US3373794A - Ferroalloy casting process - Google Patents

Ferroalloy casting process Download PDF

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Publication number
US3373794A
US3373794A US524139A US52413966A US3373794A US 3373794 A US3373794 A US 3373794A US 524139 A US524139 A US 524139A US 52413966 A US52413966 A US 52413966A US 3373794 A US3373794 A US 3373794A
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chill
magnesium
casting
ferrosilicon
magnesium ferrosilicon
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Expired - Lifetime
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US524139A
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Richard A Crago
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Elkem Metals Co LP
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Union Carbide Corp
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Priority to US524139A priority Critical patent/US3373794A/en
Priority to NO166581A priority patent/NO120649B/no
Priority to JP42006273A priority patent/JPS5138645B1/ja
Priority to DEU13514A priority patent/DE1299802B/en
Priority to FR93357A priority patent/FR1509815A/en
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Assigned to ELKEM METALS COMPANY, A NEW YORK GENERAL PARTNERSHIP reassignment ELKEM METALS COMPANY, A NEW YORK GENERAL PARTNERSHIP ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: UNION CARBIDE CORPORATION, A NY CORP.
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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
    • B22D3/00—Pig or like casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002—Castings of light metals
    • B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product

Definitions

  • the present invention relates to the casting of alloys. More particularly the present invention relates to the casting of magnesium ferrosilicon.
  • magnesium ferrosilicon for use as an addition agent to pour the molten alloy into large open chills up to about five to six inches deep and about five feet by five feet in section.
  • the cast metal was permitted to air-cool and the solid product was then subjected to crushing to obtain a suitable industrially sized product of say 1% inches by inch.
  • FIGURE 1 shows, in elevation and somewhat schematically, apparatus for the practice of this invention
  • FIGURE 2 shows a modification of the apparatus of FIGURE 1
  • FIGURE 3 shows the plan view of the apparatus of FIGURE 2.
  • a process in accordance with the present invention comprises preparing molten magnesium ferrosilicon; pouring the molten magnesium ferrosilicon into a chill; providing a metal member in contact with the upper surface of the molten magnesium ferrosilicon; causing the molten magnesium ferrosilicon to solidify in the chill in contact with said metal member; removing the metal member after solidification of the magnesium ferrosilicon and removing the solidified magnesium ferrosilicon from the chill.
  • FIGURE 1 shows at 1 a conventional chill for casting magnesium ferrosilicon.
  • the chill for example can be made of cast iron 3,373,794 Patented Mar. 19, 1968 with a base about 4-6 inches thick and side walls about 5-10 inches in height tapering in width from 6 inches to 4 inches.
  • molten magnesium ferrosilicon is prepared by any suitable technique. For example, magnesium can be plunged into molten ferrosilicon alloy to give a desired magnesium content e.g. about 9%.
  • the metal 3 is poured into the chill 1 which is provided with a removable metal cover 5, which can be a steel billet about 4-6 inches thick or more and which is conveniently supported on steel mill balls 7.
  • a relatively small opening between the chill and the billet is provided at 9 for the entry of the molten metal which as shown is in an amount sufiicient to contact the metal member 5 and be substantially covered thereby.
  • metal cover member 5 by inclining metal cover member 5 slightly to the horizontal, the dross, i.e. low density impurities which are usually present, separate at the small exposed surface of the molten metal and surface contamination of the magnesium ferrosilicon is avoided.
  • the molten metal cast into the chill as aforedescribed freezes and solidifies, the solidification progressing concurrently from both the top and bottom of the chill, with the result that the magnesium segregation characteristic of castings prepared by prior methods is avoided. That is to say that the condition of high magnesium material i.e. 12-15% at the top of the casting, 4-7% at the bottom, is avoided by causing concurrent freezing of the casting at the top and bottom thus preventing separation of the lower melting and lower density magnesium sili con phase.
  • the covering metal member prevents contact with the air, but magnesium distribution is highly uniform from top to bottom in the casting.
  • the casting can be easily removed from the chill and readily crushed to industrially suitable size, in the course of which the supporting steel balls are recovered, and since there is practically no oxide formation on the casting, cleaning of the material is unnecessary.
  • FIGS 2 and 3 show different views of a modification of the apparatus of FIG- URE 1, it can be seen that the use of steel balls for supporting the removable chill cover 5 can be eliminated by using suspension bars 13 in the manner indicated.
  • FIG- URES 2 and 3 also show that the small exposed area of the casting can be further decreased by providing a pouring hole 15 in the removable cover and dimensioning the cover so that it closely fits the chill.
  • Example I Molten magnesium ferrosilicon containing 9% magnesium was prepared and at a temperature of about 1250 C. was cast into a chill.
  • the chill was similar to that shown in the drawing having a base thickness of 6 inches.
  • a steel billet 5 x 5' x 6" was suspended over the chill also as shown in the drawing and was arranged with its lower surface about 5 inches from the bottom of the chill.
  • the molten magnesium ferrosilicon poured into the chill was in contact with the steel billet at its upper surface and was substantially covered. After solidification of the metal in the chill, the casting, 5 inches thick, was removed and examined. There was no oxide on the surface of the casting and analysis showed the following magnesium analysis:
  • Example ll ysis of the casting after removing the oxide layer showed the following:
  • the present invention provides a simple and effective way to obtain higher recoveries of magnesium in magnesium ferrosilicon castings and also provides castings having an improved magnesium distribution, thus constituting a significant industrial advance in the art.
  • a process for casting magnesium ferrosilicon which comprises preparing molten magnesium ferrosilicon, pouring the molten magnesium ferrosilicon into a chill, providing a metal member in contact with the upper surface of the molten magnesium ferrosilicon in the chill, said metal member substantially covering the upper surface of the molten magnesium ferrosilicon, causing the molten magnesium fer-rosilicon to solidify in the chill in contact with said metal member, removing the metal member after solidification of the magnesium ferrosilicon and removing the solidified magnesium ferrosilicon from the chill.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)
  • Manufacture And Refinement Of Metals (AREA)

Description

Filed Feb. 1, 1966 Mill Balls Lifr Back of Chill Suspenswn Bars Walla:
Pour
Exposed Surface Dross Area M Y n M .w W m m S n H M. W K Y 1 5 R B 8 l 7 United States Patent 3,373,794 FERROALLOY CASTING PROCESS Richard A. Crago, Grand Island, N.Y., assignor to Union Carbide Corporation, a corporation of New York Filed Feb. 1, 196 6, Ser. No. 524,139
2 Claims. (Cl. 164-127) The present invention relates to the casting of alloys. More particularly the present invention relates to the casting of magnesium ferrosilicon.
In the past, ithas been the usual practice in making magnesium ferrosilicon for use as an addition agent to pour the molten alloy into large open chills up to about five to six inches deep and about five feet by five feet in section. The cast metal was permitted to air-cool and the solid product was then subjected to crushing to obtain a suitable industrially sized product of say 1% inches by inch.
There are several drawbacks to this prior process for example since a large portion of the molten metal was exposed to air while cooling in the chill a substantial layer of objectionable magnesium oxide was formed which had to be removed before sale and use of the product and this led to a significant loss of magnesium. Further, the segregation of magnesium is severe and in the usual product the magnesium for a nominal 9% Mg alloy would range from 12-15% at the top of the casting to 4-7% at the lower part of the casting. This situation is economically disadvantageous since, after the alloy is crushed to size, to be on the safe side, the user frequently assumes that the magnesium content of the particulated alloy is less than the nominal value.
It is therefore an object of the present invention to provide a process for casting magnesium ferrosilicon whereby the loss of magnesium due to oxidation can be avoided.
It is a further object of the present invention to provide a process for casting magnesium ferrosilicon whereby improved uniformity of magnesium distribution is obtained.
Other objects will be apparent from the following description and claims taken in conjunction with the drawing in which:
FIGURE 1 shows, in elevation and somewhat schematically, apparatus for the practice of this invention,
FIGURE 2 shows a modification of the apparatus of FIGURE 1, and
FIGURE 3 shows the plan view of the apparatus of FIGURE 2.
A process in accordance with the present invention comprises preparing molten magnesium ferrosilicon; pouring the molten magnesium ferrosilicon into a chill; providing a metal member in contact with the upper surface of the molten magnesium ferrosilicon; causing the molten magnesium ferrosilicon to solidify in the chill in contact with said metal member; removing the metal member after solidification of the magnesium ferrosilicon and removing the solidified magnesium ferrosilicon from the chill.
The following Table I shows the composition of magnesium ferrosilicon alloys which can be advantageously cast in accordance with the present invention:
The present invention will be more clearly understood by reference to the drawing which in FIGURE 1 shows at 1 a conventional chill for casting magnesium ferrosilicon. The chill for example can be made of cast iron 3,373,794 Patented Mar. 19, 1968 with a base about 4-6 inches thick and side walls about 5-10 inches in height tapering in width from 6 inches to 4 inches. In practicing the invention molten magnesium ferrosilicon is prepared by any suitable technique. For example, magnesium can be plunged into molten ferrosilicon alloy to give a desired magnesium content e.g. about 9%. With the molten magnesium ferrosilicon in the temperature range of about 1225 to 1300 C., the metal 3 is poured into the chill 1 which is provided with a removable metal cover 5, which can be a steel billet about 4-6 inches thick or more and which is conveniently supported on steel mill balls 7. A relatively small opening between the chill and the billet is provided at 9 for the entry of the molten metal which as shown is in an amount sufiicient to contact the metal member 5 and be substantially covered thereby. As illustrated in the drawing, by inclining metal cover member 5 slightly to the horizontal, the dross, i.e. low density impurities which are usually present, separate at the small exposed surface of the molten metal and surface contamination of the magnesium ferrosilicon is avoided.
The molten metal cast into the chill as aforedescribed freezes and solidifies, the solidification progressing concurrently from both the top and bottom of the chill, with the result that the magnesium segregation characteristic of castings prepared by prior methods is avoided. That is to say that the condition of high magnesium material i.e. 12-15% at the top of the casting, 4-7% at the bottom, is avoided by causing concurrent freezing of the casting at the top and bottom thus preventing separation of the lower melting and lower density magnesium sili con phase. As a result of this casting process, not only is magnesium loss eliminated since the covering metal member prevents contact with the air, but magnesium distribution is highly uniform from top to bottom in the casting.
Furthermore, upon lifting metal member 5 by way of ring 11, the casting can be easily removed from the chill and readily crushed to industrially suitable size, in the course of which the supporting steel balls are recovered, and since there is practically no oxide formation on the casting, cleaning of the material is unnecessary.
With reference to FIGURES 2 and 3 which show different views of a modification of the apparatus of FIG- URE 1, it can be seen that the use of steel balls for supporting the removable chill cover 5 can be eliminated by using suspension bars 13 in the manner indicated. FIG- URES 2 and 3 also show that the small exposed area of the casting can be further decreased by providing a pouring hole 15 in the removable cover and dimensioning the cover so that it closely fits the chill.
The following examples will further illustrate the present invention.
Example I Molten magnesium ferrosilicon containing 9% magnesium was prepared and at a temperature of about 1250 C. was cast into a chill. The chill was similar to that shown in the drawing having a base thickness of 6 inches. A steel billet 5 x 5' x 6" was suspended over the chill also as shown in the drawing and was arranged with its lower surface about 5 inches from the bottom of the chill. The molten magnesium ferrosilicon poured into the chill was in contact with the steel billet at its upper surface and was substantially covered. After solidification of the metal in the chill, the casting, 5 inches thick, was removed and examined. There was no oxide on the surface of the casting and analysis showed the following magnesium analysis:
Percent mg. Top of casting 10.99 Bottom of casting 8.47
Example ll ysis of the casting after removing the oxide layer showed the following:
Percent mg. Top of casting 12.06 Bottom of casting 4.94
From the foregoing description and examples it can be seen that the present invention provides a simple and effective way to obtain higher recoveries of magnesium in magnesium ferrosilicon castings and also provides castings having an improved magnesium distribution, thus constituting a significant industrial advance in the art.
What is claimed is:
1. A process for casting magnesium ferrosilicon which comprises preparing molten magnesium ferrosilicon, pouring the molten magnesium ferrosilicon into a chill, providing a metal member in contact with the upper surface of the molten magnesium ferrosilicon in the chill, said metal member substantially covering the upper surface of the molten magnesium ferrosilicon, causing the molten magnesium fer-rosilicon to solidify in the chill in contact with said metal member, removing the metal member after solidification of the magnesium ferrosilicon and removing the solidified magnesium ferrosilicon from the chill.
2. A process in accordance with claim 1 wherein molten ferrosilicon is cast into a chill having a removable cover and wherein the molten metal is poured into the chill in an amount sufficient to make contact with the cover.
References Cited UNITED STATES PATENTS 1,484,076 2/ 1924 Perry 249--174 XR 1,491,881 4/1924 Perry 249-174 XR 1,494,021 5/1924 Robbins 164-47 1,716,833 6/1929 Rich 164125 XR FOREIGN PATENTS 516,533 1/ 1940 Great Britain. 833,609 7/1938 France.
43,818 3/ 1927 Norway.
J. SPENCER OVERHOLSER, Primary Examiner. VERNON KILBOURN RISING, Assistant Examiner.

Claims (1)

1. A PROCESS FOR CASTING MAGNESIUM FERROSILICON WHICH COMPRISES PREPARING MOLTEN MAGNESIUM FERROSILICON, POURING THE MOLTEN MAGNESIUM FERROSILICON INTO A CHILL, PRO VIDING A METAL MEMBER IN CONTACT WITH THE UPPER SURFACE OF THE MOLTEN MAGNESIUM FERROSILICON IN THE CHILL, SAID METAL MEMBER SUBSTANTIALLY COVERING THE UPPER SURFACE OF THE MOLTEN MAGNESIUM FERROSILICON, CAUSING THE MOLTEN MAGNESIUM FERROSILICON TO SOLIDIFY IN THE CHILL IN CONTACT WITH SAID METAL MEMBER, REMOVING THE METAL MEMBER AFTER SOLIDIFICATION OF THE MAGNESIUM FERROSILICON AND REMOVING THE SOLIDIFIED MAGNESIUM FERROSILICON FROM THE CHILL.
US524139A 1966-02-01 1966-02-01 Ferroalloy casting process Expired - Lifetime US3373794A (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
US524139A US3373794A (en) 1966-02-01 1966-02-01 Ferroalloy casting process
NO166581A NO120649B (en) 1966-02-01 1967-01-26
JP42006273A JPS5138645B1 (en) 1966-02-01 1967-01-31
DEU13514A DE1299802B (en) 1966-02-01 1967-01-31 Casting mold for ferrosilicon containing magnesium
FR93357A FR1509815A (en) 1966-02-01 1967-02-01 Casting process of ferro-silicon-magnesium alloys

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3433283A (en) * 1968-04-03 1969-03-18 Ohio Ferro Alloys Corp Method of reducing friability of ferro-alloys
US3483916A (en) * 1968-01-31 1969-12-16 Union Carbide Corp Ferro alloy casting process
US3604494A (en) * 1966-10-04 1971-09-14 Metallgesellschaft Ag Process for the production of composite ingots of magnesium containing prealloys

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA1070474A (en) * 1975-08-22 1980-01-29 Prem P. Mohla Nodularizing catalyst for cast iron and method of making same
JPS52140049U (en) * 1976-07-23 1977-10-24
JP6175345B2 (en) * 2013-10-19 2017-08-02 株式会社Ｊｆｓ貿易 Method for producing graphite spheroidizing agent

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1484076A (en) * 1920-10-26 1924-02-19 Valley Mould & Iron Corp Inverted horizontal ingot mold and process of casting
US1491881A (en) * 1920-10-21 1924-04-29 Valley Mould & Iron Corp Method, mold, and ingot
US1494021A (en) * 1920-04-08 1924-05-13 Robbins Lorin Roy Method of and apparatus for producing ingots
US1716833A (en) * 1926-03-06 1929-06-11 Riley Stoker Corp Method of casting
FR833609A (en) * 1937-06-25 1938-10-26 Cie Des Forges De Chatillon Method for locating sinkage in flat cast ingots
GB516533A (en) * 1937-06-25 1940-01-04 Cie Des Forges De Chatillon Co Process for restricting the piping hole in flat cast ingots

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1494021A (en) * 1920-04-08 1924-05-13 Robbins Lorin Roy Method of and apparatus for producing ingots
US1491881A (en) * 1920-10-21 1924-04-29 Valley Mould & Iron Corp Method, mold, and ingot
US1484076A (en) * 1920-10-26 1924-02-19 Valley Mould & Iron Corp Inverted horizontal ingot mold and process of casting
US1716833A (en) * 1926-03-06 1929-06-11 Riley Stoker Corp Method of casting
FR833609A (en) * 1937-06-25 1938-10-26 Cie Des Forges De Chatillon Method for locating sinkage in flat cast ingots
GB516533A (en) * 1937-06-25 1940-01-04 Cie Des Forges De Chatillon Co Process for restricting the piping hole in flat cast ingots

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3604494A (en) * 1966-10-04 1971-09-14 Metallgesellschaft Ag Process for the production of composite ingots of magnesium containing prealloys
US3483916A (en) * 1968-01-31 1969-12-16 Union Carbide Corp Ferro alloy casting process
US3433283A (en) * 1968-04-03 1969-03-18 Ohio Ferro Alloys Corp Method of reducing friability of ferro-alloys

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DE1299802B (en) 1969-07-24
NO120649B (en) 1970-11-16
JPS5138645B1 (en) 1976-10-22
FR1509815A (en) 1968-01-12

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Owner name: ELKEM METALS COMPANY, 270 PARK AVENUE, NEW YORK, N

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