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
  • B22D11/14—Plants for continuous casting
  • B22D11/145—Plants for continuous casting for upward 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
  • B22D11/04—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
  • B22D11/041—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds for vertical 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
  • B22D11/12—Accessories for subsequent treating or working cast stock in situ
  • B22D11/128—Accessories for subsequent treating or working cast stock in situ for removing
  • B22D11/1281—Vertical removing
• • 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
  • B22D11/14—Plants for continuous casting
  • B22D11/141—Plants for continuous casting for vertical 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
  • B22D11/16—Controlling or regulating processes or operations
  • B22D11/22—Controlling or regulating processes or operations for cooling cast stock or mould
  • B22D11/225—Controlling or regulating processes or operations for cooling cast stock or mould for secondary cooling
• • C—CHEMISTRY; METALLURGY
  • C30—CRYSTAL GROWTH
  • C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
  • C30B15/00—Single-crystal growth by pulling from a melt, e.g. Czochralski method
  • C30B15/002—Continuous growth
• • C—CHEMISTRY; METALLURGY
  • C30—CRYSTAL GROWTH
  • C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
  • C30B15/00—Single-crystal growth by pulling from a melt, e.g. Czochralski method
  • C30B15/20—Controlling or regulating
  • C30B15/22—Stabilisation or shape controlling of the molten zone near the pulled crystal; Controlling the section of the crystal
  • C30B15/24—Stabilisation or shape controlling of the molten zone near the pulled crystal; Controlling the section of the crystal using mechanical means, e.g. shaping guides
• • C—CHEMISTRY; METALLURGY
  • C30—CRYSTAL GROWTH
  • C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
  • C30B15/00—Single-crystal growth by pulling from a melt, e.g. Czochralski method
  • C30B15/34—Edge-defined film-fed crystal-growth using dies or slits

Definitions

• the invention relates to an up-drawing continuous casting apparatus and an up-drawing continuous casting method.
• JP 2012-61518 A Japanese Patent Application Publication No. 2012-61518
• a starter is first immersed into the surface of molten metal (a molten metal surface), and then when the starter is drawn up, molten metal is also drawn out following the starter by surface tension and the surface film of the molten metal.
• a casting that has a desired sectional shape is able to be continuously cast by drawing out the molten metal via a shape determining member arranged near the molten metal surface, and cooling it (i.e., the drawn out molten metal).
• the sectional shape and the shape in the longitudinal direction are both determined by a mold.
• the solidified metal i.e., the casting
• the shape determining member in the free casting method determines only the sectional shape of the i casting, the shape in the longitudinal direction is not determined.
• the shape determining member is able to move in a direction parallel to the molten metal surface (i.e., horizontally), so castings of various shapes in the longitudinal direction are able to be obtained.
• JP 2012-61518 A describes a hollow casting (i.e., a pipe) formed in a zigzag shape or a helical shape, not a linear shape in the longitudinal direction.
• slag foreign matter
• the invention thus provides an up-drawing continuous casting apparatus and an up-drawing continuous casting method that inhibits the inclusion of foreign matter in a casting.
• a first aspect of the invention relates to an up-drawing continuous casting apparatus.
• This up-drawing continuous casting apparatus includes a holding furnace that holds molten metal; a shape determining member that is arranged near a molten metal surface of the molten metal held in the holding furnace, and that determines a sectional shape of a casting by the molten metal passing through the shape determining member; and a cooling portion that cools the molten metal that has passed through the shape determining member.
• the shape determining member includes, on a main surface on the molten metal surface side, at least one of a protruding portion that protrudes from the main surface, or a recessed portion that is recessed from the main surface.
• This kind of structure enables foreign matter floating on the molten metal surface to be blocked, such that the inclusion of foreign matter in the casting is able to be effectively inhibited.
• the up-drawing continuous casting apparatus may also include a molten metal passage portion that is provided in the shape determining member and through which the molten metal passes.
• the protruding portion may be a first protruding portion that is formed along an edge of the molten metal passage portion.
• a gap may be provided between the main surface of the shape determining member and the molten metal surface.
• the shape determining member may have the recessed portion formed at a base of the first protruding portion.
• the protruding portion may include a second protruding portion that is provided on the shape determining member, and that protrudes ori a side opposite the molten metal passage portion from a tip end of the first protruding portion.
• the recessed portion may have a triangular sectional shape, and be provided in plurality on the shape determining member.
• a second aspect of the invention relates to an up-drawing continuous casting method that uses an up-drawing continuous casting apparatus having a shape determining member that determines a sectional shape of a casting, and a protruding portion or a recessed portion provided on a main surface on a molten metal surface side of the shape determining member, the protruding portion protruding from the main surface and the recessed portion being recessed from the main surface.
• the up-drawing continuous casting method includes arranging the shape determining member near a molten metal surface of molten metal; passing the molten metal through the shape determining member and drawing up the molten metal; and cooling the molten metal that has passed through the shape determining member and been drawn up.
• This kind of structure enables foreign matter floating on the molten metal surface to be blocked, such that the inclusion of foreign matter in the casting is able to be effectively inhibited.
• the shape determining member may be provided with a molten metal passage portion through which the molten metal passes, and the protruding portion may be a first protruding portion formed along an edge of the molten metal passage portion.
• a gap may be provided between the main surface of the shape determining member and the molten metal surface.
• the shape determining member may have the recessed portion formed at a base of the first protruding portion.
• the shape determining member may be provided with a second protruding portion that protrudes on a side opposite the molten metal passage side from a tip end of the first protruding portion.
• the shape determining member may be provided with a plurality of the recessed members each of which has a triangular sectional shape.
• FIG 1 is a sectional view of a free casting apparatus according to a first example embodiment of the invention
• FIG. 2 is an enlarged sectional view of only an inner shape determining member and an outer shape determining member in FIG. 1;
• FIG. 3 is a top view of the inner shape determining member and the outer shape determining member
• FIG. 4 is a bottom view of the inner shape determining member and the outer shape determining member
• FIG. 5 is a sectional view of the inner shape determining member and the outer shape determining member according to a second example embodiment of the invention.
• FIG. 6 is an enlarged sectional view of the outer shape determining member encircled by the dotted line in FIG 5;
• FIG 7 is a modified example of the outer shape determining member shown in FIG.
• FIG 8 is a sectional view of the inner shape determining member and the outer shape determining member according to a third example embodiment of the invention.
• FIG 9 is an enlarged sectional view of the outer shape determining member encircled by the dotted line in FIG 8.
• FIG. 1 is a sectional view of the free casting apparatus according to the first example embodiment.
• the free casting apparatus according to the first example embodiment includes a molten metal holding furnace 101, an inner shape determining member 102a, an outer shape determining member 102b, support rods 103 and 104, an actuator 105, and a cooling gas nozzle 106.
• the molten metal holding furnace 101 holds molten metal Ml such as aluminum or an aluminum alloy, for example, and keeps it at a predetermined temperature.
• molten metal Ml such as aluminum or an aluminum alloy, for example, and keeps it at a predetermined temperature.
• molten metal Ml is not replenished into the molten metal holding furnace 101, so the surface of the molten metal Ml (i.e., the molten metal level) drops as casting proceeds.
• molten metal may also be instantly replenished into the molten metal holding furnace 101 during casting such that the molten metal level is kept constant.
• the molten metal Ml may be another metal or alloy other than aluminum.
• the inner shape determining member 102a and the outer shape determining member 102b are made of ceramic or stainless steel, for example, and are arranged near the molten metal surface. More specifically, the inner shape determining member 102a and the outer shape determining member 102b are arranged such that there is a gap G of approximately 0.5 mm between the molten metal surface and main surface on the lower side (i.e., the molten metal surface side) of each of the inner shape determining member 102a and the outer shape determining member 102b. Providing this gap G makes it possible to inhibit the temperature of the molten metal from decreasing as well as inhibit the incidence of slag (foreign matter) M4 on the molten metal surface.
• FIG. 2 is an enlarged sectional view of only the inner shape determining member 102a and the outer shape determining member 102b in FIG. 1.
• the inner shape determining member 102a includes a base portion 21a and a protruding portion 22a.
• the protruding portion 22a that protrudes downward from the base portion 21a i.e.* from a lower-side main surface of the inner shape determining member 102a
• the outer shape determining member 102b includes a base portion 21b and a protruding portion 22b.
• the protruding portion 22b that protrudes downward from the base portion 21b i.e., from a lower-side main surface of the outer shape determining member 102b
• the protruding portion 22b that protrudes downward from the base portion 21b is formed along an inside edge of the outer shape determining member 102b.
• the inner shape determining member 102a determines the inner shape of a casting M3, and the outer shape determining member 102b determines the outer shape of the casting M3.
• the casting M3 shown in FIG. 1 is a hollow casting (i.e., a pipe) with a tube-shaped cross-section in the horizontal direction (hereinafter referred to as "transverse section"). That is, more specifically, the inner shape determining member 102a determines an inner diameter of the transverse section of the casting M3, and the outer shape determining member 102b determines an outer diameter of the transverse section of the casting M3.
• FIG 3 is a top view of the inner shape determining member 102a and the outer shape determining member 102b.
• FIG 4 is a bottom view of the inner shape determining member 102a and the outer shape determining member 102b.
• FIG. 2 corresponds to a sectional view taken along line II - II in FIGS. 3 and 4.
• the outer shape determining member 102b has a rectangular planar shape, for example, and has a circular open portion in the center portion.
• the inner shape determining member 102a has a circular planar shape, for example, and is arranged in the center portion of the open portion of the outer shape determining member 102b.
• a gap between the inner shape determining member 102a and the outer shape determining member 102b is a molten metal passage portion 102c through which molten metal passes.
• the connecting member 102 is formed by the inner shape determining member 102a, the outer shape determining member 102b, and the molten metal passage portion 102c.
• the protruding portion 22a is formed along an edge of the inner shape determining member 102a on a side of the molten metal passage portion 102c (i.e., an outer edge), on the lower-side main surface of the inner shape determining member 102a.
• the protruding portion 22b is formed along an edge of the outer shape determining member 102b on a side of the molten metal passage portion 102c (i.e., an inner edge), on the lower-side main surface of the outer shape determining member 102b.
• a tip end of each of the protruding portions 22a and 22b is immersed in molten metal. Therefore, slag M4 floating on the molten metal surface is able to be blocked by the protruding portions 22a and 22b, so the inclusion of the slag M4 in the casting M3 is able to be effectively inhibited.
• the molten metal Ml is drawn up following the casting M3 by the surface tension and the surface film of the molten metal, and passes through the molten metal passage portion 102c.
• the molten metal that is drawn up from the molten metal surface following the casting M3 by the surface film and the surface tension of the molten metal will be referred to as "retained molten metal M2".
• the interface between the casting M3 and the retained molten metal M2 is a solidification interface.
• the support rod 103 supports the inner shape determining member 102a and the support rod 104 supports the outer shape determining member 102b.
• the positional relationship between the inner shape determining member 102a and the outer shape determining member 102b is able to be maintained by these support rods 103 and 104.
• a gap G is able to be provided by these support rods 103 and 104.
• having the support rod 103 be a pipe structure flowing cooling gas through the support rod 103, and moreover, providing blow holes in the inner shape determining member 102a, enables the casting M3 to be cooled from the inside as well.
• the support rods 103 and 104 are both connected to the actuator 105.
• This actuator 105 enables the support rods 103 and 104 to move in the top-bottom direction (the perpendicular direction) and the left-right direction, while maintaining the positional relationship between the inner shape determining member 102a and the outer shape determining member 102b.
• the inner shape determining member 102a and the outer shape determining member 102b are able to be moved downward while keeping the gap G at a constant value, as the molten metal level drops as casting proceeds.
• the inner shape determining member 102a and the outer shape determining member 102b are able to be moved horizontally, so the shape of the casting M3 in the longitudinal direction is able to be changed freely.
• a cooling gas nozzle (a cooling portion) 106 is used to spray cooling gas (e.g., air, nitrogen, argon, or the like) at the casting M3 to cool the casting M3.
• the casting M3 is cooled by the cooling gas while being drawn up by a drawer, not shown, that is connected to a starter ST. Accordingly, the retained molten metal M2 near the solidification interface solidifies sequentially, thus forming the casting M3.
• the free casting method according to the first example embodiment will be described with reference to FIG. 1.
• the starter ST is lowered so that it passes through the molten metal passage portion 102c between the inner shape determining member 102a and the outer shape determining member 102b, and the tip end of the starter ST is immersed in the molten metal Ml.
• the starter ST starts to be drawn up at a predetermined speed.
• the retained molten metal M2 that follows the starter ST and is drawn up from the molten metal surface by the surface film and surface tension is formed.
• the retained molten metal M2 is formed in the molten metal passage portion 102c between the inner shape determining member 102a and the outer shape determining member 102b. That is, the inner shape determining member 102a and the outer shape determining member 102b give the retained molten metal M2 its shape.
• the starter ST is cooled by cooling gas blown from the cooling gas nozzle 106, so the retained molten metal M2 solidifies sequentially from the upper side toward the lower side, thus forming the casting M3. In this way, the casting M3 is able to be continuously cast.
• slag M4 floating on the molten metal surface is able to be blocked before the molten metal Ml passes through the molten metal passage portion 102c, by the protruding portion 22a provided on the inner shape determining member 102a, and the protruding portion 22b provided on the outer shape determining member 102b. Therefore, the inclusion of slag M4 in the retained molten metal M2 that has passed through the molten metal passage portion 102c is able to be inhibited. As a result, the inclusion of slag M4 in the casting M3 is able to be effectively inhibited.
• the gap G of approximately 0.5 mm is provided between the molten metal surface and the main surfaces on the lower side of the inner shape determining member 102a and the outer shape determining member 102b. Therefore, a decrease in the temperature of the molteii metal, and the incidence of slag M4 on the molten metal surface are able to be inhibited. Even if the gap G is not provided, the inclusion of the slag M4 in the casting M3 is able to be effectively inhibited by the protruding portion 22b. Therefore, in the first example embodiment, the gap G is not absolutely necessary.
• FIG 5 is a sectional view of the inner shape determining member 102a and the outer shape determining member 102b according to the second example embodiment.
• the inner shape determining member 102a and the outer shape determining member 102b according to the second example embodiment have a more complex structure for blocking the slag M4 than the inner shape determining member 102a and the outer shape determining member 102b according to the first example embodiment shown in FIG 2 do.
• the other structure is similar to that of the first example embodiment, so a description thereof will be omitted.
• FIG. 6 is an enlarged sectional view of the outer shape determining member 102b encircled by the dotted line in FIG 5.
• the outer shape determining member 102b includes a base portion 21b, a first protruding portion 22b, a recessed portion 23b, and a second protruding portion 24b.
• the first protruding portion 22b that protrudes downward from the base portion 21b is formed along the inside edge of the outer shape determining member 102b.
• the recessed portion 23b is a groove structure formed in the base portion 21b, at the base of the first protruding portion 22b, and is formed in an annular shape when viewed in a plan view from below.
• the second protruding portion 24b is formed protruding to the outside (i.e., the side opposite the molten metal passage portion 102c) from the tip end of the first protruding portion 22b.
• a cross-section of the outer shape determining member 102b has a hook shape.
• the sectional shape of the recessed portion 23b is not limited to being rectangular, and may also be another shape such as triangular or semi-circular.
• the outer shape determining member 102b according to the second example embodiment includes the recessed portion 23b. Therefore, the blocked slag M4 is able to be collected in the recessed portion 23b, so the inclusion of the slag M4 in the casting M3 is able to be even more effectively inhibited than it is with the outer shape determining member 102b according to the first example embodiment. Furthermore, the outer shape determining member 102b according to the second example embodiment includes the second protruding portion 24b, so the ability of the outer shape determining member 102b according to the second example embodiment to retain the blocked slag M4 is higher than it is with the outer shape determining member 102b according to the first example embodiment.
• the inner shape determining member 102a shown in FIG 5 also has the same structure as the outer shape determining member 102b, so it displays the same effect.
• FIG 7 is a modified example of the outer shape determining member 102b shown in FIG. 6.
• the blocked slag M4 is able to be collected in the recessed portion 23b. That is, the inclusion of the slag M4 in the casting M3 is able to be even more effectively inhibited than it is by the outer shape determining member 102b according to the first example embodiment.
• FIG. 8 is a sectional view of the inner shape determining member 102a and the outer shape determining member 102b according to the third example embodiment.
• the inner shape determining member 102a and the outer shape determining member 102b according to the third example- embodiment have a different structure for blocking the slag M4 than the inner shape determining member 102a and the outer shape determining member 102b according to the first example embodiment shown in FIG 2 do.
• the other structure is similar to that of the first example embodiment, so a description thereof will be omitted.
• FIG 9 is an enlarged sectional view of the outer shape determining member 102b encircled by the dotted line in FIG 8.
• the outer shape determining member 102b has a base portion 21b and a plurality of recessed portions 23b.
• the plurality of recessed portions 23b are groove structures formed in a lower-side main surface of the base portion 21b, and are formed in concentric annular shapes when viewed in a plan view from below.
• the plurality of recessed portions 23b all have triangular cross-sections.
• the apex that faces the bottom side is positioned to the inside (i.e., the side with the molten metal passage portion 102c) of the center of the bottom side on all of the recessed portions 23b.
• the height (i.e., the gap G) of the triangular shapes on the top-bottom direction is preferably approximately 0.5 mm.
• the overall cross-section of the outer shape determining member 102b is saw blade-shaped.
• the outer shape determining member 102b according to the third example embodiment is able to block and collect the slag M4 by the recessed portion 23b.
• this kind of effect is able to be further improved.
• the inclusion of the slag M4 in the casting M3 is able to be even more effectively inhibited.
• the inner shape determining member 102a shown in FIG. 8 has the same structure as the outer shape determining member 102b, and therefore displays the same effect.
• the inner shape determining member 102a includes at least one of the protruding portion 22a and a recessed portion (a portion corresponding to the recessed portion 23b), on the main surface that is on the lower side (i.e. the molten metal surface side), and is thus able to block the slag M4.
• the inclusion of the slag M4 in the casting M3 is able to be effectively inhibited.
• the outer shape determining member 102b includes at least one of the first protruding portion 22b and the recessed portion 23b on the main surface on the lower side (i.e., the molten metal side), and is thus able to block the slag M4.
• the inclusion of the slag M4 in the casting M3 is able to be effectively inhibited.
• a certain effect is able to be obtained when a structure for blocking the slag M4 is provided only on the outer shape determining member i02b and not on the inner shape determining member 102a.
• the invention is not limited to the example embodiments described above, but may be modified as appropriate.
• the outer shape determining member 102b when casting a solid casting instead of the hollow casting illustrated in the example embodiments, only the outer shape determining member 102b according to the example embodiments need be used, without using the inner shape determining member 102a.
• the inclusion of slag (i.e., foreign matter) in the casting is able to be effectively inhibited just as it is in the example embodiments described above.
• the open portion provided in the outer shape determining member 102b serves as the molten metal passage portion 102c just as it is.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Continuous Casting (AREA)
• Casting Support Devices, Ladles, And Melt Control Thereby (AREA)

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• 2012
  • 2012-09-18 JP JP2012204464A patent/JP2014057981A/ja not_active Ceased
• 2013
  • 2013-09-13 AU AU2013319900A patent/AU2013319900A1/en not_active Abandoned
  • 2013-09-13 CN CN201380032156.1A patent/CN104395014A/zh active Pending
  • 2013-09-13 US US14/411,290 patent/US20150122451A1/en not_active Abandoned
  • 2013-09-13 BR BR112014031956A patent/BR112014031956A2/pt not_active IP Right Cessation
  • 2013-09-13 WO PCT/IB2013/002130 patent/WO2014045116A2/en active Application Filing
  • 2013-09-13 IN IN11081DEN2014 patent/IN2014DN11081A/en unknown
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