US3444010A - Fluid-mold casting slag - Google Patents

Fluid-mold casting slag Download PDF

Info

Publication number
US3444010A
US3444010A US583911A US3444010DA US3444010A US 3444010 A US3444010 A US 3444010A US 583911 A US583911 A US 583911A US 3444010D A US3444010D A US 3444010DA US 3444010 A US3444010 A US 3444010A
Authority
US
United States
Prior art keywords
slag
nickel
ingot
fluid
mold
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
Application number
US583911A
Other languages
English (en)
Inventor
James E Roberts
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Huntington Alloys Corp
Original Assignee
International Nickel Co Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by International Nickel Co Inc filed Critical International Nickel Co Inc
Application granted granted Critical
Publication of US3444010A publication Critical patent/US3444010A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Images

Classifications

    • 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 is directed to an improvement in the fluid-mold casting process to produce ingot castings made of nickel and nickel-containing alloys having improved surface and improved metallurgical quality and to a special casting slag composition for use in such a process.
  • the fluid-mold casting process has now been available to the art for a number of years and has been employed successfully in connection with the production of ingot castings made of a number of different metals.
  • a quantity of molten slag is placed at the bottom of an ingot mold and molten metal conditioned for the production of an ingot is teemed into the mold through the slag.
  • the slag advances upward on the surface of the metal and forms a thin coating on the ingot mold surface. The coating remains during the casting process and separates the ingot from the ingot mold.
  • Another object of the invention is to provide a fluidmold casting process applicable to nickel and nickel-containing alloys which provides improved ingot surface and improved metal yield upon hot rolling of the ingots, as well as improved metallurgical quality.
  • FIGURE 1 is a reproduction of a photograph depicting the surface of a inch square by 90 inch long nickel ingot produced in accordance with the concepts of the present invention.
  • FIGURE 2 is a reproduction of a photograph depicting the surface of a 20 inch square by 90 inch long nickelchromium-iron alloy ingot produced in accordance with the invention.
  • FIGURE 3 is a reproduction of a photograph of a hot rolled billet produced from an age hardenable nickelchromium alloy ingot cast in accordance with the invention which was hot rolled without any surface overhauling.
  • the present invention is directed to a casting slag composition consisting essentially of, by weight, about 2.0% to about 40% alumina, about to about 50% calcium oxide, with the alumina content not exceeding the calcium oxide content by more than 5 weight percent, about 5% to about 20% magnesium oxide, about 3% to about 10% sodium oxide, and about 10% to about of an alkaline earth fluoride ingredient from the group consisting of cryolite (Na AlF potassium aluminum fluoride (K AlF and fluorspar (CaF)
  • the casting slag composition contains about to about 50% calcium oxide, about 25% to about alumina, about 5% to about 15% magnesia, about 10% to about 30% of an alkaline earth fluoride from the group consisting of cryolite, potassium aluminum fluoride, calcium fluoride and about 3% to about 10% sodium oxide.
  • a preferred slag composition contains about 35% to about 40% calcium oxide, about 25% to about 40% alumina, about 5% to about 8% magnesia, about 10% to about 20% cryolite, about 5% to about 10% fluorspar and about 3% to about 6% sodium oxide.
  • the slags produced in accordance with the invention have a flow point on heating in the tem perature range of about 2300 F. to about 2450 F.
  • the special slag compositions are essentially devoid of silica and titania, although, in some instances, for example, those in which minor pick-up of silicon is permissible, up to about 3% silica may be present. Titania should not exceed about 0.5%, by weight, e.g., 0.1% or 0.2%.
  • Metal oxides such as manganese oxide, chromium oxide, nickel oxide and copper oxide are preferably absent but may be in some cases present in amounts up to about 1% each. Impurities harmful to nickel and nickel alloys, including arsenic, lead, tin, zinc, sulfur, etc., should be absent from the slag. For purposes of controlling the flow point on heating the slag to be in the advantageous neighborhood of 2300 F. to about 2450 F. in the case of nickel and nickel-containing alloys, including nickel-chromium, nickel-chrom'ium-iron, nickel-copper alloys, cupronickel alloys, etc., the ingredients for forming the slag are carefully proportioned.
  • the bulk of the slag composition comprises calcium oxide and alumina with the alumina being present in amounts not exceeding the calcium oxide by more than weight percent.
  • Magnesia and sodium oxide in the controlled amounts specified hereinbefore assist in controlling the melting point. Magnesia is employed in amounts not exceeding 20% and preferably not exceeding about since greater amounts undesirably raise the slag melting point.
  • the fluoride ingredients namely, cryolite, potassium aluminum fluoride and fluorspar, are employed in the amounts described for purposes of pared in a submerged electrode furnace and was heated to about 3100 F. inch by 20 inch square ingot molds were set up on copper stools. About 250 pounds of the molten casting slag was poured into the bottom of the first ingot mold.
  • Nickel from the induction furnace heat was teemed from a bottom pour ladle at a temperature of about 2870 F. into the ingot mold at a steady rate through the slag pool to completely fill the ingot with further controlling fluidity and melting point of the slag. 10 metal and flush the excess casting slag from the top of In compounding the slag, it is important that the dry inthe mold. The remaining ingot molds were then filled in gredients be thoroughly blended prior to melting since the same manner. Metal from the ingots met the rigid it is otherwise found impractical to secure a uniform slag chemical specification for this grade of material.
  • the special casting slag composition is particularly advantageous for the production of ingots in commercial wrought nickel containing 99% and more of nickel,
  • nickel-copper alloys containing 50% or more of nickel, 30
  • the alloys may also contain other usual alloying ingredients such as up to about 10% molybdenum, up to about 10% columbium, up to about 30% cobalt, up to about 5% tungsten, up to about 5% manganese, up to about 3% silicon, up to about 0.5% carbon, up to about 2% vanadium, up to about 6% aluminum, up to about 40 It was found that the use of the special casting slag in accordance with the foregoing example eliminated the ingot cracking problem which has been encountered during solidification of nickel ingots heretofore. Such cracks rupture during hot working with major losses of metal. Elimination of the ingot cracking and the ingot overhauling in this electronic grade of nickel provides a yield increase at the hot rolling stage on the order of 6% to 8% by Weight. The fluid-mold cast material was not only hot rolled from the ingot stage without overhaul of the ingot surface but it was found that when the material was worked down into strip form blistering was 70% less than on strip produced from non-flux cast ingots.
  • Example II An ingot of a nickel-chomium-iron alloy containing about 32% nickel, about 0.04% carbon, about 0.75% manganese, about 0.35% silicon, about 0.3% copper, about 20.5% chromium, and the balance essentially iron, was produced by the fluid-mold process employing a fluidmold casting slag having the composition set forth in TAB LE II Percent Percent Percent Percent Percent Percent Percent Percent Percent Percent Percent Percent 09 Ni 0 Mn Fe Si C Cr Al Ti th.
  • Example I A melt weighing about 9880 pounds made of a commercially pure nickel alloy containing about 99.5% nickel, about 0.09% carbon, not more than 0.3% manganese, not more than about 0.1% iron, not more than about 0.1% silicon, not more than about 0.1% copper, and not more than about 0.003% titanium was prepared for easting in an induction furnace.
  • a casting slag melt made from a charge of blended dry ingredients containing about 37% calcium oxide, about 37% alumina, about 6% magnesia, about 5% fluorspar, about 10% cryolite and about 5% sodium oxide added as sodium carbonate was pre- Example I. When the ingot was stripped from the mold, it was found to have a high quality surface free from the shotting defect.
  • Example III Ingots made of an age hardenable nickel-chromium alloy containing about 7% iron, about 16% chromium, about 3% titanium, about 0.04% carbon, about 0.15% silicon, and the balance essentially nickel, were produced by the fluid-mold casting process employing a slag having the composition set forth in Example I.
  • the ingots were 18 inches square and 48 inches long. Ingots stripped from the mold demonstrated an excellent surface which permitted hot rolling to bloom without ingot overhaul.
  • the surface of a hot rolled shape having a 10 inch by inch section produced from the 18 inch square ingot of this alloy without ingot overhaul is depicted in the accompanying FIGURE 3.
  • the special fluid-mold casting slag compositions provided in accordance with the invention must be carefully controlled to secure the desired results.
  • the alumina content should not exceed the lime content by more than 5 weight percent while maintaining other slag ingredients in the ranges set forth hereinbefore or it becomes impractical to obtain the required melting point even with the use of fluoride ingredients.
  • a slag containing 5 moles of C210 and 3 moles of A1 0 with no other ingredients representing a weight content of 52.5% A1 0 has a flow point on heating which is far in excess of 2450" F. and remains too sluggish and refractory to produce good nickel alloy ingot surfaces in slag casting even when diluted with a fluoride ingredient such as fiuorspar.
  • a fluid-mold casting slag composition consisting essentially of, by weight, about 20% to 40% alumina, about to 50% calcium oxide, with the alumina content not exceeding the calcium oxide content by more than 5 weight percent, about 5% to about 20% magnesium oxide, about 3% to about 10% sodium oxide, and about 10% to about of an alkaline earth fluoride.
  • a casting slag in accordance with claim 1 containing about to about calcium oxide, about 25 to about 40% alumina, about 5% to about 15% magnesia, about 3% to about 10% sodium oxide and about 10% to about 30%.of an alkaline earth fluoride.
  • a casting slag in accordance with claim 1 containing about 35% to about 40% calcium oxide, about 25 to about 40% alumina, about 5% to about 8% magnesia, about 3% to about 6% sodium oxide, about 10% to about 20% cryolite and about 5% to about 10% fluorspar.
  • a casting slag in accordance with claim 1 containing about 35% to about 43% calcium oxide, about 27% to about 37% alumina, about 6% to about 10% magnesia, about 5% sodium oxide and about 15 to about 19% of a fluoride ingredient from the group consisting of fluorspar, cryolite and potassium aluminum fluoride.
  • a casting slag in accordance with claim 1 containing about 37% calcium oxide, about 37% alumina, about 6% magnesia, about 5% sodium oxide, about 5% calcium fluoride and about 10% cryolite.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Treatment Of Steel In Its Molten State (AREA)
US583911A 1966-10-03 1966-10-03 Fluid-mold casting slag Expired - Lifetime US3444010A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US58391166A 1966-10-03 1966-10-03

Publications (1)

Publication Number Publication Date
US3444010A true US3444010A (en) 1969-05-13

Family

ID=24335111

Family Applications (1)

Application Number Title Priority Date Filing Date
US583911A Expired - Lifetime US3444010A (en) 1966-10-03 1966-10-03 Fluid-mold casting slag

Country Status (6)

Country Link
US (1) US3444010A (xx)
AT (1) AT272675B (xx)
BE (1) BE704608A (xx)
DE (1) DE1583728A1 (xx)
GB (1) GB1162864A (xx)
SE (1) SE324866B (xx)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH596909A5 (xx) * 1975-05-16 1978-03-31 Mannesmann Ag
DE2527553C3 (de) * 1975-06-19 1978-08-10 Mannesmann Ag, 4000 Duesseldorf Gießpulver für den Strang- und Blockguß

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2493394A (en) * 1946-08-27 1950-01-03 Vanadium Corp Of America Process of pouring metals and products produced thereby
US2631344A (en) * 1950-10-14 1953-03-17 Union Carbide & Carbon Corp Method of casting metal ingots
US3214806A (en) * 1962-03-27 1965-11-02 Int Nickel Co Method for fluid mold casting using casting slag
US3224887A (en) * 1962-03-27 1965-12-21 Int Nickel Co Slag composition for fluid mold casting

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2493394A (en) * 1946-08-27 1950-01-03 Vanadium Corp Of America Process of pouring metals and products produced thereby
US2631344A (en) * 1950-10-14 1953-03-17 Union Carbide & Carbon Corp Method of casting metal ingots
US3214806A (en) * 1962-03-27 1965-11-02 Int Nickel Co Method for fluid mold casting using casting slag
US3224887A (en) * 1962-03-27 1965-12-21 Int Nickel Co Slag composition for fluid mold casting

Also Published As

Publication number Publication date
BE704608A (xx) 1968-04-03
GB1162864A (en) 1969-08-27
DE1583728A1 (de) 1970-08-27
AT272675B (de) 1969-07-10
SE324866B (xx) 1970-06-15

Similar Documents

Publication Publication Date Title
EP0095645B2 (en) Method and apparatus for melting and casting metal
US4140555A (en) Nickel-base casting superalloys
EP0107334B1 (en) Improvements in or relating to aluminium alloys
US2631344A (en) Method of casting metal ingots
JPH08509913A (ja) 塩被膜下のアルミニウム−リチウム合金のダイレクトチル鋳造
US3649253A (en) Deoxidation of aluminum-killed molten steel
US2244608A (en) Process of making alloys of aluminum beryllium
US3598170A (en) Fluid-mold casting process
US3850624A (en) Method of making superalloys
US3929467A (en) Grain refining of metals and alloys
US3444010A (en) Fluid-mold casting slag
CN108660320A (zh) 一种低铝高钛型高温合金电渣重熔工艺
US1906567A (en) Metal alloy
US3993474A (en) Fluid mold casting slag
US585036A (en) Making ingots or castings of iron or steel
US3459540A (en) Production of clean fine grain steels
US3224887A (en) Slag composition for fluid mold casting
US3214806A (en) Method for fluid mold casting using casting slag
JP2503119B2 (ja) ベリリウム銅合金の鋳造方法
JP2819190B2 (ja) Ｔｉ含有超合金鋳造方法及びそれに用いるパウダー
JPS5944156B2 (ja) 肉盛溶接用フラツクス
US3311972A (en) Production of ingots for wrought metal products
JP3290603B2 (ja) チクソキャスティング法の適用下で得られたＦｅ−Ｃ−Ｓｉ系合金鋳物
US2510154A (en) Process for treatment of molten stainless steel
US2150095A (en) Method of treating nickel-copper alloys and products resulting therefrom