WO2024137582A1 - Conception de courroie d'appareil de coulée continue - Google Patents

Conception de courroie d'appareil de coulée continue Download PDF

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Publication number
WO2024137582A1
WO2024137582A1 PCT/US2023/084752 US2023084752W WO2024137582A1 WO 2024137582 A1 WO2024137582 A1 WO 2024137582A1 US 2023084752 W US2023084752 W US 2023084752W WO 2024137582 A1 WO2024137582 A1 WO 2024137582A1
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WO
WIPO (PCT)
Prior art keywords
approximately
aluminum
casting belt
endless
layer
Prior art date
Application number
PCT/US2023/084752
Other languages
English (en)
Inventor
Alp Manavbasi
Simon William BARKER
Original Assignee
Novelis Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Novelis Inc. filed Critical Novelis Inc.
Publication of WO2024137582A1 publication Critical patent/WO2024137582A1/fr

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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
    • B22D11/10—Supplying or treating molten metal
    • B22D11/108—Feeding additives, powders, or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C3/00—Selection of compositions for coating the surfaces of moulds, cores, or patterns
    • 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
    • B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
    • B22D11/0605—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars formed by two belts, e.g. Hazelett-process
    • 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
    • B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
    • B22D11/0637—Accessories therefor
    • B22D11/0648—Casting surfaces
    • B22D11/0654—Casting belts
    • 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
    • B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
    • B22D11/0637—Accessories therefor
    • B22D11/0665—Accessories therefor for treating the casting surfaces, e.g. calibrating, cleaning, dressing, preheating
    • B22D11/0668—Accessories therefor for treating the casting surfaces, e.g. calibrating, cleaning, dressing, preheating for dressing, coating or lubricating
    • 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
    • B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
    • B22D11/0637—Accessories therefor
    • B22D11/0665—Accessories therefor for treating the casting surfaces, e.g. calibrating, cleaning, dressing, preheating
    • B22D11/0671—Accessories therefor for treating the casting surfaces, e.g. calibrating, cleaning, dressing, preheating for heating or drying

Definitions

  • This application relates to a continuous casting apparatus for casting metal product. More particularly, this application relates to continuous casting apparatus belt designs which modify or replace a standard steel, aluminum, or copper belt.
  • Continuous casters such as twin belt casters, single belt casters and recirculating block casters, are commonly used for producing strip ingots (continuous metal strips) from molten metals, particularly aluminum alloys.
  • a casting cavity is formed between continuously moving casting surfaces and molten metal is introduced into the casting cavity on a continuous basis.
  • Heat is withdrawn from the metal via the casting surfaces and the metal solidifies in the form of a strip ingot that is continuously withdrawn from the casting cavity by the moving casting surfaces.
  • the heat flux through the casting surfaces must be carefully controlled to achieve cast strip ingots of good surface quality and to avoid distortion of the casting cavity.
  • Different metals e.g. aluminum alloys
  • the primary heat flux control is usually achieved by applying cooling water to the casting belts or blocks. In most belt casters, this is done on the back face of the belt in the region where the belt passes though the casting cavity.
  • the heat flux is often adjusted more precisely by additional means.
  • belt casters have been provided with porous ceramic coatings over the metal belts. Such coatings may optionally be partially or completely filled with a high conductivity inert gas, such as helium, to provide further refinement. In such cases, the expense of maintaining a consistent ceramic coating and the cost of the inert gas have made such procedures economically unattractive.
  • a layer of a volatile or partially volatile liquid e.g. a parting agent, typically including an oil
  • a parting agent typically including an oil
  • This layer is often referred to as “belt dressing” or as a “parting layer”.
  • the thickness of the layer can be varied to provide for control of heat flux to the underlying casting surfaces.
  • the use of such oils may adversely affect the surface quality of the cast strip ingot (particularly ingots made from aluminum alloys containing high levels of alloying elements, including magnesium), and may give rise to environmental issues, particularly when excessive applications are required in order to achieve the desired degree of heat flux control.
  • an endless belt for a continuous metal casting apparatus includes a belt that is modified with a texture or barrier layer.
  • the endless belt includes a belt surface that is modified so that the need to use a parting agent is either reduced or eliminated.
  • the apparatus may comprise two endless belts, wherein at least one of the endless belts has the texture or barrier layer described herein. In some aspects, both belts have the texture or barrier layer described herein.
  • Each belt may have the same texture or barrier layer or may have different textures or barrier layers.
  • a casting apparatus for continuously casting a metal strip article, wherein the casting apparatus comprises an endless casting belt comprising a base layer and a barrier layer, wherein the base layer comprises aluminum and wherein the barrier layer is at least one of a Gibbsite-A1(OH)3 barrier layer, a pseudo -boehmite barrier layer, a complete boehmite layer, or a stable and cohesive oxide layer.
  • the barrier layer is at least one of a Gibbsite-A1(OH)3 barrier layer, a pseudo -boehmite barrier layer, a complete boehmite layer, or a stable and cohesive oxide layer.
  • Also described herein is a method of forming an endless casting belt, the method comprising: (a) providing an aluminum endless casting belt; and (b) treating the aluminum endless casting belt by at least a first hydrothermal treatment to form a pseudo-boehmite barrier layer on at least one surface of the aluminum endless casting belt providing a treated aluminum endless casting belt.
  • the hydrothermal treatment comprises boiling in water or steamtreating.
  • the hydrothermal treatment comprises submerging the aluminum endless casting belt in water at a temperature from 90 °C to 150 °C for a period of time from 1 hour to 10 hours.
  • treating the aluminum endless casting belt is conducted with at least one additive.
  • treating the aluminum endless casting belt further comprises anodizing the treated aluminum endless casting belt in an organic or inorganic acid solution to form a crystalline aluminum oxide layer.
  • the treating further comprises a second hydrothermal treatment or a post-anodizing sealing treatment of the crystalline aluminum oxide layer.
  • a method of forming the endless casting belt comprising: (a) providing an aluminum endless casting belt; (b) anodizing the aluminum endless casting belt in an inorganic acid to form an amorphous aluminum oxide layer on at least one surface of the aluminum endless casting belt; and (c) converting the amorphous aluminum oxide layer to at least one of a Gibbsite-A1(OH)3 barrier layer, a pseudo-boehmite barrier layer, a complete boehmite layer, or a cohesive and stable oxide layer.
  • converting the amorphous aluminum oxide layer comprises hydrothermally treating the amorphous aluminum oxide layer.
  • the method described herein further comprises applying a post-anodizing sealing treatment to the amorphous aluminum oxide layer, optionally with at least one additive.
  • the amorphous aluminum oxide layer is a nano-porous amorphous aluminum oxide layer, or the amorphous aluminum oxide layer is a nonporous micron-scale or submicron-scale amorphous aluminum oxide layer.
  • the method described herein further comprises forming channels on the aluminum endless casting belt before anodizing the aluminum endless casting belt, or templating the amorphous aluminum oxide layer.
  • the endless casting belt further comprises a metal foil layer, wherein the metal foil layer comprises titanium, copper, nickel, brass, stainless steel, or any combination thereof.
  • the metal foil can have a mesh size from 0.70 to 1.5 cm and openings from 30 to 95%.
  • the endless casting belt further comprises a carbon fiber layer.
  • the casting apparatus comprises an endless casting belt comprising a base layer and a barrier layer, wherein the base layer comprises aluminum, copper, or steel and wherein the barrier layer comprises a carbon fiber layer.
  • the endless casting belt further comprises a metal foil layer in contact with the carbon fiber layer.
  • Also described herein is a method of forming the endless casting belt of any preceding illustration, the method comprising: (a) providing an aluminum endless casting belt; and (b) treating the aluminum endless casting belt with a masking agent to form a textured aluminum endless casting belt.
  • Figure 1 is a schematic of a continuous metal casting apparatus described herein.
  • Figure 2 is a panel of digital images showing a comparison of surfaces described herein according to an example described herein.
  • Figure 3 is a panel of analytical images showing a comparison of surfaces described herein according to an example described herein.
  • Figure 4 shows a digital image of a surface treated endless casting belt described herein according to an example described herein.
  • Figure 5 shows a digital image of expanded metal foils described herein according to an example described herein.
  • alloys identified by aluminum industry designations such as “ ’sseerriieess”” or “6xxx.”
  • invention As used herein, the terms “invention,” “the invention,” “this invention” and “the present invention” are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.
  • the meaning of “metals” includes pure metals, alloys, and metal solid solutions unless the context clearly dictates otherwise.
  • terms such as “cast metal product,” “cast product,” “cast aluminum alloy product,” and the like are interchangeable and refer to a product produced by direct chill casting (including direct chill co-casting) or semi-continuous casting, continuous casting (including, for example, by use of a twin belt caster, a twin roll caster, a twin block caster, or any other continuous caster), electromagnetic casting, hot top casting, or any other casting method.
  • a plate generally has a thickness of greater than approximately 15 mm.
  • a plate may refer to an aluminum product having a thickness of greater than approximately 15 mm, greater than approximately 20 mm, greater than approximately 25 mm, greater than approximately 30 mm, greater than approximately 35 mm, greater than approximately 40 mm, greater than approximately 45 mm, greater than approximately 50 mm, or greater than approximately 100 mm.
  • a shate (also referred to as a sheet plate) generally has a thickness of from approximately 4 mm to approximately 15 mm.
  • a shate may have a thickness of approximately 4 mm, approximately 5 mm, approximately 6 mm, approximately 7 mm, approximately 8 mm, approximately 9 mm, approximately 10 mm, approximately 11 mm, approximately 12 mm, approximately 13 mm, approximately 14 mm, or approximately 15 mm.
  • a sheet generally refers to an aluminum product having a thickness of less than approximately 4 mm (e.g., less than 3 mm, less than 2 mm, less than 1 mm, less than 0.5 mm, less than 0.3 mm, or less than 0.1 mm).
  • a sheet may have a thickness of approximately 0.1 mm, approximately 0.2 mm, approximately 0.3 mm, approximately 0.4 mm, approximately 0.5, approximately 0.6 mm, approximately 0.7 mm, approximately 0.8 mm, approximately 0.9 mm, approximately 1 mm, approximately 1.1 mm, approximately 1.2 mm, approximately 1.3 mm, approximately 1.4 mm, approximately 1.5 mm, approximately 1.6 mm, approximately 1.7 mm, approximately 1.8 mm, approximately 1.9 mm, approximately 2 mm, approximately 2.1 mm, approximately 2.2 mm, approximately 2.3 mm, approximately 2.4 mm, approximately 2.5 mm, approximately 2.6 mm, approximately 2.7 mm, approximately 2.8 mm, approximately 2.9 mm, approximately 3 mm, approximately 3.1 mm, approximately 3.2 mm, approximately 3.3 mm, approximately 3.4 mm, approximately 3.5 mm, approximately 3.6 mm, approximately 3.7 mm, approximately 3.8 mm, or approximately 3.9 mm.
  • a foil generally refers to an aluminum alloy product having a thickness of less than about 0.2 mm, less than about 0. 1 mm, less than about 0.09 mm, less than about 0.08 mm, less than about 0.07 mm, less than about 0.06 mm, or less than about 0.05 mm.
  • An F condition or temper refers to an aluminum alloy as fabricated.
  • An O condition or temper refers to an aluminum alloy after annealing.
  • An Hxx condition or temper also referred to herein as an H temper, refers to a non-heat treatable aluminum alloy after cold rolling with or without thermal treatment (e.g., annealing). Suitable H tempers include HX1, HX2, HX3 HX4, HX5, HX6, HX7, HX8, or HX9 tempers.
  • a T1 condition or temper refers to an aluminum alloy cooled from hot working and naturally aged (e.g., at room temperature).
  • a T2 condition or temper refers to an aluminum alloy cooled from hot working, cold worked and naturally aged.
  • a T3 condition or temper refers to an aluminum alloy solution heat treated, cold worked, and naturally aged.
  • a T4 condition or temper refers to an aluminum alloy solution heat treated and naturally aged.
  • a T5 condition or temper refers to an aluminum alloy cooled from hot working and artificially aged (at elevated temperatures).
  • a T6 condition or temper refers to an aluminum alloy solution heat treated and artificially aged.
  • a T7 condition or temper refers to an aluminum alloy solution heat treated and artificially overaged.
  • a T8 condition or temper refers to an aluminum alloy solution heat treated, cold worked, and artificially aged.
  • a T9 condition or temper refers to an aluminum alloy solution heat treated, artificially aged, and cold worked.
  • a W condition or temper refers to an aluminum alloy after solution heat treatment.
  • the “high strength temper” refers to a temper in which the aluminum alloy is artificially aged to peak age strength.
  • a 6xxx series aluminum alloy can be solution heat treated and artificially aged to a T6 temper to obtain a peak age strength.
  • exemplary high strength tempers can include T6, T7, T8, or T9 tempers.
  • room temperature can include a temperature of from about 15 °C to about 30 °C, for example about 15 °C, about 16 °C, about 17 °C, about 18 °C, about 19 °C, about 20 °C, about 21 °C, about 22 °C, about 23 °C, about 24 °C, about 25 °C, about 26 °C, about 27 °C, about 28 °C, about 29 °C, or about 30 °C.
  • Endless Casting Belt Comprising a Base Layer and a Barrier Layer
  • FIG. 1 illustrates a continuous casting system 100.
  • the continuous casting system 100 is a twin belt system with two endless casting belts 104 A and 104B having casting surfaces.
  • the continuous casting system 100 may be any type of continuous casting system, including but not limited to a twin belt caster, a twin roll caster, a single roll caster, or a twin block caster.
  • the endless casting belts 104 A and 104B are rotated continuously, and molten metal 102 is introduced from an injector 110 (sometimes referred to as a nose tip or nosepiece) into a thin mold or casting cavity 106 formed between the confronting regions of the endless casting belts 104A and 104B.
  • the solidified product 108 is continuously ejected from the casting cavity 106.
  • the casting apparatus for continuously casting a metal strip article comprises an endless casting belt.
  • the endless casting belt comprises a base layer and a barrier layer.
  • the base layer in these aspects comprises aluminum.
  • the barrier layer is formed or placed on top of the base layer so that the base layer will be in contact with the molten metal.
  • the barrier layer is formed so that it is at least one of a Gibbsite-aluminum hydroxide layer (Gibbsite-A1(OH) 3 layer), a pseudo-boehmite layer, or a complete boehmite layer.
  • the base layer of the endless casting belt may comprise an aluminum material.
  • the aluminum material is a 5xxx or 6xxx aluminum alloy
  • the aluminum alloy may be in F temper or may be heat treated.
  • the aluminum alloy in in T6 temper such as an AA6061 aluminum material in T6 temper.
  • the base layer may have a thickness from 1 to 2 mm, e.g., from 1.2 to 1.8 mm, or from 1.4 to 1.6 mm.
  • the base layer has a thickness of approximately 1 mm, approximately 1.1 mm, approximately 1.2 mm, approximately 1.3 mm, approximately 1.4 mm, approximately 1.5 mm, approximately 1.6 mm, approximately 1.7 mm, approximately 1 .8 mm, approximately 1 .9 mm, or approximately 2 mm.
  • a parting agent is typically applied to endless casting belts, regardless of the belt’s composition, in order to prevent the solidified strip from sticking to the belt.
  • a barrier layer on top of the base layer, e.g., facing the solidified strip, the need to use a parting agent is reduced or entirely eliminated.
  • the barrier layer comprises a Gibbsite-A1(OH) 3 layer, a pseudo-boehmite layer, a complete boehmite layer, or combinations thereof
  • the barrier layer may be formed by a variety of methods, so long as the final resulting barrier layer results in the reduction or elimination of the need to use a parting agent.
  • the barrier layer may have a thickness from 10 nanometers to 1 micron, e.g., from 25 nanometers to 750 nanometers, from 50 nanometers to 500 nanometers, or from 75 nanometers to 250 nanometers.
  • the barrier layer has a thickness of approximately 10 nm, approximately 15 nm, approximately 20 nm, approximately 25 nm, approximately 30 nm, approximately 35 nm, approximately 40 nm, approximately 45 nm, approximately 50 nm, approximately 55 nm, approximately 60 nm, approximately 65 nm, approximately 70 nm, approximately 75 nm, approximately 80 nm, approximately 85 nm, approximately 90 nm, approximately 95 nm, approximately 100 nm, approximately 125 nm, approximately 150 nm, approximately 175 nm, approximately 200 nm, approximately 225 nm, approximately 250 nm, approximately 275 nm, approximately 300 nm, approximately 325 nm, approximately 350 nm, approximately 10 nm,
  • the thickness can be greater than 1000 nm.
  • the thickness refers to the height of the barrier layer from the bottom of the barrier layer in contact with the top of the base layer to the top of the barrier layer which would contact the solidified strip.
  • a Gibbsite- A1(OH) 3 layer refers to a mineral form of aluminum hydroxide that is formed by stacking octahedral sheets of aluminum hydroxide. Each layer has an octahedral coordinated aluminum 3 + cation sandwiched between two layers of hydroxide anion, resulting in each hydroxyl being bonded to two aluminums, resulting in two thirds of available octahedral sites being occupied.
  • Gibbsite-A1(OH) 3 may have small crystals, e.g., less than 2 microns in diameter.
  • the Gibbsite-A1(OH) 3 layer can form a stable oxide layer on the aluminum surface that allows the aluminum alloy to be continuously cast with minimal parting agent or no parting agent at all.
  • the desirable Gibbsite- A1(OH) 3 layer forms preferably at casting temperatures of from 690 °C to 720 °C (e.g., 695 °C to 715 °C, 691 °C to 719 °C, 700 °C to 720 °C, or from 690 °C to 710 °C), for example about 690 °C, about 691 °C, about 692 °C, about 693 °C, about 694 °C, about 695 °C, about 696 °C, about 697 °C, about 698 °C, about 699 °C, about 700 °C, about 701 °C, about 702 °C, about 703 °C, about 704 °C, about 705 °C, about 706 °C, about 707 °C, about 708 °C, about 709 °C, about 710 °C, about 711 °C, about 712 °C, about 713 °
  • a complete boehmite layer is an aluminum oxide hydroxide layer that is dimorphous.
  • the stable oxide layer formed from initial Boehmite layers may improve wettability of aluminum surfaces and may improve heat flux.
  • the base layer Prior to forming the barrier layer, the base layer may be cleaned.
  • Methods for cleaning the base layer include solvent cleaning, acid cleaning, base cleaning, surfactant cleaning, or the like.
  • the entry cleaning can be performed using a solvent (e.g., an aqueous or organic solvent).
  • one or more additives can be added to the solvent.
  • the entry cleaning can be performed using an acid (e.g., an acid electrolyte, described in detail below).
  • the entry cleaner can be sprayed onto one or more surfaces of the continuous coil.
  • the cleaning step can be performed by spraying water and/or a cleaning solution onto one or more surfaces of the continuous coil at a pressure of from about 2 bar to about 4 bar.
  • the surfaces of the continuous coil can be sprayed at a pressure of about 2 bar, 2.1 bar, 2.2 bar, 2.3 bar, 2.4 bar, 2.5 bar, 2.6 bar, 2.7 bar, 2.8 bar, 2.9 bar, 3 bar, 3.1 bar, 3.2 bar, 3.3 bar, 3.4 bar, 3.5 bar, 3.6 bar, 3.7 bar, 3.8 bar, 3.9 bar, 4 bar, or anywhere in between.
  • the entry cleaner can be heated prior to application to one or more surfaces of the continuous coil. In some non-limiting examples, the entry cleaner can be heated to a temperature of from about 85 °C to about 100 °C.
  • the entry cleaner can be heated to a temperature of about 85 °C, 86 °C, 87 °C, 88 °C, 89 °C, 90 °C, 91 °C, 92 °C, 93 °C, 94 °C, 95 °C, 96 °C, 97 °C, 98 °C, 99 °C, 100 °C, or anywhere in between.
  • the cleaning is conducted in order to remove localized distortions, oxide build up, and other defects that may affect application and/or formation of the barrier layer on the base layer.
  • the cleaned endless casting belt is then provided to begin formation/application of the barrier layer.
  • the aluminum endless casting belt surface After cleaning the aluminum endless casting belt surface, it can be steam treated or boiled in water with or without specific additives to form stable pseudo-boehmite layer that will provide barrier layer and also modify the heat flux in a similar way parting agent provides on the conventional copper and steel belts used for continuous casting of aluminum alloys.
  • a method of forming the endless casting belt described herein includes providing an aluminum endless casting belt and treating the aluminum endless casting belt by a hydrothermal treatment to form a pseudo-boehmite barrier layer on at least one surface of the aluminum endless casting belt.
  • the hydrothermal treatment includes boiling the endless casting belt in water (e.g., in a bath) at a temperature of from about 90 °C to about 150 °C (e.g., from about 90 °C to about 140 °C, from about 100 °C to about 130 °C, from about 95 °C to about 145 °C, or from about 100 °C to about 125 °C).
  • the water is heated to a temperature of approximately 90 °C, aapppprrooxxiimmaatteellyy 9911 °C, approximately 92 °°CC,, aapppprrooxxiimmaatteellyy 9933 °C, approximately 94 °C, approximately 95 °C, approximately 96 °C, approximately 97 °C, approximately 98 ° C, approximately 99 ° C, approximately 100 °C, approximately 101 °C, approximately 102 °C, approximately 103 C, approximately 104 °C, approximately 105 °C, approximately 106 °C, approximately 107 °C, approximately 108 °C, approximately 109 °C, approximately 110 °C, approximately 111 °C, approximately 112 °C, approximately 113 °C, approximately 114 °C, approximately 115 ° C, approximately 116 °C, approximately 117 °C, approximately 118 °C, approximately 119 °C, approximately 120 °C,
  • the endless casting belt may be placed in the heated water for a time period from 1 to 10 hours, e.g., approximately 1 hour, approximately 2 hours, approximately 3 hours, approximately 4 hours, approximately 5 hours, approximately 6 hours, approximately 7 hours, approximately 8 hours, approximately 9 hours, or approximately 10 hours.
  • the hydrothermal treatment includes steam treating.
  • the steam treatment may be conducted at a temperature of at least 100 °C.
  • the steam treatment occurs at a temperature of approximately 100 °C, approximately 101 °C, approximately 102 °C, approximately 103 °C, approximately 104 °C, approximately 105 °C, approximately 106 °C, approximately 107 °C, approximately 108 °C, approximately 109 °C, approximately 110 °C, approximately 111 °C, approximately 112 °C, approximately 113 °C, approximately 114 °C, approximately 115 °C, approximately 116 °C, approximately 117 °C, approximately 118 °C, approximately 119 °C, approximately 120 °C, approximately 121 °C, approximately 122 °C, approximately 123 °C, approximately 124 °l ', approximately 125 °C, approximately 126 °C, approximately 127 °C, approximately 128 °C, approximately 129 °C
  • the endless casting belt may be exposed to the steam for a time period from 0.1 to 10 hours, e.g., approximately 6 minutes, approximately 12 minutes, approximately 18 minutes, approximately 24 minutes, approximately 30 minutes, approximately 36 minutes, approximately 42 minutes, approximately 48 minutes, approximately 54 minutes, approximately 1 hour, approximately 2 hours, approximately 3 hours, approximately 4 hours, approximately 5 hours, approximately 6 hours, approximately 7 hours, approximately 8 hours, approximately 9 hours, or approximately 10 hours.
  • the steam treatment may occur in a closed chamber, optionally under pressure.
  • the pressure may range from 1 psig to 100 psig (e.g., from 5 psig to 95 psig, from 10 psig to 90 psig, from 15 psig to 85 psig, from 20 psig to 80 psig, from 2 psig to 99 psig, from 1 psig to 99 psig, or from 2 psig to 100 psig).
  • 1 psig to 100 psig e.g., from 5 psig to 95 psig, from 10 psig to 90 psig, from 15 psig to 85 psig, from 20 psig to 80 psig, from 2 psig to 99 psig, from 1 psig to 99 psig, or from 2 psig to 100 psig.
  • the pressure may be about 1 psig, about 2 psig, about 3 psig, about 4 psig, about 5 psig, about 6 psig, about 7 psig, about 8 psig, about 9 psig, about 10 psig, about 11 psig, about 12 psig, about 13 psig, about 14 psig, about 15 psig, about 16 psig, about 17 psig, about 18 psig, about 19 psig, about 20 psig, about 21 psig, about 22 psig, about 23 psig, about 24 psig, about 25 psig, about 26 psig, about 27 psig, about 28 psig, about 29 psig, about 30 psig, about 31 psig, about 32 psig, about 33 psig, about 34 psig, about 35 psig, about 36 psig, about 37 psig, about 38 psig, about 39 psig, about 40 psig, about 41 psig, about 42
  • the hydrothermal treatment may be conducted in the presence of additives.
  • the additives are accelerating agents or chemical reagents that assist in the development of the barrier layer.
  • Exemplary additives include a surface property-modifying agent such as an adhesion promoter, a coupling agent, a corrosion inhibitor, or a pretreatment.
  • the chemical additive layer can be up to about 50 nm thick (e.g., up to about 45 nm thick, up to about 40 nm thick, up to about 35 nm thick, up to about 30 nm thick, up to about 25 nm thick, up to about 20 nm thick, up to about 15 mn thick, up to about 10 nm thick, or up to about 5 nm thick).
  • the chemical additive can be applied by rolling the endless casting belt with a solution containing the chemical additive, by spraying the endless casting belt with a solution containing the chemical additive, by immersing the endless casting belt in a solution containing the chemical additive, or by electrophoretic application.
  • a curing step or chemical reaction can optionally be performed.
  • treating the aluminum endless casting belt further comprises anodizing the hydrothermally treated aluminum endless casting belt in an organic or inorganic acid solution to form a cohesive and stable aluminum oxide layer.
  • anodizing is performed to provide a thin anodized film surface.
  • the anodizing is accomplished by contacting the continuous coil surface with an electrolyte and flowing an electric current (e.g., an alternating current (AC) or a direct current (DC)) through the electrolyte.
  • an electric current e.g., an alternating current (AC) or a direct current (DC)
  • Suitable electrolytes include, for example, aqueous solutions containing inorganic acids such as phosphoric acid, nitric acid, sulfuric acid, phosphonic acid, or combinations of these.
  • exemplary electrolytes include aqueous solutions of sodium nitrate, sodium chloride, potassium nitrate, magnesium chloride, sodium acetate, copper sulfate, potassium chloride, magnesium nitrate, potassium nitrate, calcium chloride, lithium chloride, sodium carbonate, potassium carbonate, calcium carbonate, sodium bicarbonate, ammonium acetate, silver nitrate, ferric chloride, ammonium pentaborate, boric acid, citric acid, ammonium adipate, ammonium phosphate monobasic, or any combination thereof, among others.
  • the aqueous electrolyte solution can include from about 1 wt. % to about 30 wt.
  • the aqueous electrolyte solution can include about 1 %, about 2 %, about 3 %, about 4 %, about 5 %, about 6 %, about 7 %, about 8 %, about 9 %, about 10 %, about 11 %, about 12 %, about 13 %, about 14 %, about 15 %, about 16 %, about 17 %, about 18 %, about 19 %, about 20 %, about 21 %, about 22 %, about 23 %, about 24 %, about 25 %, about 26 %, about 27 %, about 28 %, about 29 %, about 30 %, or anywhere in between.
  • DC power can be ramped up to from about ⁇ 5 VDC to about ⁇ 30 VDC at a rate of from 1 Volt per minute (V/min) to about 15 V/m (e.g., from about 2.5 V/min to about 12/5 V/min, from about 5 V/min to about 10 V/min, or from about 2.5 V/min to about 15 V/min).
  • V/min Volt per minute
  • the endless casting belt can be anodized by dwelling the endless casting belt in the energized electrolyte bath for a dwell time of from about 1 minute to about 30 minutes (e.g., from about 2 min to about 28 min, from about 3 min to about 26 min, from about 4 min to about 25 min, from about 5 min to about 22.5 min, from about 6 min to about 20 min, from about 7 min to about 17.5 min, or from about 8 min to about 15 min).
  • a dwell time of from about 1 minute to about 30 minutes (e.g., from about 2 min to about 28 min, from about 3 min to about 26 min, from about 4 min to about 25 min, from about 5 min to about 22.5 min, from about 6 min to about 20 min, from about 7 min to about 17.5 min, or from about 8 min to about 15 min).
  • the endless casting belt can have a dwell time in the energized electrolyte bath for about 1 min, about 1 .5 min, about 2 min, about 2.5 min, about 3 min, about 3.5 min, about 4 min, about 4.5 min, about 5 min, about 5.5 min, about 6 min, about 6.5 min, about 7 min, about 7.5 min, about 8 min, about 8.5 min, about 9 min, about 9.5 min, about 10 min, about 10.5 min, about 11 min, about 11.5 min, about 12 min, about 12.5 min, about 13 min, about 13.5 min, about 14 min, about 14.5 min, about 15 min, about 15.5 min, about 16 min, about 16.5 min, about 17 min, about 17.5 min, about 18 min, about
  • Figure 2 shows surface microghraphs of an as-cast 5182 aluminum metal on a copper mold with a parting agent (panel A), a 6061-T6 aluminum metal mold with a parting agent (panel B), and a hydorthermally treated aluminum metal mold without a parting agent (panel C).
  • the aluminum metal mold was hydrothermally treated in a boiling water bath for 3 hours. Mold surfaces were finished with 2000 grit mechanical grinding. Each sample was subjected to a simulated continuous casting procedure. As shown in Figure 2, the hydrothermally treated aluminum mold provided the most uniform and defect free surface even though there was no parting agent used during casting.
  • hydrothermal treatment on an aluminum alloy mold generates a pseudo-boehmite and subsequent stable and cohesive oxide layer, and it modifies the heat flux to obtain smoother and less defective surfaces compared to smooth copper and aluminum endless casting belts used with parting agents.
  • Figure 3 shows the surface topography of as-cast metal samples provided by the endless belt, the samples described in the example of Figure 2 above. As shown in Figure 3, the surface topography of as-cast metal exhibited little, if any, variation. Thus, the surface metallurgical integrity and compositional distribution of the metal cast with the hydrothermally treated aluminum exhibited a comparable product when compared to endless casting belt samples using a parting agent. Accordingly, hydrothermally treated aluminum endless casting belts can be used without parting agents to obtain good surface quality on as-cast metals.
  • the endless casting belt can be prepared by a plurality of methods or a combination of methods.
  • the endless casting belt can be prepared by combining Method 1 and Method 2 detailed above.
  • combining Method 1 and Method 2 can form a cohesive and stable aluminum oxide layer on the surface of the endless casting belt, and can enhance the overall integrity, barrier layer, and thermal properties of the endless casting belt. Accordingly, enhanced overall integrity, barrier layer, and thermal properties can provide an endless casting belt capable of providing a continuously-cast metal product without added parting agents.
  • the endless casting belt can be further hydrothermally treated and/or sealed in a post-anodizing treatment to form gibbsite, pseudo-boehmite, and/or boehmite phases, and a subsequent stable and cohesive oxide layer on the surface of the endless casting belt.
  • the endless casting belt can be subjected to a patterning technique before anodizing and/or hydrothermal treatment.
  • the endless casting belt can be subjected to a laser lithography technique to provide a plurality of indentations etched into the endless casting belt surface.
  • the indentations can be arranged in any desired pattern on the surface of the endless casting belt.
  • the pattern can be provided by programming the laser etching apparatus to move the laser relative to the endless casting belt at a pulsing mode.
  • the indentations can be exposed nano-scale and/or micro-scale channels.
  • the indentations can have any desired spacing, ranging from a uniform spacing separated by a non-etched surface to overlapping indentations.
  • the indentations can be formed such that a plurality of indentations forms a singly indented area.
  • Distance between indentations, depth of each indentation, and diameter of each indentation can be adjusted by modifying various parameters of the laser apparatus, relative to the belt surface, including raster speed, laser energy levels, laser pulse duration, and the like, and are known and variable according to a person having ordinary skill in the art.
  • the indentation diameter can range from about 20 pm to about 25 pm (e g., about 20 pm, about 21 pm, about 22 pm, about 23 pm, about 24 pm, or about 25 pm).
  • the indentations can be of any geometrical shape, including triangular, square, rectangular, circular, elliptical, polygonal, or the like. In some cases, the indentations can have a non-geometrical shape (e.g., a freeform curve, an amoebic mass, or the like).
  • indentation characteristics can be controlled by the laser etching apparatus.
  • aluminum etching chemicals commonly known in the art can be used to further control the indentation morphology.
  • the endless belt caster can be laser-etched in a desired pattern and followed by exposure to an acid etch.
  • performing an acid etch after a laser etch can create desirable concave craters to simulate a shotblasting morphology.
  • Figure 4 shows an example for some of the surface textures obtained after pulsed laser application on aluminum with different size, depth, and distribution of indentation textures.
  • Aluminum belt surfaces can be texturized (e.g., roughened, softened, smoothed, or the like) by using any one of, or a combination of pulsed laser exposure, continuous laser exposure, acid etching, hydrothermal treatment, anodizing, post anodizing hydrothermal treatment, or postanodizing sealing treatment.
  • the aluminum endless casting belt can be metal plated.
  • the aluminum endless casting belt can be texturized as described in Method 4 to provide specific surface textures on the aluminum endless casting belt surface to deposit copper, nickel, or any other suitable metal plating on the aluminum endless casting belt.
  • the aluminum endless casting belt can be metal plated after cleaning and/or after zincating the aluminum endless casting belt.
  • metallic plating can be applied to an anodized aluminum endless casting belt surface, with or without hydrothermal treatment, as described in Method 2.
  • the metal plating can be applied to an entirety of the casting surface of the aluminum endless casting belt, or only a portion of the casting surface of the aluminum endless casting belt.
  • the aluminum endless casting belt can have a casting surface that is a hybrid aluminum, copper, and/or nickel surface. Copper, nickel, or any other suitable metal, plated onto the aluminum endless casting belt can improve the solidification of the metal being cast by the aluminum endless casting belt with improved and/or tailored as-cast surface quality.
  • the metal plating can be applied in any desired pattern, for example, to impart one or a plurality of surface characteristics to the metal being cast. In some cases, the pattern of the metal plating can be determined by the laser etching process described in Method 4.
  • a metal-plated hybrid design can exploit synergistic simultaneous surface textures and functionalities, including high heat flux and high durability.
  • a difference in heat flux in aluminum and copper can be used to variably solidify the metal being cast during the continuous casting process. Varied solidification can provide varied and tailored surface characteristics to the metal being cast in a single operation.
  • the as-cast metal can be provided with a surface including smooth portions, roughened portions, textured portions, and the like, without further surface treatments.
  • the aluminum endless casting belt can be a hybrid belt by incorporating expanded metal foils on the surface of the aluminum endless casting belt.
  • the expanded metal foils can be applied to a cleaned and bare aluminum endless casting belt, a pseudo-boehmite coated aluminum endless casting belt, a cleaned and anodized aluminum endless casting belt, or an anodized and hydorthermally treated aluminum endless casting belt.
  • Expanded metal foils are commercially available and, in one example, known by the trade name MicroGrid® (Dexmet Corporation (Wellingford, CT, USA)).
  • These expanded metal foils are produced from ductile and high-temperature resistant metals including titanium, copper, nickel, brass, stainless steel, MonelTM, or any other metal that can withstand temperatures greater than 700 °C while maintaining the optimum thermal conductivity and coefficient of thermal expansion.
  • FIG. 5 For example, commercially available expanded metal foils are shown in Figure 5.
  • a typical expanded metal foil with diamond mesh sizes ranging from .031" to .500" can be used for producing the hybrid belt.
  • An open area of the mesh can range from as low as 30 % to as high as 95 %.
  • other examples can include expandable metal foils with variable thicknesses and varying surfaces. The varying surfaces can be flattened, smoothed, rough, or any other suitable mesh surface, including Distex Brick, Double Distex Brick, Selvage Edge, or Solid Intersperse as shown in Figure 5.
  • the expanded metal foil can include a Side Dam.
  • Selvage Edge and/or Solid Intersperse designs can incorporate the Side Dam where the Side Dam can be positioned on an edge of the aluminum endless casting belt.
  • expanded metal foils or any other woven metal mesh can be embedded into and/or joined to the surface of the aluminum endless casting belt by roll-forming, roll bonding, or any other suitable method.
  • the method described herein can provide an alternative method to conventional embossing techniques.
  • any woven metal mesh configurations can be incorporated into the aluminum endless casting belt described herein.
  • an anodized expanded titanium foil can be welded to the anodized aluminum endless casting belt and enhance the integrity of the hybrid belt described herein.
  • Aluminum and titanium welding is described in U.S. Pat. No. 4,486,647 and incorporated herein by reference.
  • the endless casting belt can be produced from high modulus carbon fibers.
  • suitable carbon fibers with high thermal conductivity are commercially available and known by the trade name XN100® having a thermal conductivity of 900 W/mK, XN90® having a thermal conductivity of 450 W/mK, or XN80® having a thermal conductivity of 300 W/mK (Nippon Graphite Fiber Corporation (Tokyo, Japan)).
  • Suitable carbon fibers can be incorporated into the endless casting belt in the form of a yam, a fabric, a prepreg, a chopped fiber, or a milled fiber.
  • a fabric and/or prepreg carbon fiber material is more suitable for building a hybrid endless casting belt to be used in continuous casting machine.
  • copper exhibits a thermal conductivity of about 400 W/mK
  • aluminum alloys exhibit thermal conductivities of about 200 W/mK.
  • carbon fibers, exhibiting high thermal conductivities can provide a continuous casting belt suitable for casting aluminum alloys without using a parting agent.
  • Illustration 1 is a casting apparatus for continuously casting a metal strip article, wherein the casting apparatus comprises an endless casting belt comprising a base layer and a barrier layer, wherein the base layer comprises aluminum and wherein the barrier layer is at least one of a Gibbsite- A1(OH)3 barrier layer, a pseudo-boehmite barrier layer, a complete boehmite layer, or a stable and cohesive oxide layer.
  • the casting apparatus comprises an endless casting belt comprising a base layer and a barrier layer, wherein the base layer comprises aluminum and wherein the barrier layer is at least one of a Gibbsite- A1(OH)3 barrier layer, a pseudo-boehmite barrier layer, a complete boehmite layer, or a stable and cohesive oxide layer.
  • Illustration 2 is a method of forming the endless casting belt of any preceding or subsequent illustration, the method comprising: (a) providing an aluminum endless casting belt; and (b) treating the aluminum endless casting belt by at least a first hydrothermal treatment to form a pseudo-boehmite barrier layer on at least one surface of the aluminum endless casting belt providing a treated aluminum endless casting belt.
  • Illustration 3 is the method of any preceding or subsequent illustration, wherein the hydrothermal treatment comprises boiling in water or steam-treating.
  • Illustration 4 is the method of any preceding or subsequent illustration, wherein the hydrothermal treatment comprises submerging the aluminum endless casting belt in water at a temperature from 90 °C to 150 °C for a period of time from 1 hour to 10 hours.
  • Illustration 5 is the method of any of any preceding or subsequent illustration, wherein treating the aluminum endless casting belt is conducted with at least one additive.
  • Illustration 6 is the method of any of any preceding or subsequent illustration, wherein treating the aluminum endless casting belt further comprises anodizing the treated aluminum endless casting belt in an organic or inorganic acid solution to form a crystalline aluminum oxide layer.
  • Illustration 7 is the method of any preceding or subsequent illustration, wherein the treating further comprises a second hydrothermal treatment or a post-anodizing sealing treatment of the crystalline aluminum oxide layer.
  • Illustration 8 is a method of forming the endless casting belt of any preceding or subsequent illustration, the method comprising: (a) providing an aluminum endless casting belt; (b) anodizing the aluminum endless casting belt in an inorganic acid to form an amorphous aluminum oxide layer on at least one surface of the aluminum endless casting belt; and (c) converting the amorphous aluminum oxide layer to at least one of a Gibbsite-A1(OH)3 barrier layer, a pseudo-boehmite barrier layer, a complete boehmite layer, or a cohesive and stable oxide layer.
  • Illustration 9 is the method of any preceding or subsequent illustration, wherein converting the amorphous aluminum oxide layer comprises hydrothermally treating the amorphous aluminum oxide layer.
  • Illustration 10 is the method of any preceding or subsequent illustration, further comprising applying a post-anodizing sealing treatment to the amorphous aluminum oxide layer, optionally with at least one additive.
  • Illustration 11 is the method of any of any preceding or subsequent illustration, wherein the amorphous aluminum oxide layer is a nano -porous amorphous aluminum oxide layer.
  • Illustration 12 is the method of any of any preceding or subsequent illustration, wherein the amorphous aluminum oxide layer is a nonporous micron-scale or submicron-scale amorphous aluminum oxide layer.
  • Illustration 13 is the method of any of any preceding or subsequent illustration, further comprising forming channels on the aluminum endless casting belt before anodizing the aluminum endless casting belt.
  • Illustration 14 is the method of any of any preceding or subsequent illustration, further comprising templating the amorphous aluminum oxide layer.
  • Illustration 15 is the casting apparatus of any preceding or subsequent illustration, wherein the endless casting belt further comprises a metal foil layer.
  • Illustration 16 is the casting apparatus of any preceding or subsequent illustration, wherein the metal foil layer comprises titanium, copper, nickel, brass, stainless steel, or any combination thereof.
  • Illustration 17 is the casting apparatus of any preceding or subsequent illustration, wherein the metal foil has a mesh size from 0.70 to 1.5 cm and openings from 30 to 95%.
  • Illustration 18 is the casting apparatus of any preceding or subsequent illustration, wherein the endless casting belt further comprises a carbon fiber layer.
  • Illustration 19 is a casting apparatus for continuously casting a metal strip article, wherein the casting apparatus comprises an endless casting belt comprising a base layer and a barrier layer, wherein the base layer comprises aluminum, copper, or steel and wherein the barrier layer comprises a carbon fiber layer.
  • Illustration 20 is the casting apparatus of any preceding or subsequent illustration, wherein the endless casting belt further comprises a metal foil layer in contact with the carbon fiber layer.
  • Illustration 21 is a method of forming the endless casting belt of any preceding illustration, the method comprising: (a) providing an aluminum endless casting belt; and (b) treating the aluminum endless casting belt with a masking agent to form a textured aluminum endless casting belt.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)

Abstract

Une face latérale pour un appareil de coulée continue de métal comprend un isolant et un système de courroie comprenant une courroie sans fin. La courroie sans fin comprend une surface de courroie, et la courroie sans fin est mobile relativement à l'isolant de telle sorte qu'une partie de la surface de courroie est configurée pour faire face à une cavité de coulée de l'appareil de coulée continue de métal lors du déplacement de la courroie sans fin. Dans certains exemples, la courroie sans fin est mobile dans un plan de déplacement qui est perpendiculaire à la surface de courroie.
PCT/US2023/084752 2022-12-21 2023-12-19 Conception de courroie d'appareil de coulée continue WO2024137582A1 (fr)

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA798301A (en) * 1968-11-05 E. Cooke William Process for anodizing aluminium
US4486647A (en) 1981-05-07 1984-12-04 Finnish Chemicals Oy Method of welding aluminum to titanium and a welded joint so produced
US4588021A (en) * 1983-11-07 1986-05-13 Hazelett Strip-Casting Corporation Matrix coatings on endless flexible metallic belts for continuous casting machines method of forming such coatings and the coated belts
US5496417A (en) 1995-06-21 1996-03-05 Electro-Steam Generator Co. Process for steam conversion coating aluminum
US20070193714A1 (en) * 2003-10-03 2007-08-23 Novelis Inc. Surface texturing of casting belts of continuous casting machines
US20070209778A1 (en) * 2003-10-03 2007-09-13 Novelis Inc. Belt Casting Of Non-Ferrous And Light Metals And Apparatus Therefor

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA798301A (en) * 1968-11-05 E. Cooke William Process for anodizing aluminium
US4486647A (en) 1981-05-07 1984-12-04 Finnish Chemicals Oy Method of welding aluminum to titanium and a welded joint so produced
US4588021A (en) * 1983-11-07 1986-05-13 Hazelett Strip-Casting Corporation Matrix coatings on endless flexible metallic belts for continuous casting machines method of forming such coatings and the coated belts
US5496417A (en) 1995-06-21 1996-03-05 Electro-Steam Generator Co. Process for steam conversion coating aluminum
US20070193714A1 (en) * 2003-10-03 2007-08-23 Novelis Inc. Surface texturing of casting belts of continuous casting machines
US20070209778A1 (en) * 2003-10-03 2007-09-13 Novelis Inc. Belt Casting Of Non-Ferrous And Light Metals And Apparatus Therefor

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