US3224887A - Slag composition for fluid mold casting - Google Patents
Slag composition for fluid mold casting Download PDFInfo
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- US3224887A US3224887A US350603A US35060364A US3224887A US 3224887 A US3224887 A US 3224887A US 350603 A US350603 A US 350603A US 35060364 A US35060364 A US 35060364A US 3224887 A US3224887 A US 3224887A
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- United States
- Prior art keywords
- casting
- slag
- mold
- ingot
- nickel
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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- 239000002893 slag Substances 0.000 title claims description 81
- 238000005266 casting Methods 0.000 title claims description 72
- 239000000203 mixture Substances 0.000 title description 27
- 239000012530 fluid Substances 0.000 title description 8
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 62
- 229910052751 metal Inorganic materials 0.000 claims description 37
- 239000002184 metal Substances 0.000 claims description 37
- 229910052759 nickel Inorganic materials 0.000 claims description 31
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 27
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 20
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 18
- 235000008733 Citrus aurantifolia Nutrition 0.000 claims description 13
- 235000011941 Tilia x europaea Nutrition 0.000 claims description 13
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 13
- 239000004571 lime Substances 0.000 claims description 13
- 229910052719 titanium Inorganic materials 0.000 claims description 13
- 239000010936 titanium Substances 0.000 claims description 13
- 229910052782 aluminium Inorganic materials 0.000 claims description 12
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 12
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 12
- 229910001610 cryolite Inorganic materials 0.000 claims description 12
- 229910052710 silicon Inorganic materials 0.000 claims description 10
- 239000010703 silicon Substances 0.000 claims description 10
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 9
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 9
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 9
- 229910052799 carbon Inorganic materials 0.000 claims description 9
- 229910052804 chromium Inorganic materials 0.000 claims description 9
- 239000011651 chromium Substances 0.000 claims description 9
- 229910052742 iron Inorganic materials 0.000 claims description 9
- 229910052749 magnesium Inorganic materials 0.000 claims description 9
- 239000011777 magnesium Substances 0.000 claims description 9
- 239000010955 niobium Substances 0.000 claims description 9
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 claims description 9
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 8
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims description 8
- 239000010941 cobalt Substances 0.000 claims description 8
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 8
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 claims description 8
- 229910052750 molybdenum Inorganic materials 0.000 claims description 8
- 239000011733 molybdenum Substances 0.000 claims description 8
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 8
- 229910052721 tungsten Inorganic materials 0.000 claims description 8
- 239000010937 tungsten Substances 0.000 claims description 8
- 229910052720 vanadium Inorganic materials 0.000 claims description 8
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 claims description 8
- 229910052726 zirconium Inorganic materials 0.000 claims description 8
- 229910017052 cobalt Inorganic materials 0.000 claims description 7
- 229910045601 alloy Inorganic materials 0.000 description 40
- 239000000956 alloy Substances 0.000 description 40
- PUZPDOWCWNUUKD-UHFFFAOYSA-M sodium fluoride Chemical compound [F-].[Na+] PUZPDOWCWNUUKD-UHFFFAOYSA-M 0.000 description 22
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 20
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 16
- AMWRITDGCCNYAT-UHFFFAOYSA-L hydroxy(oxo)manganese;manganese Chemical compound [Mn].O[Mn]=O.O[Mn]=O AMWRITDGCCNYAT-UHFFFAOYSA-L 0.000 description 12
- 239000000395 magnesium oxide Substances 0.000 description 12
- 235000013024 sodium fluoride Nutrition 0.000 description 11
- 239000011775 sodium fluoride Substances 0.000 description 11
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 9
- ODINCKMPIJJUCX-UHFFFAOYSA-N Calcium oxide Chemical compound [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 8
- 239000010949 copper Substances 0.000 description 8
- 239000010436 fluorite Substances 0.000 description 8
- 239000000377 silicon dioxide Substances 0.000 description 8
- KKCBUQHMOMHUOY-UHFFFAOYSA-N sodium oxide Chemical compound [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 description 8
- 229910001948 sodium oxide Inorganic materials 0.000 description 8
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 7
- 238000003483 aging Methods 0.000 description 7
- 229910052802 copper Inorganic materials 0.000 description 7
- 239000004615 ingredient Substances 0.000 description 7
- 238000000034 method Methods 0.000 description 7
- 230000008569 process Effects 0.000 description 7
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 6
- 239000000292 calcium oxide Substances 0.000 description 6
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 6
- 229910000831 Steel Inorganic materials 0.000 description 5
- 239000010959 steel Substances 0.000 description 5
- 230000007547 defect Effects 0.000 description 4
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- KRHYYFGTRYWZRS-UHFFFAOYSA-M Fluoride anion Chemical compound [F-] KRHYYFGTRYWZRS-UHFFFAOYSA-M 0.000 description 3
- 229910000990 Ni alloy Inorganic materials 0.000 description 3
- 239000003513 alkali Substances 0.000 description 3
- 229910001515 alkali metal fluoride Inorganic materials 0.000 description 3
- 229910001618 alkaline earth metal fluoride Inorganic materials 0.000 description 3
- 239000002585 base Substances 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- 235000012255 calcium oxide Nutrition 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 150000002739 metals Chemical class 0.000 description 3
- 229910000975 Carbon steel Inorganic materials 0.000 description 2
- 229910000640 Fe alloy Inorganic materials 0.000 description 2
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 2
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 2
- QVQLCTNNEUAWMS-UHFFFAOYSA-N barium oxide Chemical compound [Ba]=O QVQLCTNNEUAWMS-UHFFFAOYSA-N 0.000 description 2
- 238000007373 indentation Methods 0.000 description 2
- 230000006698 induction Effects 0.000 description 2
- PQXKHYXIUOZZFA-UHFFFAOYSA-M lithium fluoride Chemical compound [Li+].[F-] PQXKHYXIUOZZFA-UHFFFAOYSA-M 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- NROKBHXJSPEDAR-UHFFFAOYSA-M potassium fluoride Chemical compound [F-].[K+] NROKBHXJSPEDAR-UHFFFAOYSA-M 0.000 description 2
- 230000000630 rising effect Effects 0.000 description 2
- 239000011734 sodium Substances 0.000 description 2
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- IATRAKWUXMZMIY-UHFFFAOYSA-N strontium oxide Chemical compound [O-2].[Sr+2] IATRAKWUXMZMIY-UHFFFAOYSA-N 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229910001018 Cast iron Inorganic materials 0.000 description 1
- 229910000531 Co alloy Inorganic materials 0.000 description 1
- 241000723368 Conium Species 0.000 description 1
- QPLDLSVMHZLSFG-UHFFFAOYSA-N Copper oxide Chemical compound [Cu]=O QPLDLSVMHZLSFG-UHFFFAOYSA-N 0.000 description 1
- 239000005751 Copper oxide Substances 0.000 description 1
- 229910000881 Cu alloy Inorganic materials 0.000 description 1
- 235000019738 Limestone Nutrition 0.000 description 1
- 206010039509 Scab Diseases 0.000 description 1
- 239000004115 Sodium Silicate Substances 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- WGLPBDUCMAPZCE-UHFFFAOYSA-N Trioxochromium Chemical compound O=[Cr](=O)=O WGLPBDUCMAPZCE-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 230000001464 adherent effect Effects 0.000 description 1
- 229910052783 alkali metal Inorganic materials 0.000 description 1
- 150000001340 alkali metals Chemical class 0.000 description 1
- 229910000287 alkaline earth metal oxide Inorganic materials 0.000 description 1
- 150000001342 alkaline earth metals Chemical group 0.000 description 1
- 229910052785 arsenic Inorganic materials 0.000 description 1
- RQNWIZPPADIBDY-UHFFFAOYSA-N arsenic atom Chemical compound [As] RQNWIZPPADIBDY-UHFFFAOYSA-N 0.000 description 1
- OYLGJCQECKOTOL-UHFFFAOYSA-L barium fluoride Chemical compound [F-].[F-].[Ba+2] OYLGJCQECKOTOL-UHFFFAOYSA-L 0.000 description 1
- 229910001632 barium fluoride Inorganic materials 0.000 description 1
- 229910052810 boron oxide Inorganic materials 0.000 description 1
- 150000001642 boronic acid derivatives Chemical class 0.000 description 1
- 239000010962 carbon steel Substances 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000000788 chromium alloy Substances 0.000 description 1
- BIJOYKCOMBZXAE-UHFFFAOYSA-N chromium iron nickel Chemical compound [Cr].[Fe].[Ni] BIJOYKCOMBZXAE-UHFFFAOYSA-N 0.000 description 1
- 229910000423 chromium oxide Inorganic materials 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- YOCUPQPZWBBYIX-UHFFFAOYSA-N copper nickel Chemical compound [Ni].[Cu] YOCUPQPZWBBYIX-UHFFFAOYSA-N 0.000 description 1
- 229910000431 copper oxide Inorganic materials 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 239000010459 dolomite Substances 0.000 description 1
- 229910000514 dolomite Inorganic materials 0.000 description 1
- 150000004673 fluoride salts Chemical class 0.000 description 1
- 238000005242 forging Methods 0.000 description 1
- 238000007710 freezing Methods 0.000 description 1
- 230000008014 freezing Effects 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 239000011133 lead Substances 0.000 description 1
- 239000006028 limestone Substances 0.000 description 1
- ORUIBWPALBXDOA-UHFFFAOYSA-L magnesium fluoride Chemical compound [F-].[F-].[Mg+2] ORUIBWPALBXDOA-UHFFFAOYSA-L 0.000 description 1
- 229910001635 magnesium fluoride Inorganic materials 0.000 description 1
- 235000002908 manganese Nutrition 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 229910000623 nickel–chromium alloy Inorganic materials 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- MOWNZPNSYMGTMD-UHFFFAOYSA-N oxidoboron Chemical class O=[B] MOWNZPNSYMGTMD-UHFFFAOYSA-N 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 235000003270 potassium fluoride Nutrition 0.000 description 1
- 239000011698 potassium fluoride Substances 0.000 description 1
- 235000019353 potassium silicate Nutrition 0.000 description 1
- 230000009257 reactivity Effects 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 235000017550 sodium carbonate Nutrition 0.000 description 1
- 229910000029 sodium carbonate Inorganic materials 0.000 description 1
- 229910052911 sodium silicate Inorganic materials 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- FVRNDBHWWSPNOM-UHFFFAOYSA-L strontium fluoride Chemical compound [F-].[F-].[Sr+2] FVRNDBHWWSPNOM-UHFFFAOYSA-L 0.000 description 1
- 229910001637 strontium fluoride Inorganic materials 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 229910052715 tantalum Inorganic materials 0.000 description 1
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- 239000011135 tin Substances 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- 235000010215 titanium dioxide Nutrition 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
Classifications
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/20—Measures not previously mentioned for influencing the grain structure or texture; Selection of compositions therefor
Definitions
- the present invention relates to a fluid mold casting process for producing ingot castings having improved surface quality and, more particularly, to a fluid mold casting process for producing nickel and nickel-base alloy ingots having improved surface and improved metallurgical quality and to a special casting slag composition for use in such a process.
- ingot practice is a very important step in the production of wrought metal and alloy shapes.
- Ingots are usually produced by static casting in a permanent mold which may be of cast iron or other suitable metal.
- the ingot mold generally is placed in an upright position and the metal to be cast into ingots can be poured into the mold either from the top or from the bottom thereof.
- the ingot phase of operations involved in producing wrought shapes from nickel-containing heat-resistant, oxidation-resistant and/ or corrosion-resistant alloys is even more critical than it is in the case of ordinary carbon steel.
- alloys include alloys of nickel, iron and cobalt with each other and with chromium, copper, molybdenum, aluminum, titanium, columbium, tantalum, carbon, manganeses, silicon, vanadium, tungsten, etc., and may be such alloys as nickel-chromium alloys, nickel-chromium-iron alloys, nickel-copper alloys, stainless steels, etc. Alloys of this class are characterized by a refractory and very adherent oxide when heated to high temperatures.
- any folds, laps, scabs, metal splashes, or other mechanical defects on the surface of an ingot produced from such alloys must be mechanically removed from the ingot surface before the ingot can be subjected to further mill processing because oxides included beneath the ingot surface will remain as inclusions and will be elongated during further mill processing such as forging, rolling and the like and will be present in the final wrought shape with disastrous results upon the quality of the final material.
- slag-casting processes or fluid-mold casting processes for producing ingots of steel and the like have been developed.
- Such processes provide steel ingots having improved surface quality and involve pouring a quantity of molten silicate slag into an ingot mold and then teeming molten metal into the thus-formed pool of molten slag.
- the slag covers the rising metal surface in the mold and floats to the top of the ingot mold as a surface layer of some depth.
- the slag freezes continuously in contact with the ingot mold Wall in advance of the rising molten metal surface and forms a thin shell between the ingot and the mold. In this way, the skin of the ingot does not touch the ingot mold and improvements in the surface quality of steel ingots are made possible.
- silicate-type slags for use in the slag-casting process, e.g., slags containing about 25% to about 65% of silica, along with other ingredients such as alumina, magnesia, lime, etc., so as to have a basic ratio of about 0.3 to about 2.
- Sodium silicate (water glass) has also been suggested for this purpose.
- slag reportedly provide satisfactory results in casting carbon steels, alloy steels and even some grades of stainless steels, it has been found that serious dilficulties are encountered in attempting to utilize them in the slag-casting of nickel and nickel-base alloys containing, for example, 40% or more of nickel.
- the silicon content of metal in the circuit underwent an increase such that heats were rejected as falling outside the chemistry definition, although ingots of acceptable surface quality were obtained in some cases.
- the observed defects included (1) a notch toward the toe of the ingot which comprised a peripheral indentation which resulted in overhaul costs and losses of metal before further processing of the ingot could be undertaken and (2) a shotted surface condition on the ingot which became more severe from the toe to the head of the ingot and which comprised irregular indentations and/or folds in the ingot surface and which also required very substantial overhauling before any further processing of the ingot could be undertaken if it could be undertaken at all. Furthermore, analysis of the resulting slag-cast metal showed an impermissible increase in silicon content indicative of a slag-metal interaction. Experience thus demonstrated that the recommended silicate slags could not be employed for slag casting age-hardenable nickel and nickel alloys.
- a special casting slag composition provides improved results in the fluid mold casting of nickel and nickel alloys containing 1% or 1.5% or more of age hardening elements, enables the production of sound, clean ingots of such alloys and results in an ingot surface of such quality that the ingots can be forged, rolled or otherwise processed in the mill without overhauling.
- Another object of the invention is to provide a casting slag composition particularly adapted for the production of fluid-mold cast ingots of nickel-containing alloys.
- the invention also contemplates providing a special casting slag composition useful for the production of ingots having improved surface quality in nickel-containing alloys which also contain about 1% or more of age hardening elements.
- the present invention contemplates a process for fluid mold casting nickel-containing alloy ingots comprising placing in the bottom of an upright 3 ingot mold a quantity of a molten casting slag containing about 10% to 60% calcium oxide (CaO), about 10% to 60% alumina (A1 about 2% to 20% titanium oxide (TiO up to about 10% magnesium oxide (MgO),
- the titania, cryolite, sodium fluoride, fluorspar, and sodium oxide preferably does not exceed about 25% of the composition.
- the slag most advantageously is devoid of silica, although as much as up to about 10% sodium oxide (Na O), up to about 25% 5 3% or even 5% silica may be present in some instances.
- cryolite Na AlF up to about 25% sodium fluoride
- Magnesia generally has the effect of unduly raising the (NaF), and up to about 25% tluorspar (CaF with the melting point and, hence, should not be present in amounts total amount of cryolite, sodium fluoride, and fluorspar exceeding about Titania has a markedly benebeing at least about 5% or about 10% but not exceeding ficial effect on the melting point of the slag and even about 50% of the slag composition and teeming into said 10 2% titania has a very real effect on this slag property.
- titania should not exceed 20% and, advanto substantially fill the mold. tageously, this ingredient should not exceed about 10%
- the invention also contemplates the said casting slag of the composition because greater amounts unduly procompositions and these compositions are characterized by mote reactivity of the slag.
- Sodium oxide in amounts substantially maintaining their compositions while they up to about 10% also helps promote fluidity of the slag are in contact, in the molten state, with molten nickelbut greater amounts are not used principally because of containing alloys containing at least about 7% of nickel fuming.
- C-ryolite, sodium fluoride, and fluorspar act as and at least about 1% or 1.5% of elements such as alufluidizers in the slag and are present in amounts of 5% minum, titanium, magnesium, zirconium, etc., which form up to 50% therein.
- Cryolite and sodium fluoride are oxides having high free energies of formation and which more effective than fluorspar and are preferred for this can be employed to contribute age-hardening to the reason.
- the slag should be devoid of impurities such alloy.
- the casting slag is used in the amount of apas arsenic, lead, tin, zinc, sulfur, etc., and should not proximately forty pounds per ton of metal being cast, contain more than about 1% each of metal oxides such although greater or lesser amounts can be used.
- metal oxides such although greater or lesser amounts can be used.
- the casting slag composition contains ox-ide, copper oxide, etc.
- a number of satisfactory slag compositions are set 10% magnesia, up to about 10% sodium oxide, and forth in the following Table I:
- A1203 CaO T10 Na um can MgO Na O NaF about 5% to about 20% of a material from the group 45
- calcium oxide may consisting of cryolite, sodium fluoride, and fluorspar. be added in the usual commercial terms such as burned
- the slag contains about 40% to 45% CaO, lime and limestone, titanium dioxide may be added as 40% to 45% A1 0 5% to 10% TiO and 5% to 15% rutile, magnesia may be added as such or as dolomite and cryol'ite.
- a casting slag composition containing about sodium oxide may be added as soda ash.
- the slag may 40% lime (CaO), about 40% alumina (A1 0 about 50 be melted in any furnace capable of attaining tempera- 5% titania (TiO and about 15% cryolite gives very tures on the order of about 3000 F. A convenient satisfactory results.
- These compositions are further charfurnace for this purpose is a submerged electrode furnace acterized in that, upon freezing against the mold during having a water-cooled steel shell.
- the molten slag comthe casting process they provide a more substantial slag posit-ions are electrically conductive. shell between the ingot and the mold, which shell has The special casting slag composition set forth herein improved resistance to penetration by the molten metal.
- this slag shell advantageously is on the nickel-containing alloys which include about 1% or about order of approximately one-sixteenth of an inch in thick- 1.5% or about 2% up to a total of about 8.5% or 10% ness.
- the thickness of the of metals such as aluminum, titanium, magnesium, zirslag shell may vary due to irregularities in the ingot mold 6O Conium, and the like, which form OXideS having g free wall and due to many other factors, including slag temenergies of formation exceeding the free energy of formaperature, metal temperature, mold temperature, etc., and tion of silica (SiO and which are employed in such the thickness can be up to about one-eighth of an inch. alloys for various purposes including deoxidation, age The casting slag should have a melting point in the neighhardening, etc.
- alloys may also contain up to borhood of 2300 to 2350 F., i.e., the slag composition about 30% chromium, up to about 75% iron, e.g., up to should not have any thermal arrests on cooling from a about 0f 45 of iron, 10 to about c pper, up temperature above this range, e.g., about 3000 F., to the to about 10% columbium, up to about 30% cobalt, up range of 2300 to 2350 F.
- the slag composition about 30% chromium
- 75% iron e.g., up to should not have any thermal arrests on cooling from a about 0f 45 of iron, 10 to about c pper, up temperature above this range, e.g., about 3000 F., to the to about 10% columbium, up to about 30% cobalt, up range of 2300 to 2350 F.
- the total content of lime and and the balance essentially nickel, with the nickel content alumina (and magnesia if any be present) preferably is being at least about 7% and up to about 95% of the about or more of the composition while the balance 75 alloy.
- compositions of nickel-containing alloys which may satisfactorily be fluid-mold cast in accordance with the invention are set forth in the following Table II:
- Alloys such as those shown in Table II do not undergo any substantial change in composition when fluid-mold cast in the special casting slag provided in accordance with the invention. This is a very important feature of the invention as it permits employing the process of the invention in the regular mill circuit while maintaining chemical specification limits in the alloys produced. It will be appreciated that Alloys Nos. 1 to 10 in Table II are age-hardening alloys, and that the invention is particularly applicable to the fluid-mold casting of agehardening alloys containing, for example, about 35% or 40% or more of nickel and containing about 2% or more of age-hardening elements.
- a 9400-pound melt of an alloy containing about 6.75% iron, about 0.7% manganese, about chromium, about 2.5% titanium, about 0.8% aluminum, about 0.85% columbium, about 0.04% carbon, and the balance essentially nickel was prepared for casting in an induction furnace.
- a casting slag melt made from a charge of dry ingredients including about 40% CaO, about 40% A1 0 about 5% TiO and about 15% cryolite was prepared in a submerged electrode furnace and was heated to about 3000 F.
- Two 18" x 18 square ingot molds were set up on copper stools having a cavity in the shape of an inverted pyramid. Each of the ingot molds was provided with an exothermic hot top material placed in a recess at the top of the mold.
- a quantity of the molten casitng slag was transferred to a ladle and about 100 pounds of the molten slag was poured into the bottom of the first ingot mold. This was sufficient to fill the cavity in the stool and to extend about two inches up the ingot mold wall.
- Metal from the induction furnace heat was then teemed from a bottom-pour ladle at a temperature of about 2900 F. into the ingot mold at a steady rate through the slag pool to completely fill the ingot mold with metal and to flush the excess casting slag over the top of the mold.
- the process was then repeated with the second ingot mold. In this way, two 18" x 18 ingots weighing about 4300 pounds apiece were prepared.
- the ingots were cooled to a red heat in the mold and were then stripped. Upon inspection, it was found that the ingots had an excellent surface which permitted the ingots to be forged without overhaul.
- the special casting slags provided in accordance with the invention enable the successful fluid-mold casting of alloys containing metals forming oxides having a higher free energy of formation than silica without encountering the severe difliculties and limitations met heretofore in fluid-mold casting of these alloys in silicate casting slags containing about 25% or more, e.g., up to about 65%, of silica.
- silicate casting slags containing about 25% or more, e.g., up to about 65%, of silica.
- fluid-mold cast ingots of such alloys are obtained which have an improved cast surface and improved ing out the process of the invention, the ingots produced can be maintained within the close specification chemical limits which must be maintained in connection with these alloys. It is further found that ingots produced in accordance with the present invention are free from the shotted surface defect found when silicate slags are used and that the slag-notch defect is mitigated or eliminated entirely.
- fluorides of the alkali metal and alkaline earth metal group e.g., lithium fluoride, potassium fluoride, barium fluoride, magnesium fluoride, strontium fluoride, etc.
- lithium fluoride, potassium fluoride, barium fluoride, magnesium fluoride, strontium fluoride, etc. may be employed in the place of cryolite, fluorspar, and sodium fluoride in formulating the casting slag compositions contemplated in accordance with the invention.
- other alkaline earth metal oxides such as barium oxide, strontium oxide, etc., may be employed in the place of calcium oxide, aluminum oxide and/ or magnesium oxide in formulating the special casting slag.
- a casting slag particularly useful in the molten condition in the fluid-mold ingot casting of molten metal to produce ingots having good surface quality said moten metal consisting essentially of up to about 30% chromium, up to about 75% iron, up to about 70% copper, up to about 10% columbium, up to about 30% cobalt, up to about 10% molybdenum, up to about 6% tungsten, up to about 5% manganese, up to about 4% silicon, up to about 0.3% carbon, up to about 2% vanadium, up to about 7.5% aluminum, up to about 7.5% titanium, up to about 0.2% zirconium, up to about 0.5% magnesium, the balance essentially nickel with the nickel content being at least about 7% and up to about of the alloy and the said molten metal being reactive with casting slags of the silicate type and producing with silicate type slags fluid-mold ingot castings having poor surface quality, said casting slag consisting essentially of about 40% to about 45% alumina, about 40% to
- a casting slag particularly useful in the molten condition in the fluid-mold ingot casting of molten metal to produce ingots having good surface quality said moten metal consisting essentially of up to about 30% chromium, up to about 75 iron, up to about 70% copper, up to about 10% columbium, up to about 30% cobalt, up to about 10% molybdenum, up to about 6% tungsten, up to about 5% manganese, up to about 4% silicon, up to about 0.3% carbon, up to about 2% vanadium, up to about 7.5% aluminum, up to about 7.5 titanium, up to about 0.2% zirconium, up to about 0.5% magnesium, the balance essentially nickel with the nickel content being at least about 7% and up to about 95% of the alloy and the said molten metal being reactive with casting slags of the silicate type and producing with silicate type slags fluid-mold ingot castings having poor surface quality, said casting slag consisting essentially of about 20% to about 50% alumina, about 2%
- a casting slag particularly useful in the molten con dition in the fluid-mold ingot casting of molten metal to produce ingots having good surface quality said molten metal consisting essentially of up to about 30% chromium, up to about 75% iron, up to about 70% copper, up to about columbium, up to about 30% cobalt, up to about 10% molybdenum, up to about 6% tungsten, up to about 5% manganese, up to about 4% silicon, up to about 0.3% carbon, up to about 2% vanadium, up to about 7.5% aluminum, up to about 7.5% titanium, up to about 0.2% zirconium, up to about 0.5% magnesium, the balance essential nickel and with the nickel content being at least about 7% of the alloy and the said molten metal being reactive with casting slags of the silicate type and producing with silicate type slags fluid-mold ingot castings having poor surface quality, said casting slag consisting essentially of a major proportion of ingredients from the group consisting of lime and
- a casting slag particularly useful in the molten condition in the fluid-mold ingot casting of molten metal to produce ingots having good surface quality said moten metal consisting essentially of up to about 30% chromium, up to about 75 iron, up to about 70% copper, up to about 10% columbium, up to about 30% cobalt, up to about 10% molybdenum, up to about 6% tungsten, up to about 5% manganese, up to about 4% silicon, up to about 0.3% carbon, up to about 2% vanadium, up to about 7.5 aluminum, up to about 7.5 titanium, up to about 0.2% zirconium, up to about 0.5% magnesium, the balance essentially nickel with the nickel content being at least about 7% and up to about 95 of the alloy and the said molten metal being reactive with casting slags of the silicate type and producing with silicate type slags fluid-mold ingot castings having poor surface quality, said casting slags consisting essentially of about 10% to about alumina, about 2% to
- a casting slag particularly useful in the molten condition in the fluid-mold ingot casting of molten metal to produce ingots having good surface quality said moten metal consisting essentially of up to about 30% chromium, up to about iron, up to about 70% copper, up to about 10% columbium, up to about 30% cobalt, up to about 10% molybdenum, up to about 6% tungsten, up to about 5% manganese, up to about 4% silicon, up to about 0.3% carbon, up to about 2% vanadium, up to about 7.5 aluminum, up to about 7.5 titanium, up to about 0.2% zirconium, up to about 0.5% magnesium, the balance essentially nickel with the nickel content being at least about 7% and up to about of the alloy and the said molten metal being reactive with casting slags of the silicate type and producing with silicate type slags fluid-mold ingot castings having poor surface quality, said casting slag consisting essentially of about 10% to about 60% alumina, about 2% to 20% titan
Description
United States Patent 3,224,887 SLAG COMPOSlTlUN FOR FLUID MOLD CASTING James Stanislaus Fox, Willoughby, Ohio, and James Henry De Bord, Huntington, W. Va., assignors to The International Nickel Company, Inc., New York, N.Y., a corporation of Delaware No Drawing. Original application Mar. 27, 1962, Ser. No. 182,974. Divided and this application Mar. 9, 1964, Ser. No. 350,603
5 Claims. (Cl. lilo-38.27)
This application is a division of our copending US. application Serial No. 182,974 filed March 27, 1962.
The present invention relates to a fluid mold casting process for producing ingot castings having improved surface quality and, more particularly, to a fluid mold casting process for producing nickel and nickel-base alloy ingots having improved surface and improved metallurgical quality and to a special casting slag composition for use in such a process.
Those skilled in the art know that ingot practice is a very important step in the production of wrought metal and alloy shapes. Ingots are usually produced by static casting in a permanent mold which may be of cast iron or other suitable metal. The ingot mold generally is placed in an upright position and the metal to be cast into ingots can be poured into the mold either from the top or from the bottom thereof. The ingot phase of operations involved in producing wrought shapes from nickel-containing heat-resistant, oxidation-resistant and/ or corrosion-resistant alloys is even more critical than it is in the case of ordinary carbon steel. These alloys include alloys of nickel, iron and cobalt with each other and with chromium, copper, molybdenum, aluminum, titanium, columbium, tantalum, carbon, manganeses, silicon, vanadium, tungsten, etc., and may be such alloys as nickel-chromium alloys, nickel-chromium-iron alloys, nickel-copper alloys, stainless steels, etc. Alloys of this class are characterized by a refractory and very adherent oxide when heated to high temperatures. As a result, any folds, laps, scabs, metal splashes, or other mechanical defects on the surface of an ingot produced from such alloys must be mechanically removed from the ingot surface before the ingot can be subjected to further mill processing because oxides included beneath the ingot surface will remain as inclusions and will be elongated during further mill processing such as forging, rolling and the like and will be present in the final wrought shape with disastrous results upon the quality of the final material. It has been common practice to surface mill the entire ingot produced in such alloys or to use machine chipping and/or grinding to remove imperfections from the ingot which have occurred as a result of the ingot casting operations. These overhauling operations are very expensive in themselves and result in a further economic loss in that the metal removed from the ingot cannot be converted into acceptable mill products.
In an effort to overcome these difiiculties, slag-casting processes or fluid-mold casting processes for producing ingots of steel and the like have been developed. Such processes provide steel ingots having improved surface quality and involve pouring a quantity of molten silicate slag into an ingot mold and then teeming molten metal into the thus-formed pool of molten slag. During teeming, the slag covers the rising metal surface in the mold and floats to the top of the ingot mold as a surface layer of some depth. The slag freezes continuously in contact with the ingot mold Wall in advance of the rising molten metal surface and forms a thin shell between the ingot and the mold. In this way, the skin of the ingot does not touch the ingot mold and improvements in the surface quality of steel ingots are made possible.
The art has recommended silicate-type slags for use in the slag-casting process, e.g., slags containing about 25% to about 65% of silica, along with other ingredients such as alumina, magnesia, lime, etc., so as to have a basic ratio of about 0.3 to about 2. Sodium silicate (water glass) has also been suggested for this purpose. Although such slag reportedly provide satisfactory results in casting carbon steels, alloy steels and even some grades of stainless steels, it has been found that serious dilficulties are encountered in attempting to utilize them in the slag-casting of nickel and nickel-base alloys containing, for example, 40% or more of nickel. Thus, it was found that the silicon content of metal in the circuit underwent an increase such that heats were rejected as falling outside the chemistry definition, although ingots of acceptable surface quality were obtained in some cases.
Attempts to utilize such silicate slags in fluid mold casting of nickel and nickel-base alloys containing about 1% or about 1.5% or more of age hardening elements such as aluminum, titanium, etc., resulted in very serious problems and produced defective ingots having a surface greatly inferior to that which was obtained in casting these metals directly into an ingot mold without using any slag at all. The observed defects included (1) a notch toward the toe of the ingot which comprised a peripheral indentation which resulted in overhaul costs and losses of metal before further processing of the ingot could be undertaken and (2) a shotted surface condition on the ingot which became more severe from the toe to the head of the ingot and which comprised irregular indentations and/or folds in the ingot surface and which also required very substantial overhauling before any further processing of the ingot could be undertaken if it could be undertaken at all. Furthermore, analysis of the resulting slag-cast metal showed an impermissible increase in silicon content indicative of a slag-metal interaction. Experience thus demonstrated that the recommended silicate slags could not be employed for slag casting age-hardenable nickel and nickel alloys.
Although other attempts were made to overcome the foregoing difiiculties and other difficulties, none, as far as we are aware, was entirely successful when carried into practice commercially on an industrial scale.
It has now been discovered that a special casting slag composition provides improved results in the fluid mold casting of nickel and nickel alloys containing 1% or 1.5% or more of age hardening elements, enables the production of sound, clean ingots of such alloys and results in an ingot surface of such quality that the ingots can be forged, rolled or otherwise processed in the mill without overhauling.
It is an object of the present invention to provide an improved fluid-mold casting process for producing nickelcontaining alloy ingots having improved metallurgical quality.
Another object of the invention is to provide a casting slag composition particularly adapted for the production of fluid-mold cast ingots of nickel-containing alloys.
The invention also contemplates providing a special casting slag composition useful for the production of ingots having improved surface quality in nickel-containing alloys which also contain about 1% or more of age hardening elements.
Other objects and advantages will become apparent from the following description.
Generally speaking, the present invention contemplates a process for fluid mold casting nickel-containing alloy ingots comprising placing in the bottom of an upright 3 ingot mold a quantity of a molten casting slag containing about 10% to 60% calcium oxide (CaO), about 10% to 60% alumina (A1 about 2% to 20% titanium oxide (TiO up to about 10% magnesium oxide (MgO),
of the composition, including the titania, cryolite, sodium fluoride, fluorspar, and sodium oxide preferably does not exceed about 25% of the composition. The slag most advantageously is devoid of silica, although as much as up to about 10% sodium oxide (Na O), up to about 25% 5 3% or even 5% silica may be present in some instances. cryolite (Na AlF up to about 25% sodium fluoride Magnesia generally has the effect of unduly raising the (NaF), and up to about 25% tluorspar (CaF with the melting point and, hence, should not be present in amounts total amount of cryolite, sodium fluoride, and fluorspar exceeding about Titania has a markedly benebeing at least about 5% or about 10% but not exceeding ficial effect on the melting point of the slag and even about 50% of the slag composition and teeming into said 10 2% titania has a very real effect on this slag property. ingot mold a quantity of molten nickel-containing alloy Generally, titania should not exceed 20% and, advanto substantially fill the mold. tageously, this ingredient should not exceed about 10% The invention also contemplates the said casting slag of the composition because greater amounts unduly procompositions and these compositions are characterized by mote reactivity of the slag. Sodium oxide in amounts substantially maintaining their compositions while they up to about 10% also helps promote fluidity of the slag are in contact, in the molten state, with molten nickelbut greater amounts are not used principally because of containing alloys containing at least about 7% of nickel fuming. C-ryolite, sodium fluoride, and fluorspar act as and at least about 1% or 1.5% of elements such as alufluidizers in the slag and are present in amounts of 5% minum, titanium, magnesium, zirconium, etc., which form up to 50% therein. Cryolite and sodium fluoride are oxides having high free energies of formation and which more effective than fluorspar and are preferred for this can be employed to contribute age-hardening to the reason. The slag should be devoid of impurities such alloy. The casting slag is used in the amount of apas arsenic, lead, tin, zinc, sulfur, etc., and should not proximately forty pounds per ton of metal being cast, contain more than about 1% each of metal oxides such although greater or lesser amounts can be used. as manganese oxide, iron oxide, chromium oxide, nickel Advantageously, the casting slag composition contains ox-ide, copper oxide, etc. Boron oxides and borates about 20% to 50% calcium oxide, about 20% to 50% should not be present in the slag. alumina, about 2% to 10% titanium oxide, up to about A number of satisfactory slag compositions are set 10% magnesia, up to about 10% sodium oxide, and forth in the following Table I:
Table I Slag Percent Percent Percent Percent Percent Percent Percent Percent N0. A1203 CaO T10 Na um can MgO Na O NaF about 5% to about 20% of a material from the group 45 In making up the slag composition, calcium oxide may consisting of cryolite, sodium fluoride, and fluorspar. be added in the usual commercial terms such as burned Preferably, the slag contains about 40% to 45% CaO, lime and limestone, titanium dioxide may be added as 40% to 45% A1 0 5% to 10% TiO and 5% to 15% rutile, magnesia may be added as such or as dolomite and cryol'ite. A casting slag composition containing about sodium oxide may be added as soda ash. The slag may 40% lime (CaO), about 40% alumina (A1 0 about 50 be melted in any furnace capable of attaining tempera- 5% titania (TiO and about 15% cryolite gives very tures on the order of about 3000 F. A convenient satisfactory results. These compositions are further charfurnace for this purpose is a submerged electrode furnace acterized in that, upon freezing against the mold during having a water-cooled steel shell. The molten slag comthe casting process, they provide a more substantial slag posit-ions are electrically conductive. shell between the ingot and the mold, which shell has The special casting slag composition set forth herein improved resistance to penetration by the molten metal. provides special advantages in the fluid mold casting of The thickness of this slag shell advantageously is on the nickel-containing alloys which include about 1% or about order of approximately one-sixteenth of an inch in thick- 1.5% or about 2% up to a total of about 8.5% or 10% ness. It will be appreciated that the thickness of the of metals such as aluminum, titanium, magnesium, zirslag shell may vary due to irregularities in the ingot mold 6O Conium, and the like, which form OXideS having g free wall and due to many other factors, including slag temenergies of formation exceeding the free energy of formaperature, metal temperature, mold temperature, etc., and tion of silica (SiO and which are employed in such the thickness can be up to about one-eighth of an inch. alloys for various purposes including deoxidation, age The casting slag should have a melting point in the neighhardening, etc. These alloys may also contain up to borhood of 2300 to 2350 F., i.e., the slag composition about 30% chromium, up to about 75% iron, e.g., up to should not have any thermal arrests on cooling from a about 0f 45 of iron, 10 to about c pper, up temperature above this range, e.g., about 3000 F., to the to about 10% columbium, up to about 30% cobalt, up range of 2300 to 2350 F. to about 10% molybdenum, up to about 6% tungsten, In preparing the casting slag composition, lime and up to about 5% manganese, up to about 4% silicon, up alumina more advantageously constitute the major pro- 70 to about 0.3% carbon, up to about 2% vanadium, up to portion, i.e., at least 50% or more, of the ingredients about 7.5% aluminum, up to about 7.5% titanium, up to used and these ingredients preferably are used in subabout 0.2% zirconium, up to about 0.5% magnesium, stantially equal amounts. The total content of lime and and the balance essentially nickel, with the nickel content alumina (and magnesia if any be present) preferably is being at least about 7% and up to about 95% of the about or more of the composition while the balance 75 alloy.
Compositions of nickel-containing alloys which may satisfactorily be fluid-mold cast in accordance with the invention are set forth in the following Table II:
metallurgical quality as compared to the results attained when it is attempted to fluid-mold cast ingots of such alloys in silicate casting slags. It is found that, in carry- Table II Alloy N0. Percent Ni Percent Percent Fe Percent Percent Si Percent Percent Cr Percent Percent Al Percent 'Il Mn Other Mo 0. 15 0. 15 0.25 0.55 4. 0. i 0. 15 1 0.6 0.15 29.5 Cu 2.8 0. 5 0. 04 6. 75 0.7 0. 3 Ch 15 0.8 2. 5 0. 04 18 0. 2 0. 2 19 0. 6 0. 8 0. 04 7. 2 2. 25 0. 12 16 3 0. 04 6. 5 0.55 0.2 15 0. 6 2. 4 0. 12 0. 7 0. 1 0. 3 15 3 2. 2 0. 04 0.35 0.05 0. 2 15. 6 3. 4 0. 7 0.05 34 0.45 0. 4 13. 5 6. 2 0. 25 2. 5 0. 02 48. 5 0.4 0. 5 5. 4 0.65 2.4 0. 04 44. 5 0. 75 0. 35 20. 5 1
Alloys such as those shown in Table II do not undergo any substantial change in composition when fluid-mold cast in the special casting slag provided in accordance with the invention. This is a very important feature of the invention as it permits employing the process of the invention in the regular mill circuit while maintaining chemical specification limits in the alloys produced. It will be appreciated that Alloys Nos. 1 to 10 in Table II are age-hardening alloys, and that the invention is particularly applicable to the fluid-mold casting of agehardening alloys containing, for example, about 35% or 40% or more of nickel and containing about 2% or more of age-hardening elements.
In order to give those skilled in the art a better understand-ing of the invention, the following illustrative example is given:
A 9400-pound melt of an alloy containing about 6.75% iron, about 0.7% manganese, about chromium, about 2.5% titanium, about 0.8% aluminum, about 0.85% columbium, about 0.04% carbon, and the balance essentially nickel was prepared for casting in an induction furnace.- A casting slag melt made from a charge of dry ingredients including about 40% CaO, about 40% A1 0 about 5% TiO and about 15% cryolite was prepared in a submerged electrode furnace and was heated to about 3000 F. Two 18" x 18 square ingot molds were set up on copper stools having a cavity in the shape of an inverted pyramid. Each of the ingot molds was provided with an exothermic hot top material placed in a recess at the top of the mold. A quantity of the molten casitng slag was transferred to a ladle and about 100 pounds of the molten slag was poured into the bottom of the first ingot mold. This was sufficient to fill the cavity in the stool and to extend about two inches up the ingot mold wall. Metal from the induction furnace heat was then teemed from a bottom-pour ladle at a temperature of about 2900 F. into the ingot mold at a steady rate through the slag pool to completely fill the ingot mold with metal and to flush the excess casting slag over the top of the mold. The process was then repeated with the second ingot mold. In this way, two 18" x 18 ingots weighing about 4300 pounds apiece were prepared. The ingots were cooled to a red heat in the mold and were then stripped. Upon inspection, it was found that the ingots had an excellent surface which permitted the ingots to be forged without overhaul.
It is to be appreciated that the special casting slags provided in accordance with the invention enable the successful fluid-mold casting of alloys containing metals forming oxides having a higher free energy of formation than silica without encountering the severe difliculties and limitations met heretofore in fluid-mold casting of these alloys in silicate casting slags containing about 25% or more, e.g., up to about 65%, of silica. Thus, in carrying out the process contemplated in accordance with the invention, fluid-mold cast ingots of such alloys are obtained which have an improved cast surface and improved ing out the process of the invention, the ingots produced can be maintained within the close specification chemical limits which must be maintained in connection with these alloys. It is further found that ingots produced in accordance with the present invention are free from the shotted surface defect found when silicate slags are used and that the slag-notch defect is mitigated or eliminated entirely.
Those skilled in the art will appreciate that other fluorides of the alkali metal and alkaline earth metal group, e.g., lithium fluoride, potassium fluoride, barium fluoride, magnesium fluoride, strontium fluoride, etc., may be employed in the place of cryolite, fluorspar, and sodium fluoride in formulating the casting slag compositions contemplated in accordance with the invention. In addition, other alkaline earth metal oxides, such as barium oxide, strontium oxide, etc., may be employed in the place of calcium oxide, aluminum oxide and/ or magnesium oxide in formulating the special casting slag.
Although the present invention has been described in conjunction with preferred embodiments, it is to be understood that modifications and variations may be resorted to without departing from the spirit and scope of the invention as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the invention and appended claims.
We claim:
1. A casting slag particularly useful in the molten condition in the fluid-mold ingot casting of molten metal to produce ingots having good surface quality, said moten metal consisting essentially of up to about 30% chromium, up to about 75% iron, up to about 70% copper, up to about 10% columbium, up to about 30% cobalt, up to about 10% molybdenum, up to about 6% tungsten, up to about 5% manganese, up to about 4% silicon, up to about 0.3% carbon, up to about 2% vanadium, up to about 7.5% aluminum, up to about 7.5% titanium, up to about 0.2% zirconium, up to about 0.5% magnesium, the balance essentially nickel with the nickel content being at least about 7% and up to about of the alloy and the said molten metal being reactive with casting slags of the silicate type and producing with silicate type slags fluid-mold ingot castings having poor surface quality, said casting slag consisting essentially of about 40% to about 45% alumina, about 40% to about 45 lime, about 5% to about 10% titania, not more than about 1% manganese oxide, and about 5% to about 15% cryolite.
2. A casting slag particularly useful in the molten condition in the fluid-mold ingot casting of molten metal to produce ingots having good surface quality, said moten metal consisting essentially of up to about 30% chromium, up to about 75 iron, up to about 70% copper, up to about 10% columbium, up to about 30% cobalt, up to about 10% molybdenum, up to about 6% tungsten, up to about 5% manganese, up to about 4% silicon, up to about 0.3% carbon, up to about 2% vanadium, up to about 7.5% aluminum, up to about 7.5 titanium, up to about 0.2% zirconium, up to about 0.5% magnesium, the balance essentially nickel with the nickel content being at least about 7% and up to about 95% of the alloy and the said molten metal being reactive with casting slags of the silicate type and producing with silicate type slags fluid-mold ingot castings having poor surface quality, said casting slag consisting essentially of about 20% to about 50% alumina, about 2% to 10% titania, not more than about 1% manganese oxide, up to about 10% magnesia, up to about 10% sodium oxide, about 5% to about 20% of at least one fluoride from the group consisting of alkali and alkaline earth metal fluorides, and the balance essentially lime, with the lime content being about 20% to about 50% of the composition.
3. A casting slag particularly useful in the molten con dition in the fluid-mold ingot casting of molten metal to produce ingots having good surface quality, said molten metal consisting essentially of up to about 30% chromium, up to about 75% iron, up to about 70% copper, up to about columbium, up to about 30% cobalt, up to about 10% molybdenum, up to about 6% tungsten, up to about 5% manganese, up to about 4% silicon, up to about 0.3% carbon, up to about 2% vanadium, up to about 7.5% aluminum, up to about 7.5% titanium, up to about 0.2% zirconium, up to about 0.5% magnesium, the balance essential nickel and with the nickel content being at least about 7% of the alloy and the said molten metal being reactive with casting slags of the silicate type and producing with silicate type slags fluid-mold ingot castings having poor surface quality, said casting slag consisting essentially of a major proportion of ingredients from the group consisting of lime and alumina with these ingredients being present in substantially equal amounts, about 2% to about 10% titania, not more than about 1% manganese oxide, and a minor proportion of at least one fluoride from the group consisting of alkali and alkaline earth metal fluorides.
4. A casting slag particularly useful in the molten condition in the fluid-mold ingot casting of molten metal to produce ingots having good surface quality, said moten metal consisting essentially of up to about 30% chromium, up to about 75 iron, up to about 70% copper, up to about 10% columbium, up to about 30% cobalt, up to about 10% molybdenum, up to about 6% tungsten, up to about 5% manganese, up to about 4% silicon, up to about 0.3% carbon, up to about 2% vanadium, up to about 7.5 aluminum, up to about 7.5 titanium, up to about 0.2% zirconium, up to about 0.5% magnesium, the balance essentially nickel with the nickel content being at least about 7% and up to about 95 of the alloy and the said molten metal being reactive with casting slags of the silicate type and producing with silicate type slags fluid-mold ingot castings having poor surface quality, said casting slags consisting essentially of about 10% to about alumina, about 2% to about 10% titania, not more than about 1% manganese oxide, up to about 10% magnesia, up to about 10% sodium oxide, up to about 25% cryolite, up to about 25% sodium fluoride, up to about 25% fluorspar, with the total amount of cryolite, sodium fluoride and fluorspar being at least about 5% but not exceeding about 50% of the slag composition, up to about 5% silica, and the balance essentially lime, with the lime content being about 10% to about 60% of the composition.
5. A casting slag particularly useful in the molten condition in the fluid-mold ingot casting of molten metal to produce ingots having good surface quality, said moten metal consisting essentially of up to about 30% chromium, up to about iron, up to about 70% copper, up to about 10% columbium, up to about 30% cobalt, up to about 10% molybdenum, up to about 6% tungsten, up to about 5% manganese, up to about 4% silicon, up to about 0.3% carbon, up to about 2% vanadium, up to about 7.5 aluminum, up to about 7.5 titanium, up to about 0.2% zirconium, up to about 0.5% magnesium, the balance essentially nickel with the nickel content being at least about 7% and up to about of the alloy and the said molten metal being reactive with casting slags of the silicate type and producing with silicate type slags fluid-mold ingot castings having poor surface quality, said casting slag consisting essentially of about 10% to about 60% alumina, about 2% to 20% titania, not more than about 1% manganese oxide, up to about 10% magnesia, up to about 10% sodium oxide, about 5% to about 50% of at least one fluoride from the group consisting of alkali and alkaline earth metal fluorides, up to about 5% silica, and the balance essentially lime, with the lime content being about 10% to about 60% of the composition.
References Cited by the Examiner UNITED STATES PATENTS 1.912,815 6/1933 Witty 106-l17 2,510,155 6/1950 Tanczyn 222l5 2,694,023 11/1954 Hopkins 14826 2,719,801 10/1955 Stringham et al. 14826 2,814,579 11/1957 Stringham et al. 14826 2,868,681 1/1959 Shrubsall et al. 148-25 2,882,568 4/1959 Leaberry et al. 22-2165 XR 2,912,729 11/1959 Webb 10638.9 XR 3,093,570 6/1963 Dewey.
3,052,936 9/1962 Hamilton 22215 XR 3,097,979 7/1963 Amsel et al. 148-26 ALEXANDER H. BRODMERKEL, Primary Examiner.
J. B. EVANS, Assistant Examiner.
Claims (1)
1. A CASTING SLAG PARTICULARLY USEFUL IN THE MOLTEN CONDITION IN THE FLUID-MOLD INGOT CASTING OF MOLTEN METAL TO PRODUCE INGOTS HAVING GOOD SURFACE QUALITY, SAID MOTEN METAL CONSISTING ESSENTIALLY OF UP TO ABOUT 30% CHROMIUM, UP TO ABOUT 75% IRON, UP TO ABOUT 70% COPPER, UP TO ABOUT 10% COLUMBIUM, UP TO ABOUT 30% COBALT, UP TO ABOUT 10% MOLYBDENUM, UP TO ABOUT 6% TUNGSTEN, UP TO ABOUT 5% MANGANESE, UP TO ABOUT 4% SILICON, UP TO ABOUT 0.3% CARBON, UP TO ABOUT 2% VANADIUM, UP TO ABOUT 7.5% ALUMINUM, UP TO ABOUT 7.5% TITANIUM, UP TO ABOUT 7.2% ALUMINUM, UP TO ABOUT 7.5% TITANIUM, UP TO ABOUT 0.2% ZIRCONIUM, UP TO ABOUT 0.5% MAGNESIUM, THE BALANCE ESSENTIALLY NICKEL WITH THE NICKEL CONTENT BEING AT LEAST ABOUT 7% AND UP TO ABOUT 95% OF THE ALLOY AND THE SAID MOLTEN METAL BEING REACTIVE WITH CASTING SLAGS OF THE SILICATE TYPE AND PRODUCING WITH SILICATE TYPE SLAGS FLUID-MOLD INGOT CASINGS HAVING POOR SURFACE QUALITY, SAID CASING SLAG CONSISTING ESSENTIALLY OF ABOUT 40% TO ABOUT 45% ALUMINA, ABOUT 43% TO ABOUT 45% LIME, ABOUT 5% TO ABOUT 10% TITANIA, NOT MORE THAN ABOUT 1% MANAGENESE OXIDE, AND ABOUT 5% TO ABOUT 15% CRYOLITE.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US350603A US3224887A (en) | 1962-03-27 | 1964-03-09 | Slag composition for fluid mold casting |
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Application Number | Priority Date | Filing Date | Title |
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US182974A US3214806A (en) | 1962-03-27 | 1962-03-27 | Method for fluid mold casting using casting slag |
US350603A US3224887A (en) | 1962-03-27 | 1964-03-09 | Slag composition for fluid mold casting |
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US3333625A (en) * | 1964-11-19 | 1967-08-01 | Howard A Fromson | Method of casting fusible materials |
US3444010A (en) * | 1966-10-03 | 1969-05-13 | Int Nickel Co | Fluid-mold casting slag |
US3598170A (en) * | 1968-09-19 | 1971-08-10 | Int Nickel Co | Fluid-mold casting process |
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US2882568A (en) * | 1954-10-12 | 1959-04-21 | Int Nickel Co | Lining for ingot molds |
US2912729A (en) * | 1956-07-24 | 1959-11-17 | John M Webb | Refractory molds |
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US1912815A (en) * | 1931-07-22 | 1933-06-06 | Witty George | Slag cement |
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Publication number | Priority date | Publication date | Assignee | Title |
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US3333625A (en) * | 1964-11-19 | 1967-08-01 | Howard A Fromson | Method of casting fusible materials |
US3444010A (en) * | 1966-10-03 | 1969-05-13 | Int Nickel Co | Fluid-mold casting slag |
US3598170A (en) * | 1968-09-19 | 1971-08-10 | Int Nickel Co | Fluid-mold casting process |
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