US3321007A - Method of cooling continuous cast metal in the mold - Google Patents

Method of cooling continuous cast metal in the mold Download PDF

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Publication number
US3321007A
US3321007A US543644A US54364466A US3321007A US 3321007 A US3321007 A US 3321007A US 543644 A US543644 A US 543644A US 54364466 A US54364466 A US 54364466A US 3321007 A US3321007 A US 3321007A
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United States
Prior art keywords
mold
molten metal
temperature
cooling
heat
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Expired - Lifetime
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US543644A
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English (en)
Inventor
Daniel B Cofer
Thomas L Bray
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Southwire Co LLC
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Southwire Co LLC
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Filing date
Publication date
Priority to NL134109D priority Critical patent/NL134109C/xx
Application filed by Southwire Co LLC filed Critical Southwire Co LLC
Priority to US543644A priority patent/US3321007A/en
Priority to GB9366/67A priority patent/GB1157218A/en
Priority to NL6705460A priority patent/NL6705460A/xx
Application granted granted Critical
Publication of US3321007A publication Critical patent/US3321007A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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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
    • B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
    • B22D11/0637—Accessories therefor
    • B22D11/068—Accessories therefor for cooling the cast product during its passage through the mould surfaces

Definitions

  • This invention relates to the casting of molten metals and more particularly, to the continuous casting of a molten metal in a shape which provides a small surface area relative to the mass of molten metal to be cooled during casting and where the continuous casting mold is exposed to cyclic temperature conditions.
  • the continuous casting mold which is substantially closed and in which molten metal is solidified to obtain cast metal as the molten metal passes through or travels with the mold.
  • the continuous casting mold may be formed by continuously travelling Walls, by a combination of continuously travelling and stationary elements, or simply by a stationary tube from which cast metal passes after solidification of the molten metal.
  • the solidification of molten metal to obtain cast metal is accomplished by the transfer of heat from the molten metal to or through the mold which is itself frequently cooled by the subsequent transfer of heat to a fluid medium such as water or air.
  • a difiiculty with using a material having a high rate of heat transfer for a continuous casting mold is that such materials frequently have relatively poor structural strength.
  • many continuous casting molds such as casting wheels are exposed to cyclic temperature conditions as molten metal is repeatedly received and cooled, and the relatively large temperature fluctuations which generally occur throughout most materials having a high rate of heat transfer with exposure to these cyclic temperature conditions cause excessive thermal fatigue in such molds.
  • the useful life of a continuous casting mold constructed of a material having a high rate of heat transfer has characteristically been relatively short because of the formation of large thermal cracks in the mold and often because of the complete structural failice ure of the mold.
  • the poor structural strength and thermal fatigue encountered in the prior art have frequently resulted in thermal ratcheting and the partial closing of the casting groove.
  • the non-uniform cooling of the molten metal which is characteristic of prior art continuous casting molds constructed of materials having a high rate of heat transfer also results in the early forming of only partially solidified molten metal while substantial heat remains in the central portion of the molten metal. Since the partially solidified molten metal occupies less space in the mold than that occupied by the molten metal initially, a gap is formed between the mold and some of the perip-h eral portions of the partially solidified molten which retards the continued cooling of the molten metal by contact between the molten metal and the mold.
  • this reduc tion in the cooling efficiency of the mold while there is still substantial heat in the central portion of the molten metal causes a reheating of the previously solidified peripheral portions of the molten metal by heat transferred from the central portion to these peripheral portions.
  • This causes a partial melting of the peripheral portions of the partially solidified molten metal and the previously formed gap to be in whole or in part eliminated.
  • there is a second rapid cooling of the peripheral portions of the molten metal which further contributes to the non-uniform cooling of the molten metal and may even cause a second chilling of the peripheral portions of the molten metal.
  • the invention disclosed herein overcomes these and other difficulties encountered in the prior art in that it provides for the continuous casting of metal under cyclic temperature conditions at efficient casting rates with substantially uniform cooling of all portions of the molten metal and without significant chilling of any portion of the molten metal even though the surface of the molten metal is small relative to the mass of molten metal to be cooled.
  • the invention provides cast metal which has little tendency to crack or fail mechanically.
  • the invention provides a continuous casting mold .3 which has a relatively long useful life because of its initial structural strength and because of the small amount of thermal fatigue and the lack of thermal ratcheting in the mold even though the mold is exposed to cyclic temperature conditions.
  • the rate of heat transfer is such that that portion of the mold adjacent the molten metal increases rapidly in temperature to a temperature which substantially slows the initial cooling of the molten metal by the mold and is such that the mold nevertheless transfers heat from the molten metal to a cooling medium.
  • the rate of temperature transfer of the mold is such that the increase in temperature when the mold initially receives the molten metal and other extreme temperature changes are restricted to that portion of the mold adjacent the molten metal.
  • the slowing of the initial cooling of the molten metal prevents the rapid initial solidification of the peripheral portions of the molten metal.
  • the invention provides for substantially uniform cooling of all portions of the molten metal.
  • the substantially uniform cooling of the molten metal has educed the heat in the central portion of the molten metal to a degree which avoids that substantial reheating of the peripheral portions of the molten metal which is frequently encountered in the prior art.
  • the rate at which heat is nevertheless transferred from the molten metal to a coolant by the mold results in the complete solidification of the molten metal at casting rates equivalent to those achieved in the prior art.
  • the mold is a casting wheel or other mold arrangement which is exposed to the cyclic temperature conditions of repeatedly receiving and cooling molten metal
  • the restricting of extreme temperature changes to that portion of the mold adjacent the molten metal prevents those extreme fiuctuations in temperature throughout the mold which cause substantial thermal fatigue.
  • FIG. 1 is a side elevational View of a continuous casting machine of a type in which the invention disclosed herein may be readily embodied;
  • FIG. 2 is a partial sectional view of the continuous casting machine shown in FIG. 1 taken substantially in line 2-2 in FIG. 1;
  • FIG. 3 is a schematic presentation of solidification of molten metal in the casting machine of FIG. 1 in accordance with the invention showing the solidifying molten metal at the four points indicated in FIG. 1;
  • FIG. 4 is a schematic presentation of the solidification of molten metal in a casting machine similar to that of FIG. 1 in accordance with the prior art showing the solidifying molten metal at the four points indicated in FIG. 1;
  • FIG. 5 is a schematic presentation of temperature gradients between the casting cavity and the coolant in the casting machine of FIG. 1 when molten metal is solidified in accordance with the invention and shows a temperature gradient before molten metal is received in the mold and a temperature gradient substantially immediately after molten metal is received in the mold;
  • FIG. 6 is a schematic presentation of temperature gradients between the casting cavity and the coolant in a casting machine similar to that shown in FIG. 1 when molten metal is solidified in accordance with the prior art and shows a temperature gradient before molten metal is received in the mold and a temperature gradient substantially immediately after molten metal is received in the mold.
  • the invention in the continuous casting of metals disclosed herein may be most easily understood in terms of a continuous casting machine it) such as that shown in FIG. 1.
  • the continuous casting machine 10 shown in FIG. 1 is representative of many mold arrangements which substantially enclose molten metal as it is solidified to obtain cast metal and with which efficient casting rates can be obtained only by relatively rapid solidification of the molten metal.
  • the continuous casting machine 10 is representative of those casting machines which have been used in the prior art for casting of a bar 30 or other shape having a small surface relative to the mass of molten metal to be cooled during casting and which are exposed to cyclic temperature conditions as it continuously receives molten metal to be cooled and removed as cast metal.
  • the continuous casting machine 10 selected to illustrate an embodiment of the invention comprises a casting wheel 11 rotably mounted on a support member (not shown) for rotation by a motor (not shown) or other power source.
  • a motor not shown
  • Rotatably carried by the support member (not shown) on opposite sides of and adjacent the casting wheel 11 are two idler pulleys 14 and 15. These idler pulleys 14 and 15 cooperate with an idler pulley 16 carried by the support member (not shown) below the casting wheel 11 to support a continuous belt 17 which engages the lower periphery of the casting Wheel 11 between the idler pulley 14 and the idler pulley 15.
  • the casting wheel 11 has a peripheral groove 18 which is closed by the belt 17 and provides mold members or walls 20 which cooperate with the belt 17 to define a continuous casting mold M with a casting cavity V into one end of which molten metal 21 is poured from a crucible 22 and from the other end of which completely solidified molten metal passes as a bar 30.
  • the mold M is cooled by the passage of coolant 23 in three channels 24 adjacent the walls 20 and by the spraying of coolant 23 on the belt 17 with nozzles 27 extending from an arcuate duct 28.
  • the coolant 23 is fed to the three channels 24 and to the arcuate duct 28 from a coolant supply (not shown) and that after passing through the channels 24 and over the belt 17, the coolant 23 is either discharged from the system or recirculated.
  • the cooling arrangement described provides an effective means for removing heat from the mold M by the transfer of heat from the mold M to the coolant 23. More importantly, it will be understood by those skilled in the art that in a continuous casting mold such as the mold M having an effective cooling arrangement, the removal of heat from the molten metal 21 for solidification of the molten metal 21 is primarily determined by the transfer of heat between the molten metal 21 and the mold M and by the transfer of heat between the mold M and the coolant 23.
  • the continuous casting machine used herein for the purpose of illustrating the invention is a conventional casting machine to the extent that the solidifying of the molten metal 21 is a function of the heat trans ferred between the molten metal 21 and the mold M and of the heat transferred between the mold M and the coolant 23. It is for this reason and because the structural arrangement of the continuous casting machine 10 in general resembles prior art casting machines that the structural arrangement of the continuous casting machine 10 is not described in greater detail.
  • both the belt 17 and that portion of the casting wheel 11 forming the mold M between the coolant 23 and the molten metal 21 are formed of a material having a rate of heat transfer which results in that portion of the mold M adjacent the molten metal rapidly increasing in temperature to a temperature which substantially retards the cooling of the molten metal immediately after the molten metal 21 is poured from the crucible 22 into the casting cavity V while at the same time providing for the transfer of heat from the molten metal 21 to the coolant 23 and having a rate of temperature transfer which prevents the rapid transfer of this temperature increase throughout the mold M.
  • FIG. 3 schematically shows the progressive solidification of a segment of molten metal 21 in the mold M at various arbitrarily selected points a, b, c, and d during the rotation of the casting wheel 11.
  • FIG. 4 schematically shows the progressive solidification of the molten metal 21 in the mold M at the same arbitrarily selected points during the rotation of the casting wheel 11.
  • FIGS. 3 and 4 schematically show the solidification of molten metal 21 at corresponding points in its passage through a mold M and a mold M with rotation of the casting wheel 11.
  • FIGS. 3 and 4 are merely representative of the solidification of the molten metal 21 and that they are not intended to show the acutal state or degree of solidification of molten metal 21 at any specific point in its passage through a mold M or M.
  • the prior art mold M is constructed of a material having a high rate of heat transfer, the initial heat transferred to the mold M from the molten metal 21 passes almost as rapidly through the mold M to the coolant 23 as it is received from the molten metal 21 and the transfer of heat from the molten metal 21 to the mold M continues at a rate of heat transfer which causes the peripheral portions P of the molten metal 21 to solidify rapidly.
  • the peripheral portions P of the molten metal 21 are quickly cooled by the mold M and before there has been a significant transfer of heat from the central portion C of the molten metal 21 to these peripheral portions P.
  • there is a substantially non-uniform cooling of the molten metal 21 which adversely affects the properties of the cast bar 30.
  • the cooling of the peripheral portions P is so excessive as to cause chilling of the peripheral portions P of the molten metal 21 which further adversely affects the properties of the bar 3 11.
  • the mold M retards the rapid cooling of the peripheral portion P of the molten metal 21 before there is excessive cooling of the peripheral portions P of the molten metal 21 and the gap G is formed.
  • the relatively low rate of heat transfer of the material from which the mold M is formed causes a susbtantial amount of the heat initially transferred from the molten metal 21 to the mold M to be retained by the portion S of the mold M adjacent the molten metal 21 so as to cause a rapid and substantial increase in the temperature of the portion S of the mold M to a temperature which substantially reduces the temperature difference between the molten metal 21 and the mold M.
  • the transfer of heat from the molten metal 21 to the mold M is retarded before excessive cooling of the peripheral portions P of the molten metal 21 and sufiicient solidification of the molten metal 21 to form the gap G occur.
  • the material from which the mold M is constructed has a rate of heat transfer which provides for the heat from the molten metal 21 to be continuously transferred through the mold M to the coolant 23 at a rate which results in the heat transferred to the coolant 23 alone or the heat transferred to the coolant 7 23 and the heat retained in the portion S of the mold M together being equal to that amount of heat which must be removed from the molten metal 21 in order to completely solidify the molten metal 21 in a predetermined interval of time.
  • the invention provides controlled cooling of the molten metal 21 in a manner which causes the heat transferred from the peripheral portions P of the molten metal 21 to the mold M subsequent to the initial heat transferred to the portion S to not substantially exceed the heat transferred from the central portion C of the molten metal 21 to the peripheral portions P.
  • substantially uniform cooling of the molten metal 21 occurs until that point in the solidification of the molten metal 21 indicated in FIG. 3c is reached at which the gap G is formed between the molten metal 21 and the mold M because of the solidification of the molten metal 21.
  • the forming of the gap G in the mold M further retards the transfer of heat from the molten metal 21 to the mold M because it reduces the contact between the molten metal 21 and the mold M.
  • the gap G is formed later and after a longer period of substantially uniform cooling.
  • the cooling and solidification of the molten metal 21 continues in a substantially uniform manner without that non-uniform cooling or chilling of the peripheral portions P of the molten metal 21 which is frequently encountered in the prior art because of the heat remaining in the central portion C of the molten metal 21 when the gap G is formed.
  • the mold M is both a means for retaining heat adjacent the molten metal 21 to provide an initial temperature increase which prevents too rapid initial cooling of the molten metal 21 and a means for transferring heat from the molten metal 21 to a coolant 23. It will also be understood that the solidification of the molten metal 21 to obtain the cast bar between the points a and d in FIG. 1 requires the transfer from the molten metal 21 to the mold M of a particular amount of heat between the points a and d and that the casting rate is dependent upon the length of time required to transfer this particular amount of heat from the molten metal 21 to the mold M.
  • the length of time required to transfer this particular amount of heat from the molten metal 21 to the mold M or M is dependent not only upon the rate at which heat is transferred by the material of the mold M or the mold M and the degree of cooling provided by the coolant 23 but also upon the distance through the mold M or M between the molten metal 21 and the coolant 23. It is because of this and because many materials having a relatively low rate of heat transfer also have great structural strength that the mold M provides casting rates equivalent to those achieved in the prior art by simply reducing the distance through the mold M between the molten metal 21 and the coolant 23 to a degree not possible with prior art materials without seriously impairing the strength of the mold M.
  • the mold M unlike the mold M, initially retains a substantial amount of heat to provide a temperature of the portion S of the mold M which retards the cooling of the molten metal 21, the total amount of heat transferred to the mold M from the molten metal 21 between the points a and d in FIG. 1 is the sum of the amount of heat initially retained in the portion S of the mold M which remains in the mold M at point d and of the heat transferred by the mold M to the coolant 23 between the points a and d in FIG. 1.
  • the mold M will also provide casting rates equivalent to those of prior art mold M even if the distance between the molten metal 21 and the coolant 23 is the same in the mold M and the mold M by allowing some or most of the amount of heat initially retained in the portion S of the mold to remain in the mold M at point d in FIG. 1 and by removing this heat from the mold between points d and a with the coolant 23 in the channels 24 while the mold M is empty.
  • the cooling of the molten metal 21 by the mold M is a function both of the cooling between the points a and d in FIG. 1 by the coolant 2'3 and of the amount of heat retained by the portion S of the mold M at point at in FIG. 1 that the mold M provides convenient control of casting rates.
  • the cooling of molten metal 21 between the points a and V d in FIG. 1 in a particular length of time can be varied by varying the cooling of the mold M between points a and d, by varying the temperature of the mold M just prior to point a in FIG. 1 so as to vary the amount of heat initially transferred to and retained by the portion S of the mold M, or by varying the amount of the heat retained by the portion S of the mold M at the point d in FIG. 1 and which is removed between points at and a.
  • FIG. 5 it will be seen that in a mold M having a. relatively low rate of temperature transfer, the substantial change in the temperature of the portion S of the mold M which retards the cooling of the molten metal 21 and which occurs because of the relatively low rate of heat transfer does not pass through the mold M because of the relatively low rate of temperature transfer.
  • both the mold M and M are used to cast molten copper at the same temperature A as shown in FIGS. 5 and 6 and that both the mold M and the mold M are at approximately the same temperature B as shown in FIGS. 5 and 6 just prior to point a in FIG.
  • the mold M provides a temperature difference between the temperature C of the mold M and the temperature A of the molten metal 21 which is substantially less than the temperature diiference between the temperature C of the mold M and the temperature A of the molten metal 21 but which nevertheless is sufficiently large for the cooling of the molten metal 21 to be achieved. It is this relatively small temperature difference between the temperature C of the mold M and the temperature A of the molten metal 21 which retards the cooling of the peripheral portions P of the molten metal 21 in the mold M and it is the relatively large temperature difference between the temperature C of the mold M and the temperature A of the molten metal 21 which causes the excessive and nonuniform cooling of the molten metal 21 in the mold M.
  • a method of continuously casting a molten metal in a mold defined by the peripheral groove of a casting wheel the steps of pouring molten metal at a first temperature into a mold having a second temperature substantially less than said first temperature, initially cooling said molten metal by a transfer of heat from said molten metal to said mold while substantially simultaneously increasing the temperature of said mold to a third temperature which is greater than said second temperature but less than said first temperature by retaining in said mold adjacent said molten metal substantially all of the heat transferred from said molten metal to said mold during initial cooling of said molten metal and so as to retard initial cooling of said molten metal, subsequently cooling said molten metal until it is substantially solidified into a cast metal, removing said cast metal from said mold, and cooling said mold to said second temperature, all of said steps being cyclic and being repeated a plurality of times during the continuous casting of a molten metal.
  • step of cooling said mold includes cooling said mold during the steps of initially cooling said molten metal and subsequently cooling said molten metal.
  • step of increasing the temperature of said mold includes transferring heat from said mold adjacent said molten metal to a coolant at that rate of heat transfer which is provided by low carbon steel.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Continuous Casting (AREA)
US543644A 1966-04-19 1966-04-19 Method of cooling continuous cast metal in the mold Expired - Lifetime US3321007A (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
NL134109D NL134109C (enrdf_load_stackoverflow) 1966-04-19
US543644A US3321007A (en) 1966-04-19 1966-04-19 Method of cooling continuous cast metal in the mold
GB9366/67A GB1157218A (en) 1966-04-19 1967-02-28 Improvements in and relating to the Continuous Casting of Molten Metal
NL6705460A NL6705460A (enrdf_load_stackoverflow) 1966-04-19 1967-04-18

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US543644A US3321007A (en) 1966-04-19 1966-04-19 Method of cooling continuous cast metal in the mold

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US3321007A true US3321007A (en) 1967-05-23

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US (1) US3321007A (enrdf_load_stackoverflow)
GB (1) GB1157218A (enrdf_load_stackoverflow)
NL (2) NL6705460A (enrdf_load_stackoverflow)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3646772A (en) * 1967-09-22 1972-03-07 Nippon Steel Corp Method of cooling molds
US3670799A (en) * 1971-01-14 1972-06-20 Essex International Inc Method and apparatus for siphoning molten metal to a continuous casting machine
US4082136A (en) * 1976-11-15 1978-04-04 Southwire Company Casting machine with translatable band
US4204568A (en) * 1976-11-15 1980-05-27 Southwire Company Method of prolonging the life of a rotary casting machine band
CN102513387A (zh) * 2012-01-02 2012-06-27 成都蜀虹机械设备有限公司 用于钢材连铸连轧的轮带旋转喷淋冷却工艺方法及其装置

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IN153591B (enrdf_load_stackoverflow) * 1979-01-24 1984-07-28 Southwire Co

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2242350A (en) * 1938-10-06 1941-05-20 Continuous Casting Corp Continuous casting of metal shapes
US2281718A (en) * 1938-08-05 1942-05-05 John T Scully Method of casting metal ingots and apparatus therefor
US2393213A (en) * 1943-02-27 1946-01-15 Willard Storage Battery Co Casting machine
US2838814A (en) * 1956-01-19 1958-06-17 Joseph B Brennan Method and apparatus for casting
US2956320A (en) * 1955-12-28 1960-10-18 Olin Mathieson Casting of metal
US2983972A (en) * 1960-11-17 1961-05-16 Reynolds Metals Co Metal casting system

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2281718A (en) * 1938-08-05 1942-05-05 John T Scully Method of casting metal ingots and apparatus therefor
US2242350A (en) * 1938-10-06 1941-05-20 Continuous Casting Corp Continuous casting of metal shapes
US2393213A (en) * 1943-02-27 1946-01-15 Willard Storage Battery Co Casting machine
US2956320A (en) * 1955-12-28 1960-10-18 Olin Mathieson Casting of metal
US2838814A (en) * 1956-01-19 1958-06-17 Joseph B Brennan Method and apparatus for casting
US2983972A (en) * 1960-11-17 1961-05-16 Reynolds Metals Co Metal casting system

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3646772A (en) * 1967-09-22 1972-03-07 Nippon Steel Corp Method of cooling molds
US3670799A (en) * 1971-01-14 1972-06-20 Essex International Inc Method and apparatus for siphoning molten metal to a continuous casting machine
US4082136A (en) * 1976-11-15 1978-04-04 Southwire Company Casting machine with translatable band
US4204568A (en) * 1976-11-15 1980-05-27 Southwire Company Method of prolonging the life of a rotary casting machine band
CN102513387A (zh) * 2012-01-02 2012-06-27 成都蜀虹机械设备有限公司 用于钢材连铸连轧的轮带旋转喷淋冷却工艺方法及其装置

Also Published As

Publication number Publication date
NL134109C (enrdf_load_stackoverflow)
GB1157218A (en) 1969-07-02
NL6705460A (enrdf_load_stackoverflow) 1967-10-20

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