is in pouring position.
  • the gate valve 16 is composed of a metal having high thermal conductivity, brass or copper having been found to be satisfactory for this purpose.
  • the upper end of the cavity 14 is open during the pouring operation and the mold is equipped with a plug valve 13 by which this end of the cavity is closed, as will presently appear.
  • two molds are registered with the two nozzles of the pouring spout, so as to be filled simultaneously.
  • the number of molds will, of course, be determined by the volume of the member to be cast, and the dual arrangement shown is by way of example only.
  • gate valve 16 is closed by suitable power means, indicated generally at 21, to confine the metal in the mold.
  • Plug 18 is but one of a number of devices that may be used to close the upper end of the mold when the cavity is filled.
  • the plug may be operated manually or by manually controlled power. Preferably, however, closing of this end of the cavity is automatic and controlled by the molten metal in the cavity.
  • FIG. 3 the plug 18 is shown supported upon a rod that is journaled for axial movement in a bracket 26 carried by the mold structure.
  • a coil spring 27 encircles the rod and urges the plug 18 into closed position.
  • a wire 28 is interposed between the plug 18 and its seat, to hold the plug away from the seat against the force of the spring.
  • the wire 28 is composed of a low melt-point metal such as aluminum, and the molten metal on coming into engagement with the wire melts it, thereby permitting the spring to seat the plug. This arrangement is shown by way of example.
  • FIG. 4 there is shown a filled mold cavity after removal from the pouring spout.
  • the volumes of graphite 13 in the cope and drag sections of the mold are large in comparison with the volume of the metal 20 filling the mold cavity.
  • Graphite having high thermal conductivity rapidly withdraws heat from the surfaces of the metal, causing that metal to freeze around the edges of the member 20.
  • Plug valve 18 and gate valve 16 both being composed of material of high thermal conductivity, rapidly withdraw heat from the ends of the metal member 24 causing freezing of the metal at the ends as well as the sides of the member.
  • the molten metal at the center of the member upon shrinking as it cools, forms in the center of the member voids or internal fissures. Since the core section is hermetically sealed by the solid metal shell, while that core section is still in molten state the surfaces of the metal defining the voids and fissures will not be oxidized, and hence When the metal is subsequently heated to welding temperature preparatory to rolling, these voids and fissures will be closed and welded together during the rolling process.
  • rolling temperatures may vary to some extent being dependent on, for example, the size of the casting to be rolled and the speed at which rolling operations are carried out, it has been found that castings produced in accordance with the teachings of this invention can be Welded at normal rolling temperatures which at the start of rolling would be in the range of 1800 F. to 2300 F. Of course, if welding of the internal voids is to be accomplished by extrusion, the casting would be heated to the same temperature range.
  • An apparatus for casting steel into directly rollable slabs, blooms, billets and the like comprising a pressure container for holding molten metal, a pouring tube having one end extending upwardly from said container and the other end in communication with said molten metal, a graphite mold having a cavity formed therein secured to said upper end of said pouring tube in a manner causing said cavity to be slightly inclined from the horizontal, a first passageway formed in said mold for at times communicating between the upper end of said pouring tube and the lower portion of said cavity, a second passageway formed in said mold for at times communicating between the upper end of said cavity and the ambient atmosphere, a chill member for closing said first passageway when said cavity is filled, and means for at times completely closing said second passageway, said means comprising a support member secured to said mold, a second chill member axially aligned with said second passageway and slideably received by said support member, resilient means urging said second chill member toward said second passageway, and temperature responsive abut ment means interposed between said second passageway and said
  • a method of pouring meal castings and eliminating surface imperfections therein comprising the steps of first positioning a mold having an internal casting cavity and a bottom pouring opening so that all surfaces defining the cavity extend upwardly from that opening to a top opening communicating with atmosphere, then forcing molten metal from a container through said bottom opening until said cavity is completely filled, then closing said top opening with a chill member which with adjoining surfaces of the cavity forms a regular and unbroken surface portion of the casting, then closing said bottom end of the casting with a chill member traversing said bottom opening without changing the volume of the cavity and which with the adjoining surfaces of the cavity forms a regular and unbroken surface portion of the casting, the entire outer surface of the molten metal thereby being sealed within the cavity from atmosphere, and then allowing the molten metal to solidify within said cavity to the degree permitting removal from the mold.
  • a method of producing rolled metal products from molten metal in a container comprising the steps of first positioning a mold having an internal casting cavity and a bottom pouring opening so that all surfaces defining the cavity extend upwardly from that opening to a top opening communicating with atmosphere, then forcing under superatmospheric pressure the molten metal at a non-turbulent rate of flow from the container through said bottom opening until said cavity is completely filled, then closing said top opening with a chill member which with adjoining surfaces of the cavity forms a regular and unbroken surface portion of the casting, then closing said bottom end of the casting with a chill member traversing said bottom opening without changing the volume of the cavity and which with the adjoining surfaces of the cavity forms a regular and unbroken surface portion of the casting, the entire outer surface of the molten metal thereby being sealed within the cavity from atmosphere, immediately chilling the entire outer surface of the molten metal in the mold in order to solidify that outer surface and maintain it against the surface of the cavity, allowing the remainder of the molten metal to solidify to the degree

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
US3123877D 1962-04-06 Apparatus for and method of casting metal members Expired - Lifetime US3123877A (en)

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Application Number Priority Date Filing Date Title
CH425462A CH404090A (de) 1962-04-06 1962-04-06 Vorrichtung zur Herstellung eines Metallgegenstandes durch Abgiessen

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CH (1) CH404090A (de)
DE (1) DE1252375B (de)
FR (1) FR1317810A (de)
GB (1) GB972510A (de)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3191247A (en) * 1959-09-08 1965-06-29 Lindberg Engineering Co Furnace ladling apparatus
US3299480A (en) * 1963-09-13 1967-01-24 Amsted Ind Inc Bottom feed pouring head
EP0234877A1 (de) * 1986-02-21 1987-09-02 Cosworth Research And Development Limited Verfahren und Vorrichtung zum Giessen
US5065810A (en) * 1987-01-12 1991-11-19 Honda Giken Kogyo K.K. Method of producing mechanical parts by mold casting
US6540007B2 (en) 1998-03-10 2003-04-01 Montupet S.A. Molding process for the mass production of aluminum alloy castings and associated items of equipment

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3599708A (en) * 1967-08-04 1971-08-17 Sumitomo Metal Ind Bottom pouring apparatus for steel ingots
US4100960A (en) * 1977-01-28 1978-07-18 Technicon Instruments Corporation Method and apparatus for casting metals

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US131332A (en) * 1872-09-17 Improvement in ingot-molds
US1634482A (en) * 1919-02-26 1927-07-05 Clarence D Lukens Casting method and apparatus
US1912981A (en) * 1931-04-10 1933-06-06 Dow Chemical Co Method of pressure casting and means therefor
US2310703A (en) * 1941-01-08 1943-02-09 American Steel & Wire Co Method of treating steel
US2401491A (en) * 1945-01-05 1946-06-04 Ellis C Lyons Casting molten metal
US2632216A (en) * 1949-08-04 1953-03-24 Harry W Mcquaid Apparatus for making slab or billettype ingots
US2838816A (en) * 1955-09-14 1958-06-17 Griffin Wheel Co Permanent mold with sand dome
US2943369A (en) * 1959-06-01 1960-07-05 United States Pipe Foundry Apparatus for centrifugal casting of pipe

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US131332A (en) * 1872-09-17 Improvement in ingot-molds
US1634482A (en) * 1919-02-26 1927-07-05 Clarence D Lukens Casting method and apparatus
US1912981A (en) * 1931-04-10 1933-06-06 Dow Chemical Co Method of pressure casting and means therefor
US2310703A (en) * 1941-01-08 1943-02-09 American Steel & Wire Co Method of treating steel
US2401491A (en) * 1945-01-05 1946-06-04 Ellis C Lyons Casting molten metal
US2632216A (en) * 1949-08-04 1953-03-24 Harry W Mcquaid Apparatus for making slab or billettype ingots
US2838816A (en) * 1955-09-14 1958-06-17 Griffin Wheel Co Permanent mold with sand dome
US2943369A (en) * 1959-06-01 1960-07-05 United States Pipe Foundry Apparatus for centrifugal casting of pipe

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3191247A (en) * 1959-09-08 1965-06-29 Lindberg Engineering Co Furnace ladling apparatus
US3299480A (en) * 1963-09-13 1967-01-24 Amsted Ind Inc Bottom feed pouring head
EP0234877A1 (de) * 1986-02-21 1987-09-02 Cosworth Research And Development Limited Verfahren und Vorrichtung zum Giessen
US5065810A (en) * 1987-01-12 1991-11-19 Honda Giken Kogyo K.K. Method of producing mechanical parts by mold casting
US6540007B2 (en) 1998-03-10 2003-04-01 Montupet S.A. Molding process for the mass production of aluminum alloy castings and associated items of equipment

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Publication number Publication date
FR1317810A (de) 1963-05-08
GB972510A (en) 1964-10-14
CH404090A (de) 1965-12-15
DE1252375B (de) 1967-10-19

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