Classifications

• • 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
  • B22D11/04—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
• • 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
  • B22D11/04—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
  • B22D11/049—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds for direct chill casting, e.g. electromagnetic casting
• • 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
  • B22D11/07—Lubricating the moulds
• • 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
  • B22D11/08—Accessories for starting the casting procedure
• • 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
  • B22D11/12—Accessories for subsequent treating or working cast stock in situ
  • B22D11/124—Accessories for subsequent treating or working cast stock in situ for cooling

Definitions

• My invention relates to the casting of molten metal in an open ended mold cavity, and in particular, to the peripheral confinement of the molten metal in the cavity during the casting of it into an end product.
• Present day open ended mold cavities have an entry end, a discharge end opening, an axis extending between the discharge end opening and the entry end of the cavity, and a wall circumposed about the axis of the cavity between the discharge end opening and the entry end thereof to confine the molten metal to the cavity during the passage of the metal through the cavity.
• a starter block is telescopically engaged in the discharge end opening of the cavity. The block is reciprocable along the axis of the cavity, but initially, it is stationed in the opening while a body of molten startup material is inteiposed in the cavity between the starter block and a first cross sectional plane of the cavity extending relatively transverse the axis thereof.
• the layer is intercepted by the wall of the cavity where, due to the fact that the wall is at right angles to the first cross sectional plane of the cavity, the layer is forced to undergo a sharp right angular turn into the series of second cross sectional planes of the cavity, and to undertake a course through them parallel to that of the wall, i.e., perpendicular to the plane.
• the layer begins to experience thermal contraction forces, and in time, the thermal contraction forces effectively counterbalance the splaying forces and a condition of "solidus" occurs in one of the second cross sectional planes.
• the layer proceeds to shrink away from the wall as it completes its passage through the cavity in the body of metal.
• the products of its decomposition often react with the ambient air in the interface to form particles of metal oxide and the like which become “rippers” at the interface that in turn produce so-called “zippers” along the axial dimension of any product produced in this way.
• the intense heat may even cause a lubricant to combust, creating in turn a hot metal to cold surface condition wherein the frictional forces are then largely unrelieved by any lubricant whatsoever.
• My invention departs entirely from the prior art strategies for separating or lubricating the layers from the wall at the interface therebetween, and from the prior art strategies for shortening the band of contact between the two. Instead, my invention eliminates the "confrontation" between the layers and wall that gave rise to the problems requiring these prior art strategies, and in their place, substitutes a whole new strategy for confining the relatively peripherally outward distention of the respective layers in the cavity during the passage of the molten metal therethrough.
• I also arrange heat extraction means about the axis of the cavity, and I operate the heat extraction means to extract heat from the angularly successive part annular portions of the layers arrayed about the circumferences thereof.
• I also operate the baffling means to confer the circumferential outlines on the respective first and second cross sectional areas of the layers in the cavity.
• I open up a whole new world of possibilities for open ended mold casting by arranging about the axis of the cavity, axis orientation control means for controlling the orientation of the axis to a vertical line, heat extraction control means for controlling the rate at which heat is extracted by the heat extraction means from the respective angularly successive part annular portions of the layers, first circumferential outline control means for controlling the circumferential outline conferred on the first cross sectional area by the baffling means, and second circumferential outline control means for controlling the circumferential outlines conferred on the respective second cross sectional areas by the baffling means, and operating the respective axis orientation control means, heat control means, and first and second circumferential outline control means in conjunction with the baffling means to confer any predetermined circumferential outline I may choose on the cross sectional area assumed by the body of metal in the one second cross sectional plane of the cavity.
• the circumferential outline I confer on the body of metal will be larger than the circumferential outline I had conferred on the first cross sectional area with the baffling means.
• I can easily account for that in the design of each mold, and knowing that, I may operate the first circumferential outline control means so as to cause the baffling means to confer a first circumferential outline on the first cross sectional area, and operate the axis orientation control means, the heat control means, and the second circumferential outline control means, in conjunction with the baffling means, to confer on the cross sectional area of the body of metal in the one second cross sectional plane of the cavity, a predetermined circumferential outline which is larger than but corresponds to the first circumferential outline conferred on the first cross sectional area by the baffling means.
• I may operate the axis orientation control means, the heat control means and the second circumferential outline control means, in conjunction with the baffling means, to confer on the cross sectional area of the body of metal in the one second cross sectional plane of the cavity, a predetermined circumferential outline which is larger than and differs from the first circumferential outline conferred on the first cross sectional area by the baffling means.
• the first circumferential outline is an asymmetrical noncircular circumferential outline
• it generates a variance between the differentials existing between the respective splaying forces and thermal contraction forces inherent in angularly successive part annular portions of the layers that are mutually opposed to one another across the cavity in second cross sectional planes thereof
• I may operate the axis orientation control means, the heat control means, and the second circumferential outline control means, in conjunction with the baffling means, to neutralize that variance in third cross sectional planes of the cavity extending parallel to the axis thereof between the respective mutually opposing angularly successive part annular portions of the layers.
• the first circumferential outline may be relatively devoid of a variance between the differentials existing between the respective splaying forces and thermal contraction forces inherent in portions that are mutually opposed to one another across the cavity in the second cross sectional planes thereof, and I may operate the respective axis orientation control means, heat control means, and second circumferential outline control means, in conjunction with the baffling means, to create a variance between the aforesaid differentials in third cross sectional planes of the cavity extending parallel to the axis thereof between mutually opposing angularly successive part annular portions of the layers.
• the first circumferential outline I confer on the first cross sectional area may be a circular circumferential outline, and I may operate the axis orientation control means, the heat control means, and the second circumferential outline control means, in conjunction with the baffling means, to confer a symmetrical noncircular circumferential outline on the cross sectional area of the body of metal in the one second cross sectional plane of the cavity, such as an oval or oblate circumferential outline.
• the cross sectional dimensions of the body of metal are also within the realm of control that I may exercise in practicing my invention.
• first cross sectional area control means about the axis of the cavity for controlling the cross sectional dimensions conferred on the cross sectional area assumed by the body of metal in the one second cross sectional plane of the cavity, and I operate the first cross sectional area control means in conjunction with the baffling means to confer predetermined cross sectional dimensions on the cross sectional area assumed by the body of metal between a first pair of mutually opposing sides of the cavity in the one second cross sectional plane thereof.
• second cross sectional area control means about the axis of the cavity for controlling the cross sectional dimensions conferred on the cross sectional area assumed by the body of metal in the one second cross sectional plane of the cavity, and I operate the second cross sectional area control means in conjunction with the baffling means to confer predetermined cross sectional dimensions on the cross sectional area assumed by the body of metal between a second pair of mutually opposing sides of the cavity disposed at right angles to the first pair of sides in the one cross sectional plane of the cavity.
• I may control the cross sectional dimensions conferred on the cross sectional area assumed by the body of metal in one of several ways.
• I may shift the baffling means and the first and second cross sectional planes of the cavity in relation to one another along the axis of the cavity, such as by varying the volume of molten metal superimposed on the body of startup material in the respective layers of molten metal, or by rotating the baffling means about an axis of orientation transverse the axis of the cavity.
• I may divide the baffling means into pairs thereof, arrange the respective pairs of baffling means about the axis of the cavity on pairs of mutually opposing sides thereof, and shift the respective pairs of baffling means in relation to one another crosswise the axis of the cavity to control the cross sectional dimensions conferred on the cross sectional area assumed by the body of metal.
• I may reciprocate one of the pairs of baffling means in relation to one another crosswise the axis of the cavity to shift the pairs thereof in relation to one another.
• I confer the same cross sectional dimensions on the cross sectional area assumed by the body of metal with the respective baffling means.
• I form a series of annular surfaces about the axis of the cavity on the baffling means, and I orient the respective surfaces to the axis of the cavity so as to confine the relatively peripheral outward distention of the layers to the first and second cross sectional areas of the cavity while generating the aforedescribed baffling effects at the circumferential outlines thereof.
• I vary in relation to one another, the angles at which angularly successive part annular portions of the surfaces are oriented to the axis of the cavity, so as to vary in this way the circumferential outlines circumscribed by the annular surfaces in the second cross sectional planes of the cavity. And where necessary, I also vary in relation to one another, the angles at which angularly successive part annular portions of the surfaces are oriented to the axis of the cavity on mutually opposing sides of the cavity, to neutralize a variance between the differentials existing between the respective splaying forces and thermal contraction forces in the angularly successive part annular portions of the layers which are disposed opposite the respective part annular portions of the surfaces on the mutually opposing sides of the cavity.
• I vary in relation to one another, the angles at which angularly successive part annular portions of the surfaces are oriented to the axis of the cavity on mutually opposing sides of the cavity, to create a variance between the differentials existing between the respective splaying forces and thermal contraction forces in the angularly successive port annular portions of the layers which are disposed opposite the respective part annular portions of the surfaces on the mutually opposing sides of the cavity.
• I form a portion of the wall with a graphite casting ring
• I usually fo ⁇ n the skirt about the inner periphery of the ring.
• I may give the skirt a rectilinear flare about the inner periphery thereof in any of the foregoing embodiments, or I may give it a curvilinear flare about the inner periphery thereof.
• I also discharge the liquid coolant onto the body of metal between planes transverse the axis of the cavity and coinciding with the bottom and rim of the trough-shaped model formed by the successively convergent isotherms of the body of metal.
• I may discharge the liquid coolant onto the body of metal from an annulus formed about the axis of the cavity between the one second cross sectional plane of the cavity and the discharge end opening thereof, or I may discharge the liquid coolant onto the body of metal from an annulus formed about the axis of the cavity on the other side of the discharge end opening of the cavity from the one second cross sectional plane thereof.
• I discharge the liquid coolant from a series of holes arranged about the axis of the cavity and divided into rows of holes in which the respective holes thereof are staggered in relation to one another from row to row, as in USP 5,582,230.
• I also operate the baffling means to generate a reentrant baffling effect in cross sectional planes of the cavity extending transverse the axis thereof between the one second cross sectional plane of the cavity and the discharge end opening thereof, to induce "rebleed” to reenter the body of metal.
• I also superimpose sufficient layers of the molten metal on the body of startup material to elongate the body of metal axially of the cavity.
• I may also subdivide the elongated body of metal into successive longitudinal sections thereof, and I may in addition, post-treat the respective longitudinal sections, such as by post-forging them.
• Figures 1 - 5 illustrate several cross sectional areas and circumferential outlines that I may confer on a body of metal at the cross sectional plane in which "solidus” occurs; and in addition, they also show the "first" cross sectional area and the “penumbra” of second cross sectional area that is needed between the circumferential outline of the first cross sectional area and the plane of "solidus” if my process and apparatus are to be fully successful in conferring the respective areas and outlines on the body of metal;
• Figures 6 - 8 are schematic representations of a mold I may employ in casting each of the examples in Figures 1 - 3, and they also show schematically the plane in which the examples of Figures 1 - 3 are taken;
• Figure 9 is a bottom plan view of an open-topped vertical mold for casting a V-shaped body of metal such as that seen in Figure 4, and showing in addition, the circumferential outline of the first cross sectional area in the cavity of the mold;
• Figure 10 is a similar view of an open-topped vertical mold for casting a sinuous asymmetrical noncircular body of metal such as the generally L- shaped one seen in Figure 5, but showing now within the cavity of the mold, the theoretical basis for the scheme I employ in varying the rate at which heat is extracted from the angularly successive part annular portions of the body of metal to balance the thermal stresses arising between mutually opposing portions thereof in cross sectional planes of the cavity extending parallel to the axis thereof;
• Figure 11 is an isometric cross section along the line 11 - 11 of Figure 9;
• Figure 12 is a relatively enlarged and more steeply angled part schematic isometric showing the center portion of the isometric cross section seen in Figure 11 ;
• Figure 13 is a cross Section along the line 13, 15 of Figure 17, showing the two series of coolant discharge holes employed in extracting heat from the angularly successive part annular portions of the body of metal occupying a relatively concave bight in Figures 9, 11 and 12, and particularly for comparison with the two series of holes to be shown in this connection in Figure 15 hereafter;
• Figure 14 is an isometric part schematic cross section along the line 14 - 14 of Figure 9 and like that of Figure 12, more enlarged and steeply inclined than the isometric cross section of Figure 11;
• Figure 15 is another cross section along the line 13, 15 - 13, 15 of
• Figure 17 showing the two series of coolant discharge holes employed for heat extraction in a relatively convex bight in Figure 14, and in this instance, for comparison with the two series shown at the concave bight of Figure 13, as mentioned earlier;
• Figure 16 is a further schematic representation in support of Figures 2 and 7;
• Figure 17 is an axial cross section of either of the molds seen in Figures 9 and 10 and at the time when a casting operation is being conducted in the mold;
• Figure 18 is a hot topped version of the molds seen in Figures 9 - 15 and 17 at the time of use, and is accompanied by a schematic showing of certain principles employed in all of my molds;
• Figure 19 is a schematic representation of the principles, but using a set of angularly successive diagonals to represent the casting surface of each mold, so that certain areas and outlines can be seen therebelow in the Figure;
• Figure 20 is an arithmetic representation of certain principles
• Figure 21 is a view similar to that of Figures 17 and 18, but showing a modified form of mold which provides for the coolant being discharged irer-.tlv into the cavitv of the mold:
• Figure 22 is an abbreviated axial cross section like that of Figure 17, but showing a casting ring with a curvilinear casting surface to capture "rebleed;"
• Figure 23 is a largely phantomized cross section showing a reversible casting ring
• Figure 24 is a thermal cross section through a typical casting, showing the trough-shaped model of successively convergent isotherms therein and the thermal shed plane thereof;
• Figure 25 is a schematic representation of a way to generate an oval or other symmetric noncircular circumferential outline, from a first cross sectional area of circular outline, by tilting the axis of the mold;
• Figure 26 is a schematic representation of another way of doing so by varying the rate at which heat is extracted from angularly successive part annular portions of the body of metal on opposing sides of the mold;
• Figure 27 is a schematic representation of a third way of generating an oval or other symmetric noncircular circumferential outline from a first cross sectional area of circular outline, by varying the inclination of the casting surface on opposing sides of the mold;
• Figure 28 is a schematic representation of a way of varying the cross sectional dimensions of the cross sectional area of a casting
• Figure 29 is a plan view of a four-sided adjustable mold for making rolling ingot, opposing ends of which are reciprocable in relation to one another;
• Figure 30 is a part schematic representation of one of the pair of longitudinal sides of the mold when the longitudinal sides thereof are adapted to rotate in accordance with my invention
• Figure 31 is a perspective view of one of a pair of longitudinal sides of an adjustable mold when the same are fixed, rather than rotational;
• Figure 32 is a top plan view of the fixed side;
• Figure 33 is a cross section along the lines 33 - 33 of Figure 31
• Figure 34 is a cross section along the lines 34 - 34 of Figure 31
• Figure 35 is a cross section along the lines 35 - 35 of Figure 31
• Figure 36 is a cross section along the lines 36 - 36 of Figure 31
• Figure 37 is a schematic representation of the midsection of the adjustable mold when either of the sides shown in Figures 30 and 31 has been used to give the mold a particular length;
• Figure 38 is a second schematic representation of the midsection when the length of the mold has been reduced
• Figure 39 is an exploded perspective view of an elongated end product that has been subdivided into a multiplicity of longitudinal sections thereof;
• Figure 40 is a schematic representation of a prior art mold tested for the temperature thereof at the interface between the layers of molten metal and the casting surface;
• Figure 41 is a similar representation of one of my casting molds tested for the temperature at its interface when a one degree taper is used in the casting surface;
• Figure 42 is a representation similar to Figure when a three degree taper is employed in the casting surface.
• Figure 43 is another such representation when a five degree taper is employed in the casting surface.
• FIGs 9 - 20, 1 produce each of the shapes in a mold 2 having an open ended cavity 4 therein, an opening 6 at the entry end of the cavity, and a series of liquid coolant discharge holes 8 circumposed about the discharge end opening 10 of the cavity.
• the axis 12 of the cavity may be oriented along a vertical line, or along an angle to a vertical line, such as along a horizontal line.
• the cross section seen in Figures 17 and 18 is typical, but typical only, in that as one traverses about the circumference of the cavity, certain features of the mold will vary, not so much in character, but in degree, as shall be explained. Orienting the axis 12 along an angle to a vertical line, will also produce changes, as those familiar with the casting art will understand.
• the vertical molds seen in Figures 9 - 15 and 17 each comprise an annular body 14 and a pair of annular top and bottom plates 16 and 18, respectively, which are attached to the top and bottom of the mold body, respectively. All three components are made of metal and have a shape in plan view corresponding to that of the body of metal to be cast in the cavity of the mold.
• the cavity 4 in the mold body 14 has an annular rabbet 20 thereabout of the same shape as the mold body itself, and the shoulder 22 of the rabbet is recessed well below the entry end opening 6 of the cavity, so that the rabbet can accommodate a graphite casting ring 24 of the same shape as that of the rabbet.
• the opening in the casting ring has a smaller cross sectional area at the top thereof than the discharge end opening 10 of the cavity, so that at its inner periphery, the ring overhangs the opening 10.
• the casting ring also has a smaller cross sectional area at the bottom thereof, so as to overhang the opening 10 at that level as well, and between the top and bottom levels of the casting ring, the inner periphery of it has a tapered skirt-like casting surface 26, the taper of which is directed relatively peripherally outwardly from the axis 12 of the cavity in the direction downwardly thereof.
• the taper is also rectilinear in the embodiment shown, but may be curvilinear, as shall be explained more fully hereinafter.
• the taper has an inclination of about 1 - 12 degrees to the axis of the cavity, but in addition to varying in inclination from one embodiment of my invention to another, the taper may also vary in inclination as one traverses about the circumference of the cavity, as shall also be explained.
• the opening 6 in the top plate 16 has a smaller cross sectional area than those of the mold body 14 and the casting ring 24, so that when overlaid on the mold body and the ring as shown, and secured thereto by cap screws 28 or the like, the plate 16 has a slight lip overhanging the cavity at the inner periphery thereof.
• the opening 30 in the bottom plate 18 has the greatest cross sectional area of all, and in fact, is sufficiently large to allow for the fo ⁇ nation of a pair of chamfered surfaces 32 and 34 about the bottom of the mold body, between the discharge end opening 10 of the cavity and the inner periphery of the plate 18.
• the mold body 14 has a pair of annular chambers 36 extending thereabout, and in order to use the so-called “machined baffle” and “split jet” techniques of USP 5,582,230 and US Patent Application 08/643,767, the series of liquid coolant discharge holes 8 in the bottom of the inner peripheral portion ofthe mold body actually comprises two series of holes 38 and 40 which are acutely inclined to the axis 12 of the cavity 4 and open into the chamfered surfaces 32 and 34, respectively, ofthe mold body.
• the holes communicate with a pair of circumferential grooves 42 that are formed about the inner peripheries of the respective chambers 36, but are sealed therefrom by a pair of elastomer rings 44 so that they can form exit manifolds for the chambers.
• the manifolds are interconnected with the respective chambers 36 to receive coolant from the same through two circumferentially extending series of orifices 46 that also serve as a means for lowering the pressure of the coolant before it is discharged through the respective sets of holes 38 and 40.
• the mold 2 also has a number of additional components including several elastomer sealing rings, certain of which are shown at the joints between the mold body and the two plates.
• means are schematically shown at 50 for discharging oil and gas into the cavity 4 at the surface 26 of the casting ring 24, for the formation of an oil encompassed sleeve of gas (not shown) about the layers of molten metal in the casting operation, and USP 4,598,763 can be consulted for the details of the same.
• USP 5,318,098 can be consulted for the details of a leak detection system schematically represented at 52.
• the hot top mold 54 shown therein is substantially the same except that both the opening 52 of the hot top 55 and the upper half of the graphite casting ring 56 are sized to provide more of an overhang 58 than the ring 24 alone provides in Figures 9 - 15 and 17, so that the gas pocket needed for the technique of USP 4,598,763 is more pronounced.
• a reciprocable starter block 60 having the shape of the cavity 4 of the mold, is telescoped into the discharge end opening 10 or 10 ' of the mold until it engages the inclined inner peripheral surface 26 or 62 of the casting ring at a cross sectional plane of the cavity extending transverse the axis thereof and indicated at 64 in Figure 18.
• molten metal is supplied either to the opening 65 in the hot top of Figure 18, or to a trough (not shown) above the cavity in Figure 17; and the molten metal is delivered to the inside of the respective cavity either through the top opening 66 in the graphite ring of Figure 18, or through a downspout 68 depending from the trough in the throat formed by the opening 6 in the top plate 16 of Figure 17.
• the starter block 60 is stationed at a standstill in the discharge end opening 10 or 10' of the cavity, while the molten metal is allowed to accumulate and form a body 70 of startup material on the top of the block.
• This body of startup material is typically accumulated to a "first" cross sectional plane of the cavity extending transverse the axis of cavity at 72 in Figure 18. And this accumulation stage is commonly called the “butt-forming" or “start” stage of the casting operation. It is succeeded in turn by a second stage, the so-called “run” stage of the operation, and in this latter stage, the starter block 60 is lowered into a pit (not shown) below the mold, while the addition of molten metal to the cavity is continued above the block.
• the body 70 of startup material is reciprocated in tandem with the starter block downwardly through a series of second cross sectional planes 74 of the cavity extending transverse the axis 12 thereof, and as it reciprocates through the series of planes, liquid coolant is discharged onto the body of material from the sets of holes 38 and 40, to direct cool the body of metal now tending to take shape on the block.
• a pressurized gas and oil are discharged into the cavity through the surface of the graphite ring, using the means indicated generally at 50 in each of Figures 17 and 18.
• the molten metal discharge forms layers 76 of molten metal which are successively superimposed on the top of the body 70 of startup material, and at a point directly below the top opening of the graphite ring, and adjacent the first cross sectional plane 72 of the cavity.
• this point is central of the mold cavity, and in the case of one which is symmetrically or asymmetrically noncircular, is typically coincident with the "thermal shed plane" 78 ( Figures 10 and 24) ofthe cavity, a term which will be explained more fully hereinafter.
• the molten metal may also be discharged into the cavity at two or more points therein, depending again on the cross sectional shape of the cavity, and the molten metal supply procedure followed in the casting operation.
• the successive layers actually form a stream of molten metal, and as such, the layers have certain hydrodynamic forces acting on them, and these forces are characterized herein as “splaying forces" "S" ( Figure 20) acting relatively peripherally outwardly from the axis 12 of the cavity adjacent the first cross sectional plane 72 thereof. That is, the forces tend to splay the molten metal material in that direction, and so to speak, "drive” the molten metal into contact with the surface 26 or 62 of the graphite ring.
• the magnitude of the splaying forces is a function of many factors, including the hydrostatic forces inherent in the molten metal stream at the point at which each layer of molten metal is superimposed on the body of startup material, or on the layers preceding it in the stream.
• each layer is not only directed headlong into the series of second cross sectional planes 74 of the cavity, but also allowed to take on second cross sectional areas 85 therein which have progressively peripherally outwardly greater cross sectional dimensions in the second cross sectional planes 74 corresponding thereto.
• the layer is never free, however, to "bleed" out of control in those planes, but instead, is at all times under the control of the baffling means provided by the annuli 86 at the surface 26 or 62 of the ring in the respective second cross sectional planes 74 of the cavity.
• the annuli 86 operate to confine the continued relatively peripheral outward distention of the layer, and to define the circumferential outlines 88 of the second cross sectional areas 85 taken on by the layer in the planes 74. But because of their relatively peripherally outwardly inclined angles to the axis 12, and their relatively peripherally outwardly staggered relationship to one another, they do so "retractively," or passively, so that the layer can assume progressively relatively peripherally outwardly greater cross sectional dimensions in the respective second planes corresponding thereto, as indicated.
• each ring has angularly successive part annular portions 92 (between the diagonals of Figure 19 representing the surface) arrayed about the circumference thereof, and if the circumferential outline of the surface is circular, the angle of its taper is the same throughout the circumference of the surface, the axis 12 of the cavity is oriented along a vertical line, and heat is uniformly extracted from the respective angularly successive part annular portions 94 ( Figures 10 and 19) ofthe layers about the circumferences thereof, then the body of metal will likewise assume a circular outline about the cross sectional area thereof in the plane 90.
• the surface 26 or 62 of it is given these characteristics, and the heat extraction means 8 including the "split jet" system of holes, 38, 40, are operated to extract heat from the respective portions 94 of the billet at a uniform rate about the circumference thereof, then in effect, the annulus 83 will confer a circular circumferential outline 84 on the first cross sectional area 82 therewithin, the annuli 86 will confer similar circumferential outlines 88 on the respective second cross sectional areas 85 therewithin, and the body of metal will prove to be cylindrical, since any thermal stresses generated in the body crosswise thereof in third cross sectional planes 95 ( Figure 9 and the diagonals representing the surface 26 or 62 in Figure 19) of the cavity extending parallel to the axis thereof between portions 94 of the body on mutually opposing sides of the cavity, will tend to balance one another from side to side of the cavity.
• the heat extraction means 8 including the "split jet" system of holes, 38, 40
• the layers 76 of molten metal must be allowed to transition through the series of second cross sectional planes 74, at cross sectional areas 85 and circumferential outlines 88 which are suited to the cross sectional area and circumferential outline intended for the body of metal in plane 90. This means that a cross sectional area 82 and circumferential outline 84 suited to that end, must be chosen for the first cross sectional plane 72.
• thermo shed plane ( Figure 24) is that vertical plane coinciding with the line of maximum thermal convergence in the trough-shaped model 98 defined by the successively converging isotherms of any body metal. Put another way, and as seen in Figure 24, it is the vertical plane coinciding with the cross sectional plane 100 of the cavity at the bottom of the model, and in theory, is the plane to the opposing sides of which heat is discharged from the body of metal to the outline thereof.
• I also discharge the coolant onto the body of metal 48 ( Figure 24) so as to impact the same between the cross sectional plane 100 of the cavity at the bottom of the model 98 and the plane at the rim 106 thereof, and preferably, as close as I can to the latter plane, such as onto the "cap” 107 of partially solidified metal formed about the mush 108 in the trough of the model.
• this may even mean discharging the coolant through the graphite ring and into the cavity, as seen through the cross section of Figure 21.
• the mold 109 comprises a pair of top and bottom plates 110 and 112, respectively, which are cooperatively rabbeted to capture a graphite ring 114 therebetween.
• the ring 114 is operable not only to form the casting surface 116 of the mold, but also to fo ⁇ n the inner periphery of an annular coolant chamber 118 arranged about the outer periphery thereof.
• the ring has a pair of circumferential grooves 120 about the outer periphery thereof, and the grooves are chamfered at the tops and bottoms thereof to provide suitable annuli for series of orifices 122 discharging into an additional pair of circumferential grooves 124 suitably closed with elastomer sealing rings 126 at the outer peripheries thereof.
• the grooves 124 discharge in turn into two sets of holes 128 which are arranged about the axis of the cavity to discharge into the same in the manner of USP 5,582,230 and US Patent Application 08/643,767.
• the holes 128 are commonly varnished or otherwise coated to contain the coolant in its passage therethrough, and once again, sealing rings are employed between the respective plates and the graphite ring to seal the chamber from the cavity.
• I may give the surface of the ring a curvilinear flare or taper, rather than a rectilinear one.
• the surface 152 ofthe ring 154 is not only curvilinear, but also curved somewhat reentrantly toward a parallel with the axis, below the series of second cross sectional planes 74, and below plane 90 in particular, for purposes of capturing any "rebleed” occurring after "solidus” has occurred.
• the casting surface follows every movement ofthe metal, but just ahead ofthe same, to lead but also control the progressive peripheral outward development of the metal.
• I can shift the band 156 itself, relative to the first and
• the body of metal such as the flat-sided outline required for rolling ingot.
• the mold 158 comprises a frame
• the other set of members, 164 is represented by either the member
• the member is also concavely
• the inside face 170 of the member is mitered at angularly successive intervals
• the length of the same is adjusted by reciprocating the ends 162 of the ring in
• the ends 162 of the mold are mechanically or hydraulically driven at
• PLC electronic controller
• the ring 190 is shown in the context of a mold ofthe type disclosed in USP 5,323,841, and is mounted on a rabbet 194 and clamped thereto so that it can be removed, reversed, and reused as indicated.
• the other features shown in phantom can be found in USP 5,323,841.
• My invention also assures that in ingot casting, the molten metal will fill the corners of the mold.
• the corners may be elliptically rounded or otherwise shaped to enable the splaying forces to drive the metal into them most effectively.
• My invention is not limited, however, to shapes with rounded contours. Given suitable shaping of the second cross sectional areas, angles can be cast in what are otherwise rounded or unrounded bodies.
• the cast product 196 may be sufficiently elongated to be subdividable into a multiplicity of longitudinal sections 198, as is illustrated in Figure 39 wherein the V-shaped piece 196 molded in a cavity like that of Figures 9 - 15 and 17, is shown as having been so subdivided.
• each section may be post-treated in some manner, such as given a light forging or other post-treatment in a plastic state to render it more suitable as a finished product, such as a component of an automobile carriage or frame.
• the body of startup material 70 should be formulated to function as a "moving floor” or “bulkhead” for the accumulating layers of molten metal.
• Figures 39 - 42 are included to show the dramatic decrease in the temperature of the interface between the casting surface and the molten metal layers when my means and technique are employed in casting a product. They also show that the decrease is a function of the degree of taper used at any particular point about the interface, circumferentially of the mold. In fact, the best degree of taper from point to point is often determined from taking successive thermocouple readings about the circumference of the mold.
• the thermal contraction forces are a function of many factors, including the metal being cast.

Landscapes

• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Continuous Casting (AREA)
• Molds, Cores, And Manufacturing Methods Thereof (AREA)

Priority Applications (14)

Applications Claiming Priority (2)

Publications (1)

Family

ID=25495927

Family Applications (1)

Country Status (19)

Cited By (4)

Families Citing this family (22)

Citations (4)

Family Cites Families (49)

• 1997
  • 1997-10-21 US US08/954,784 patent/US6158498A/en not_active Expired - Lifetime
• 1998
  • 1998-10-13 CN CNB988125021A patent/CN1296158C/zh not_active Expired - Lifetime
  • 1998-10-13 TR TR2000/01073T patent/TR200001073T2/xx unknown
  • 1998-10-13 PL PL98340213A patent/PL187487B1/pl unknown
  • 1998-10-13 RU RU2000112553/02A patent/RU2206427C2/ru active
  • 1998-10-13 EP EP20070013366 patent/EP1867411A3/en not_active Ceased
  • 1998-10-13 CA CA2674153A patent/CA2674153C/en not_active Expired - Lifetime
  • 1998-10-13 CA CA002309043A patent/CA2309043C/en not_active Expired - Lifetime
  • 1998-10-13 NZ NZ503951A patent/NZ503951A/xx not_active IP Right Cessation
  • 1998-10-13 HU HU0200645A patent/HU230027B1/hu unknown
  • 1998-10-13 WO PCT/US1998/021567 patent/WO1999020418A1/en not_active Ceased
  • 1998-10-13 JP JP2000516794A patent/JP2001520122A/ja active Pending
  • 1998-10-13 KR KR1020077018521A patent/KR100853074B1/ko not_active Expired - Lifetime
  • 1998-10-13 SK SK571-2000A patent/SK287265B6/sk not_active IP Right Cessation
  • 1998-10-13 KR KR1020077018520A patent/KR100860669B1/ko not_active Expired - Lifetime
  • 1998-10-13 CA CA2736400A patent/CA2736400C/en not_active Expired - Lifetime
  • 1998-10-13 CA CA2736798A patent/CA2736798C/en not_active Expired - Lifetime
  • 1998-10-13 GB GB0012406A patent/GB2347887B/en not_active Expired - Lifetime
  • 1998-10-13 EP EP98953432A patent/EP1034056A4/en not_active Withdrawn
  • 1998-10-13 SK SK21-2009A patent/SK287266B6/sk not_active IP Right Cessation
  • 1998-10-13 AU AU10811/99A patent/AU750545B2/en not_active Expired
  • 1998-10-13 KR KR1020007004222A patent/KR100803859B1/ko not_active Expired - Lifetime
  • 1998-10-13 CZ CZ20001435A patent/CZ301965B6/cs not_active IP Right Cessation
  • 1998-10-13 SK SK22-2009A patent/SK287267B6/sk not_active IP Right Cessation
  • 1998-10-13 BR BR9813103-6A patent/BR9813103A/pt active IP Right Grant
• 2000
  • 2000-04-17 IS IS5458A patent/IS5458A/is unknown
  • 2000-04-18 NO NO20002020A patent/NO334519B1/no not_active IP Right Cessation
  • 2000-05-17 US US09/572,644 patent/US6260602B1/en not_active Expired - Lifetime
  • 2000-10-20 US US09/693,494 patent/US6546995B1/en not_active Expired - Lifetime
• 2009
  • 2009-04-06 JP JP2009092426A patent/JP2009148837A/ja active Pending
  • 2009-04-06 JP JP2009092425A patent/JP5039743B2/ja not_active Expired - Lifetime
  • 2009-09-25 JP JP2009221112A patent/JP5319475B2/ja not_active Expired - Lifetime
• 2012
  • 2012-02-13 JP JP2012028759A patent/JP2012091234A/ja active Pending
  • 2012-06-01 JP JP2012126303A patent/JP2012157904A/ja active Pending
  • 2012-10-22 JP JP2012233018A patent/JP5856035B2/ja not_active Expired - Lifetime
  • 2012-11-26 JP JP2012257908A patent/JP2013059810A/ja active Pending
• 2015
  • 2015-08-31 JP JP2015171079A patent/JP5894700B2/ja not_active Expired - Lifetime

Patent Citations (4)

Non-Patent Citations (1)

Also Published As

Similar Documents

Legal Events