US3836360A - Method and apparatus for pre-heating and adding master alloy to a copper melt - Google Patents
Method and apparatus for pre-heating and adding master alloy to a copper melt Download PDFInfo
- Publication number
- US3836360A US3836360A US00269965A US26996572A US3836360A US 3836360 A US3836360 A US 3836360A US 00269965 A US00269965 A US 00269965A US 26996572 A US26996572 A US 26996572A US 3836360 A US3836360 A US 3836360A
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- US
- United States
- Prior art keywords
- copper
- wire
- melt
- alloy
- launder
- 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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- 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
- B22D11/10—Supplying or treating molten metal
- B22D11/108—Feeding additives, powders, or the like
-
- 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
- B22D11/10—Supplying or treating molten metal
- B22D11/11—Treating the molten metal
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
- C21C7/0056—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00 using cored wires
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/02—Making non-ferrous alloys by melting
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D3/00—Charging; Discharging; Manipulation of charge
- F27D3/0025—Charging or loading melting furnaces with material in the solid state
- F27D3/0026—Introducing additives into the melt
Definitions
- ABSTRACT Method and apparatus for pre-heating and continuously adding a dilute master alloy, for example, such as a master alloy of 2 percent boron-balance copper, to a copper melt flowing through a launder from a source of the molten metal, such as a furnace, into the top of a casting mold.
- a dilute master alloy for example, such as a master alloy of 2 percent boron-balance copper
- the master alloy is formed as a wire, and the launder is made electrically conductive or an inert electrode is inserted into the molten metal flowing through the launder, while the wire is continuously fed into the flowing metal.
- the wire is pre-heated to a temperature level close to its melting point, e.g. within 100C of the melting point, by feeding an electrical current longitudinally through a predetermined legnth of the wire as it is being fed continously into the flowing metal.
- the electrically conductive launder or immersed electrode and molten copper serve as one portion of the circuit, and an electrically conductive member positioned to engage the moving wire at a predetermined distance from the liquid level serves as another portion of the: circuit, so that the predetermined length of wire immediately above the liquid level is heated.
- the master alloy is relatively dilute (only 2 percent boron in the illustrative embodiment) a significant quantity of ingots were added, namely, approximately 1 percent of the mass of the molten metal, which means that a significant quenching effect occurred.
- This invention relates to a method and apparatus for pre-heating and continuously adding a dilute master alloy, for example, such as a master alloy of 2 percent boron-balance copper, as a pre-heated wire being fed into a copper melt while the pure molten copper is running through a launder from a furnace into a mold.
- a dilute master alloy for example, such as a master alloy of 2 percent boron-balance copper
- the launder is narrow and elongated and is constructed of an electrically conductive material, such as graphite, or
- an inert electrode is inserted into the flowing metal.
- the launder or immersed electrode and molten copper serve as one portion of the circuit for feeding electric current longitudinally through the wire.
- An electrically conductive member positioned to engage the moving wire at a predetermined distance from the liquid level serves as another portion of the wire heating circuit.
- the copper melt can be heated to the desired temperature in the range from 1,l00 C to l,275 C, and often can be heated to the optimum temperature of 1,150 C to l,l C, without requiring overheating to compensate for any quenching effect when the dilute master alloy is added.
- the copper is continuously flowing through the narrow launder as the heated wire is being added, thus a thorough mixing of the dilute master alloy and copper melt is obtained as a result of the agitation produced by the flowing motion of the molten metal in the launder.
- Another advantage resulting from employing the present invention is that there is only a brief time period occurring while the molten copper is flowing through the launder.
- the dilute boron master alloy in the illustrative embodiment is added for the purpose of deoxiding the melt.
- a most effective deoxidizing action is obtained.
- the flowing metal is covered with a layer of carbon or soot or other chemically reducing substance to provide a reducing environment at the liquid surface.
- a further advantage of the present invention is that overheating of the master alloy wire is limited. Should the electrical energy being fed into the master alloy wire momentarily exceed the desired predetermined heating level, the wire melts and momentarily breaks the circuit, thus interrupting the heating effect.
- the wire is supplied from a reel at ambient temperature, when the wire passes through the electrically conducting zone between the conductive member and the molten metal, it is quickly heated up to a temperature close to its melting point, e.g. within C. of its melting point.
- the melting point of the dilute master alloy wire is between 1,062 C and l,O83 C.
- the wire is pre-heated to a temperature above 962 C before it enters the copper melt. Thus, any significant quenching is avoided and the alloy wire quickly melts and thoroughly mixes with the pure molten copper in the launder before it passes into the mold.
- a boron deoxidized cast copper product of high electrical conductivity and uniform properties is produced.
- the melt of metal to be alloyed for example, such as essentially pure copper, is heated to the desired temperature in a furnace 10.
- the molten metal is released at a controlled rate through an outlet 12 into a launder 14.
- the melt flows through a relatively narrow channel 16 in the launder to its discharge end 18 from which the alloyed metal is discharged continuously into the entrance 20 at the top of a direct chill casting mold 22 of the continuous casting type.
- the cast product 24 moves intermittently downward from the bottom of the mold 22.
- the residence time of the molten metal 26 in the channel 16 is brief, e.g. less than 1 minute, so that there is only a small heat loss which occurs as the metal flows toward the discharge 18.
- a layer of particulate carbon such as graphite powder or soot, is floated upon the molten metal 26, so as to maintain a reducing environment adjacent to the liquid surface.
- a barrier 28 at the discharge end of the launder retains the protective layer of particulate carbon.
- the temperature of the base metal, e.g. essentially pure copper, in the furnace 10 can be held within the desired range of 1,l00 C to l,275 C and often can be held at the optimum temperature level from 1,150 C to l,l75 C.
- the alloy constituent for example, such as the element boron, is previously mixed with the base metal to provide a dilute master alloy, consisting essentially of 2 percent boron-balance copper.
- This master alloy is formed into a wire 30 and wound into a large coil 32 to serve as a source of the master alloy.
- This wire coil 32 is mounted on a stand 34 near the launder l4, and the wire 30 is continuously fed into the molten metal 26 by passing it between an idler roller 36 and a companion roller 38 driven by an adjustable speed motor 40.
- the components 36, 38 and 40 comprise adjustable speed wire feed means generally indicated at 42.
- the rate of feed of the wire 30 is adjusted in accordance with the flow rate in the channel 16 for producing the desired alloying action in the flowing metal 26.
- the cast product 24 being produced is boron deoxidized high conductivty copper having the Copper Development Association, Inc. designation No. 109 alloy.
- the master alloy wire 30 is pre-heated. This pre-heating is advantageously accomplished by flowing electric current longitudinally through a predetermined length of the master alloy wire 30.
- An electrically conductive member 44 engages the wire 30 to make electrical contact therewith at a predetermined distance D from the surface of the molten metal 26.
- a source of electrical energy for example, shown as the secondary winding 46 of a variable transformer 47, has one side connected by a lead 48 to the conductive member 44.
- the primary 49 of the transformer is connected to an alternating current circuit, for example, such as a conventional 220 volt-60 Hertz circuit.
- the conductive member 44 serves as a portion of a circuit for feeding current through the wire 30.
- the rollers 36 and 38 of the adjustable feed mechanism 42 can be made conductive and be connected to the lead 48 and be positioned to serve in lieu of the contact member 44.
- the advantage of utilizing a separate contact member 44 is that it can be adjustably mounted on an insulating support 50 for appropriately adjusting the distance D, whereas it is more convenient to have the adjustable feed mechanism 42 fixed inposition.
- the launder 14 is formed of electrically conductive material such as graphite, and it is connected to a common return circuit 52, i.e., it is grounded.
- the other side of the secondary 46 is also connected to the common return circuit and thus the conductive launder 14 and the molten metal 26 serve as another portion of the circuit for feeding current through the predetermined length of wire 54 between the conductive member 44 and the surface of the molten metal.
- the current flow through the wire is adjusted to heat the wire length 54 up to a temperature close to its melting point before wire enters the metal 26, that is, the wire is pre-heated to within C of its melting temperature.
- the wire length 54 melts, thus temporarily interrupting the circuit. The operator can then reduce the energy output from the power source 47 to the appropriate value.
- an inert electrode (not shown) of graphite can be immersed in the molten metal 26 and be connected to a common ground circuit.
- the metal is flowing in the narrow channel 16, and is continuously passing by the point at which the master alloy is being introduced, there is a uniform distribution and inter-mixing of the alloy constituent into the flowing base metal 26.
- the fact that the master alloy is dilute aids in producing a uniform distribution of the alloy constituent throughout the melt because the relatively large or dominant proportion of pre-heated base metal in the heated wire 54 (which is close to its melting point) acts as a vehicle for carrying the alloy constituent throughout the base metal of the melt 26.
- a liquid coolant such as water is fed through passages 56 in a cooling jacket 58 for extracting heat to solidify the cast product 24.
- pre-heating the master alloy wire to a temperature close to its melting temperature said wire being heated continuously as it is being fed into the mo]- ten metal by feeding electric current longitudinally through a predetermined length of the wire immediately above the flowing metal by using the molten metal in the channel as a portion of the electric circuit for feeding the current longitudinally through the wire and through the molten metal.
- said narrow channel is formed by an electrically conductive launder which serves as a portion of the electric circuit for heating the length of wire.
- metal melt comprising:
- a furnace for heating the base metal to a desired temperature for casting and having an outlet for releasing the molten metal at a controlled rate of flow
- a launder defining a narrow channel for flowing the molten metal from the furnace outlet into a casting mold
- adjustable feeding means for feeding the wire at a predetermined rate into the molten metal flowing through the channel toward the mold
- a source of electrical current having one side connected to said member and having the other side connected to the molten metal in said narrow channel for feeding electric current longitudinally 5 through the length of wire entering the molten metal for pre-heating said length of wire to a temperature close to its melting point, said length of wire being heated continuously as it is being fed into the molten metal,
- said launder is formed of electrically conductive material and the other side of said source of electrical current is connected to the launder.
- the copper melt can initially be heated to the desired temperature in the range from l,l00 C to 1,275 C without requiring overheating to compensate for any significant quenching effect when the dilute master alloy is added.
Abstract
Description
Claims (6)
- 2. The method of adding a master alloy to a base metal in a melt, as claimed in claim 1, in which: said narrow channel is formed by an electrically conductive launder which serves as a portion of the electric circuit for heating the length of wire.
- 3. The method of adding a master alloy to a base metal in a melt, as claimed in claim 1, wherein: said base metal flowing through said narrow channel is essentially pure copper covered by a layer of material producing a reducing environment at the surface of the molten metal, the residence time of the molten copper in said narrow channel is less than 1 minute, and said dilute master alloy is an alloy of boron and copper for producing boron deoxidized high conductivity copper passing from the narrow channel into the mold.
- 4. Apparatus for introducing a master alloy into a metal melt, comprising: a furnace for heating the base metal to a desired temperature for casting and having an outlet for releasing the molten metal at a controlled rate of flow, a launder defining a narrow channel for flowing the molten metal from the furnace outlet into a casting mold, a wire formed by the master alloy with the alloy constituent being a dilute proportion of the wire, adjustable feeding means for feeding the wire at a predetermined rate into the molten metal flowing through the channel toward the mold, an electrically conductive member engaging the moving wire at a predetermined distance from the launder, and a source of electrical current having one side connected to said member and having the other side connected to the molten metal in said narrow channel for feeding electric current longitudinally through the length of wire entering the molten metal for pre-heating said length of wire to a temperature close to its melting point, said length of wire being heated continuously as it is being fed into the molten metal, thereby to avoid quenching of the melt and to hasten the alloying action.
- 5. Apparatus for introducing a master alloy into a metal melt, as claimed in claim 4, in which: said launder is formed of electrically conductive material and the other side of said source of electrical current is connected to the launder.
- 6. The method of adding a dilute master copper alloy to a copper melt in order to hasten the introduction of the alloying material into the melt and avoid holding time delay comprising the steps of: producing a dilute master copper alloy wire of the alloy constituent and copper in which the copper is the dominant proportion, heating the copper to be alloyed in a furnace a produce a melt thereof at a temperature near the desired casting temperature, said temperature being in the range from 1,100* C to 1,275* C, controllably releasing the molten copper at a predetermined flow rate from the furnace to pass through a narrow channel leading into a casting mold, flowing the copper melt along said narrow channel with a brief residence time in said channel of less than 1 minute, pre-heating the master copper alloy wire to a temperature close to its melting temperature, feeding the pre-heated master copper alloy wire into the flowing copper melt moving along said channel, said wire being heated continuously as it is being fed into the flowing copper melt, whereby the alloy becomes thoroughly mixed with the copper melt flowing in said narrow channel, thereby avoiding any holding time delay for the alloying to take place, and whereby any significant quenching effect is avoided, by virtue oF which the copper melt can initially be heated to the desired temperature in the range from 1,100* C to 1,275* C without requiring overheating to compensate for any significant quenching effect when the dilute master alloy is added.
- 7. The method of adding a dilute master copper alloy to a copper melt as claimed in claim 6, in which said master copper alloy is pre-heated to a temperature within 100* C of its melting temperature.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US00269965A US3836360A (en) | 1972-07-10 | 1972-07-10 | Method and apparatus for pre-heating and adding master alloy to a copper melt |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US00269965A US3836360A (en) | 1972-07-10 | 1972-07-10 | Method and apparatus for pre-heating and adding master alloy to a copper melt |
Publications (1)
Publication Number | Publication Date |
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US3836360A true US3836360A (en) | 1974-09-17 |
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US00269965A Expired - Lifetime US3836360A (en) | 1972-07-10 | 1972-07-10 | Method and apparatus for pre-heating and adding master alloy to a copper melt |
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Cited By (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4231792A (en) * | 1979-03-23 | 1980-11-04 | Republic Steel Corporation | Chute with hazardous flame and fume control |
US4521455A (en) * | 1982-02-23 | 1985-06-04 | Csepel Muvek Femmuve | Process and equipment for the production of alloyed copper wire rod by continuous casting |
US4591394A (en) * | 1984-04-17 | 1986-05-27 | Achter Pieter Paul Van | Method for treating copper and for using the thus-treated copper |
US4592538A (en) * | 1982-09-15 | 1986-06-03 | Elkem Metals Company | Apparatus for producing predominately iron alloy containing magnesium |
EP0185540A2 (en) * | 1984-12-18 | 1986-06-25 | Sumitomo Light Metal Industries Limited | Method of refining grains fo primary silicon in hypereutectic Al-Si alloys |
EP0259772A2 (en) * | 1986-09-02 | 1988-03-16 | Mitsubishi Materials Corporation | Apparatus and method for manufacturing copper-base alloy |
US4814235A (en) * | 1984-07-21 | 1989-03-21 | Kabel- Und Metallwerke Gutehoffnungshutte Ag | Use of oxygen-free copper deoxidized by boron or lithium as material for hollow sections |
US4981514A (en) * | 1986-09-02 | 1991-01-01 | Mitsubishi Kinzoku Kabushiki Kaisha | Method for manufacturing copper-base alloy |
US5062614A (en) * | 1986-09-02 | 1991-11-05 | Mitsubishi Kinzoku Kabushiki Kaisha | Apparatus and method for manufacturing copper-base alloy |
US5076548A (en) * | 1990-05-21 | 1991-12-31 | Aluminum Company Of America | Commutation means for on-line alloying |
US5291939A (en) * | 1992-11-23 | 1994-03-08 | Reynolds Metals Company | Start-up method and apparatus for continuous casting of metal into strip product |
EP0819772A1 (en) * | 1996-07-19 | 1998-01-21 | Alusuisse Technology & Management AG | Process and apparatus for grain refining and alloying of alloys |
US20070256520A1 (en) * | 2006-05-02 | 2007-11-08 | Taiwan Advanced Materials Technologies Corporation | Method for producing a metal alloy |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2964397A (en) * | 1958-07-28 | 1960-12-13 | Walter M Weil | Copper-boron alloys |
US3144327A (en) * | 1962-01-02 | 1964-08-11 | Walter M Weil | Copper-boron alloys and method of making same |
US3634075A (en) * | 1969-01-15 | 1972-01-11 | Kawecki Berylco Ind | Introducing a grain refining or alloying agent into molten metals and alloys |
-
1972
- 1972-07-10 US US00269965A patent/US3836360A/en not_active Expired - Lifetime
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2964397A (en) * | 1958-07-28 | 1960-12-13 | Walter M Weil | Copper-boron alloys |
US3144327A (en) * | 1962-01-02 | 1964-08-11 | Walter M Weil | Copper-boron alloys and method of making same |
US3634075A (en) * | 1969-01-15 | 1972-01-11 | Kawecki Berylco Ind | Introducing a grain refining or alloying agent into molten metals and alloys |
Cited By (15)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4231792A (en) * | 1979-03-23 | 1980-11-04 | Republic Steel Corporation | Chute with hazardous flame and fume control |
US4521455A (en) * | 1982-02-23 | 1985-06-04 | Csepel Muvek Femmuve | Process and equipment for the production of alloyed copper wire rod by continuous casting |
US4592538A (en) * | 1982-09-15 | 1986-06-03 | Elkem Metals Company | Apparatus for producing predominately iron alloy containing magnesium |
US4591394A (en) * | 1984-04-17 | 1986-05-27 | Achter Pieter Paul Van | Method for treating copper and for using the thus-treated copper |
US4814235A (en) * | 1984-07-21 | 1989-03-21 | Kabel- Und Metallwerke Gutehoffnungshutte Ag | Use of oxygen-free copper deoxidized by boron or lithium as material for hollow sections |
EP0185540A2 (en) * | 1984-12-18 | 1986-06-25 | Sumitomo Light Metal Industries Limited | Method of refining grains fo primary silicon in hypereutectic Al-Si alloys |
EP0185540A3 (en) * | 1984-12-18 | 1987-05-27 | Sumitomo Light Metal Industries Limited | Method of refining grains fo primary silicon in hypereutectic al-si alloys |
EP0259772A2 (en) * | 1986-09-02 | 1988-03-16 | Mitsubishi Materials Corporation | Apparatus and method for manufacturing copper-base alloy |
EP0259772A3 (en) * | 1986-09-02 | 1988-09-14 | Mitsubishi Kinzoku Kabushiki Kaisha | Apparatus and method for manufacturing copper-base alloy |
US4981514A (en) * | 1986-09-02 | 1991-01-01 | Mitsubishi Kinzoku Kabushiki Kaisha | Method for manufacturing copper-base alloy |
US5062614A (en) * | 1986-09-02 | 1991-11-05 | Mitsubishi Kinzoku Kabushiki Kaisha | Apparatus and method for manufacturing copper-base alloy |
US5076548A (en) * | 1990-05-21 | 1991-12-31 | Aluminum Company Of America | Commutation means for on-line alloying |
US5291939A (en) * | 1992-11-23 | 1994-03-08 | Reynolds Metals Company | Start-up method and apparatus for continuous casting of metal into strip product |
EP0819772A1 (en) * | 1996-07-19 | 1998-01-21 | Alusuisse Technology & Management AG | Process and apparatus for grain refining and alloying of alloys |
US20070256520A1 (en) * | 2006-05-02 | 2007-11-08 | Taiwan Advanced Materials Technologies Corporation | Method for producing a metal alloy |
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