US3116121A - Ingot and the mold and core structure for casting the same - Google Patents

Ingot and the mold and core structure for casting the same Download PDF

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Publication number
US3116121A
US3116121A US37266A US3726660A US3116121A US 3116121 A US3116121 A US 3116121A US 37266 A US37266 A US 37266A US 3726660 A US3726660 A US 3726660A US 3116121 A US3116121 A US 3116121A
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United States
Prior art keywords
ingot
channels
mold
edges
members
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US37266A
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Brick Robert Maynard
Maier Curtis Eugene
Ripling Edward Joseph
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Continental Can Co Inc
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Continental Can Co Inc
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Priority to US37266A priority Critical patent/US3116121A/en
Priority to GB35982/60A priority patent/GB953436A/en
Priority to FR846805A priority patent/FR1281487A/fr
Priority to CH1417060A priority patent/CH370200A/fr
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES, PROFILES OR LIKE SEMI-MANUFACTURED PRODUCTS OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00—Manufacture of metal sheets, rods, wire, tubes, profiles or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/06—Manufacture of metal sheets, rods, wire, tubes, profiles or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
    • B21C37/14—Making tubes from doubled flat material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/4981—Utilizing transitory attached element or associated separate material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/4998—Combined manufacture including applying or shaping of fluent material
    • Y10T29/49988—Metal casting
    • Y10T29/49989—Followed by cutting or removing material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12188—All metal or with adjacent metals having marginal feature for indexing or weakened portion for severing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12292—Workpiece with longitudinal passageway or stopweld material [e.g., for tubular stock, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12486—Laterally noncoextensive components [e.g., embedded, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12639—Adjacent, identical composition, components
    • Y10T428/12646—Group VIII or IB metal-base
    • Y10T428/12653—Fe, containing 0.01-1.7% carbon [i.e., steel]

Definitions

  • This invention relates to the art of preparing hollow ingots and laminate stock, and is particularly concerned with ingots and stock having longitudinal channels of closely defined cross-sections.
  • the tubular body When the tubular body must have closely controlled internal cross-section, and the thicknessrcduction and a length-extension is being effected by rolling, there is a lateral spreading which varies predictably with the metal, the rolling schedule of temperature and degree of reduction at each pass, and with the ingot shape.
  • the lateral spreading is not uniform for each unit of width, nor for each unit of thickness: for example, with a multi-channel ingot of rectangular section and plane surfaces, the lateral spreading of a channel adjacent a lateral edge is greater than that for a channel nearer the center of width.
  • An object of this invention is an apparatus for making hollow ingots, by which the dimensions of the channels can be closely controlled, by a procedure of providing therein original channels of sizes proper under the reducticn schedule to establish the predetermined final widths of the channels.
  • Another object is an appamatus for forming hollow ingcts by employment of removable cores comprising relatively movable parts, whereby the channel dimensions can be pre-set, and whereby the cores can be easily removed from the ingots without damage thereto.
  • Another object is an apparatus for casting hollow ingots in a mold of limited size, from which the ingot being formed is withdrawn as portions thereof cool to the solid state, and with cores which tnavel through the mold with the molten and laterasolidified metal, and including the withdrawal of the cores from the solidified ingots without damage thereto.
  • a further object is the preparation of hollow ingots having longitudinal edge and internal portions of metal softer than the cast ingot metal portions, and with longitudinal channels of predetermined dimensions in the central portions.
  • FIGURE 1 is a conventionalized upright sectional view of a so-called direct-chill casting apparatus showing a practice under the invention
  • FIGURE 2 is an end view of an ingot being cast in the mold, with cores and other parts in place;
  • FIGURE 3 is a horizontal view, essentially on line 33 of FIGURE 1;
  • FIGURE 4 is a penspective view of part of the mold platform, with parts of cores and other elements thereon;
  • FIGURE 5 is a perspective view of a core structure
  • FIGURE 6 is an elevation of pants of a core structure, with the angle of taper exaggerated
  • FIGURE 7 is an end View, showing the relationship of the parts of a core member having chisel-shaped edges
  • FIGURE 8 is a corresponding view of a core member having rounded edges
  • FIGURE 9 is a perspective view of a pair of spacer members
  • FIGURES 10 land 11 show engagements of core members with spacers
  • FIGURE 12 is a perspective view of part of an ingot made according to this invention.
  • FIGURE 13 is a perspective view of a pant of a strip made by rolling the ingot of FIGURE 12;
  • FIGURE 14 is an end view of part of the ingot of FIGURE 12, on a larger scale
  • FIGURE 15 is an end view of part of the same ingot, on a still larger scale
  • FIGURE 16 is a perspective view showing detachment of the edges of the strip of FIGURE 13;
  • FIGURE 17 is a perspective view of a section cut from the strip of FIGURE 16;
  • FIGURE 18 is a perspective view of a single blank
  • FIGURE 19 is a perspective view of the same after opening
  • FIGURE 20 is a perspective view showing the conformation of the URE 19.
  • FIGURE 1 conventionalized parts are shown, including an ingot casting mold 10 mounted on a deck or floor 11, above a pit into which the ingot is lowered during the course of its formation.
  • the mold has a peripheral cooling chamber 12, with ducts 13 for supply and removal of cooling fluid.
  • a tundish structure 14, served by supply troughs 15, has the valved drop tubes 16 by which molten metal is delivered into the casting mold.
  • the lower end of the mold lti is closed by a platform 17 connected to a piston ram structure 18 which can be raised and lowered by a cylinder 19 accordingly as the delivery or removal of pressure fluid to its ends is controlled by the valve 20.
  • the descending ingot B can be cooled by water jets from the nozzles 21.
  • one or more composite removable cores 25, FIGURES 1 to 4 are fixed and sealed in the platform 17 before the start of the metal pouring, and extend upwardly through the mold and between parts of the tundish structure 14.
  • FIGURE 2 the individual core structures 25, of which four are shown, are located essentially at the median plane M between the ingot surfaces which are to be brought into reduction contact with the rolls: and pairs of abutting spacer members 26 are positioned between each two adjacent core structures, with a single spacer member at the lateral edges of the outermost core structures.
  • the lateral margins 27 of the ingot need not be cast with the central portion thereof, but may be provided by pro-formed edge pieces 28 which are originally connected to the platform 17 and travel downward with the ingot.
  • Such edge pieces 28 can have a cross-section of 1 to 2 inches along the median plane M, FIGURE 2, for ingots 28 to 36 inches wide and 6 or 8 inches thick, dependent upon the metal being cast and the rolling schedule; and corresponding thickness for other ingot dimensions.
  • the mold 10 can have inwardly projecting ribs 29 which produce corresponding longitudinal grooves in the ingot, noting that pairs of such ribs can be employed of the opened blank, projecting fins of FIG- for guiding and aligning the edge pieces 28 during their descent.
  • the core structures, spacers and edge pieces are assembled and attached to the platform 17 as shown in FIG- URE 4.
  • the platform has an aperture and the core structures extend through the platform, so that cleats 55 can be positioned below the platform wherewith only parts of each core structure having flat surfaces are located within the ingot, with the wider surfaces parallel to one another and providing continuous areas for defining the wider channel surfaces in the ingot.
  • Spacers 26 can be received also in the platform aperture.
  • the edge pieces 28 are heavier, and can descend in the mold by their own weights, or by the downward pulls exerted upon the solidified ingot from the cores and spacers: pockets for aligning them may be provided in the platform, as in FIGURE 4.
  • the core structures and spacers can be held by Wedges 31 driven upward between a platform aperture wall and the structure or spacer.
  • the end pieces 28 may be likewise secured.
  • the platform aperture may be made large enough for the widest spacers 26, when ingots are to be made of differing dimensions with the single platform 17: wherewith different numbers of spacers and cores can be assembled thereto, with wedges 31 of appropriate size to essentially fill the gaps.
  • Fire clay packing 32 can be employed to fill any crevices.
  • rollers 33 engage the opposite faces of the core structures and end pieces and hold them in alignment, being rotatable on shafts carried by the rocker brackets 34 and having brakes 35 pivoted on shafts 35a which restrict the rotation of the rollers, so that a low tension is exerted along the core structures as the platform sinks: the brakes may be held engaged by springs 36.
  • the rocker brackets 34 are held engaged with the cores and end pieces by strong springs 36a which permit minor movements under the forces exerted by thermal expansion of the cores and end pieces.
  • End guides comprising rollers 33a on springpressed rocker frames 34a act against the end pieces in the plane of the cores 25, and press them toward one another so that these end pieces, the cores and the spacers 26 are held in abutment and accurately guided for downward movement.
  • the rocker frames 34, 34a are pivoted in fixed supports 37.
  • Driven rollers 38 are preferably employed below the mold, for engaging the ingot B and exerting a downward effort upon it.
  • the pouring of metal is begun.
  • This metal solidifies within the mold and upon the platform, and the level rises to near the top of the mold, by control of the metal pouring as known in the art.
  • the rollers 38 are driven and valve 20 is operated, so that the platform descends with the solidified lower part of the ingot B thereon.
  • the pouring of metal and the descent of the platform are coordinated so that the level of molten metal is kept essentially constant.
  • the metal solidifies as a film adjacent the cooled walls of the mold and against the core and other descending structures so that the zonal interface between the liquid and the solidified ingot metal has a form as indicated by the lines 30, 30 in FIGURE 1.
  • the molten ingot metal bonds or welds to the exposed surfaces of the spacers 26 and to the end pieces 28: but does not bond to the core structures nor enter between the core members or between the spacers 26.
  • the ingot metal, with the end pieces 28 and spacers 26 integrated therewith contracts and normally is free of the mold at the lower end thereof.
  • the platform 17 and the metal pouring are stopped: the molten metal is allowed to solidify, the ingot is withdrawn, new spacer and end pieces are introduced and the same or other cores positioned, and the pouring l of a new ingot begun with the platform 17 again raised into sealing position.
  • the core structures 25 can be formed as in FIGURES 5, 6 and 7.
  • the side members 40 can have linear longitudinal outer edges of rounded form, FIGURE 8, but preferably are of chisel-shaped cross-section, FIGURE 7, formed by convergent surfaces leading to the extreme edges which can be blunted by a merging curvature of radius much smaller than the thickness of the core; e.g., with a core thickness .of 0.125 inch, the included angle at the chisel edge may be 10 to degrees, and the edge radius about 1 inch. In practice, angles of 14 degrees and 28 degrees have been found to yield essentially identical results. Angles of 10 to 60 degrees are preferred for aluminum.
  • the members 40 have inner edges which converge longitudinally, FIGURE 6, for the pair of members, toward one end, e.g., the lower end in the drawings. These inner edges have keyways '41 illustrated as grooves of essentially triangular section with a 90 degree root angle.
  • the central member 42 has its edges of mating convergent form, with a triangular sectional shape for each which corresponds to the keyway-s 41 and provides a key 43 accurately fitting the keyway walls.
  • each core member can be 16 feet long; the lateral members 40 can be about 2 inches wide at one end and 1 /2 inches at the other: the central member 42 can be one inch wide at one end and two inches wide at the other: therewith, when the ends of the members are aligned, the over-all width is 5 inches at each end and along the entire length.
  • the center member can likewise be one inch wide at the lower end, and two inches wide at the upper end, and the side members can have dimensions of 2.66 inches at the lower ends and 2.06 inches at the upper ends, for the same angle of taper.
  • other coordinated dimensions can be selected, dependent upon the chosen taper angle and the desired core width.
  • Such chisel shapes facilitate the accurate assembly of the parts preliminary to pouring; and have a primary advantage in producing a cross-sectional shape of channel for receiving a liquefiable resist and wherewith the channel section changes during the early rolling passes without producing wrinkles or orange peel appearance of the surfaces of such channels during the time of bringing the .opposed inner surfaces toward one another with a thin fihn of liquid resist between them.
  • the depth of the groove 60 in the spacer 26, FIGURE 9, determines the overlap of the spacer metal onto the channel or discontinuity form by the core assembly 25; and thus onto the resist or antiwelding material later introdueed into such channel, and ultimately the overlap of the spacer metal at the edge .of the resist residue in the rolled strip.
  • the groove can be, for example, inch deep with spacers 0.125 inch thick.
  • FIGURE 10 when the core pieces 40, 42 are 0.125 inch thick, and the included edge angle is 90 degrees, the angular edges fill the grooves.
  • FIGURE 11 where the included angle is 30 degrees and the core pieces are also illustratively 0.125 inch thick, with the spacers 26 having a like thickness and grooves for half this thickness, only parts of the angular edges are received in the respective grooves.
  • FIGURES '10 and 111 the weld-bonding of the cast metal .of the ingot B to the spacers 26 is indicated by the short hatching lines at the interfaces: and the non-welding to the cores is shown by the absence of such hatching.
  • Such core members are made with surfaces of material to which the molten ingot metal will not bond.
  • the bodies can be made of steel and given approximate shaping by machining.
  • the keys and keyways are then accurately ground so that the abutment wall surfaces are plane and smoothly finished, e.g., to 10 microinches. These surfaces can be given a hard chromium plating.
  • each of the three members can be made 0.150 inch thick by machining and during the formation of the keys and keyways; and then ground to 0.125 inch thick while clamped together.
  • the central member 42 is illustratively shown, FIGURE 6, as having a number of holes 45 spaced along its center of width; and the side members 40 have holes 46.
  • a lubricant for action between the key and keyway surfaces which will be effective after the heating by the ingot metal.
  • the walls of the keyways 41 may be thinly coated with molybdenum disulfide.
  • the core members are assembled by bringing them tightly together with the keys in the keyways, and adjusting their relative longitudinal position to obtain the desired width.
  • the core structure will have a width of 5 or 6.12 inches when the ends are aligned as shown by the dash lines 47 in FIGURE 6 with the core width indicated by the dash lines 4% and the core member abutments by the dash lines 4 9; noting that the langularity and spacing have been exaggerated in FIGURE 6 for clearness.
  • the central member 42 e.g., upward in FIGURE 6 to the position shown by unbroken lines 50, and bringing the abutment between members at the unbroken lines 51
  • the over-all width between the edges of the side members is at lines 52, that is, the width has been decreased to the position shown by the dash lines 48 to that of the inbroken lines 52.
  • the width of the structure can be increased.
  • the members can then be clamped in position, e.g., by cleats 55, FIGURES 4 and 5, which have aligned holes 56 for receiving a pin or bolt 56a, which passes through a selected hole in the central member 4 2, and slits 57 for receiving bolts 57a which pass through the holes 46 of the side members 48.
  • the cleats also may have holes 58 for clamping bolts 53a which pass outside the core members.
  • the central core can be 6.122 inches wide at room temperature, and the successive lateral cores 6.102 and 6.082 inches for a fivewide billet and strip.
  • the five core widths then total 30.490 inches.
  • the spacers 26 can be 0.125 inch thick, with the grooves 60 extending for half the thickness, with a total metal dimension, upon assembly, of 0.625 inch.
  • the edge pieces 28 can each be 1%. inches thick. The ingot thereby formed will have a total width, in the mold, in excess of 34 inches: and upon cooling will have the channels essentially of the differentiated widths stated above.
  • the spacers 26 can be made, as in FIGURE 9, of rolled, extruded or forged stock of a metal compatible with the molten ingot metal: that is, the molten ingot metal can weld or bond to surfaces thereof so that the spacer becomes integrated into the ingot.
  • a metal compatible with the molten ingot metal that is, the molten ingot metal can weld or bond to surfaces thereof so that the spacer becomes integrated into the ingot.
  • an exposed face of each spacer has a conforming longitudinal groove 63 so that the core structures and spacers can be locked together, and are effective to provide corresponding edges on the channels or discontinuities being formed in the ingot.
  • the spacers 26 may be of wrought pure aluminum, which is softer than commercial aluminum alloys and is advantageous when the poured metal is harder, to provide ductility along the edges of the channels during the opening operation. Pairs of these spacers are provided between adjacent core structures, and one is provided between each outermost core structure and the adjacent edge piece 28, as shown in FIG- URE 2.
  • anti-welding coatings 61 on the backs or flat abutment surfaces of the spacers such may be a light coating of soot, e.g., by a smoky acetylene flame, or a bonded dressing of refractory oxide powder, or a thin silicone coating, for aluminum ingots.
  • Other surfaces of the spacers are preferably cleaned so that the poured metal will bond easily and strongly thereto.
  • each center member 42 can be tapped, and the wide end pulled, so that this center member is pulled out from between the side members 40, with its plane faces sliding along the inner surfaces of the channel in the ingot. As it leaves, the compressive strains exerted from solidification shrinkage in the direction of the median plane M are relieved, and the side members 4d can similarly be removed.
  • each core structure has establ shed a channel in the ingot of a size determined by its own thickness and by the adjusted width between its longitudinal edges; with parallel wider surfaces joined by the convergent end sections.
  • Similar operations can be performed for ingots of other metals, with appropriate selection of materials.
  • stainless steel can be used for the core members: for mild steels, titanium members are usable.
  • the thin carbon films from a smoky flame can be used for the anti-welding dressings: for steel, a flame sprayed refractory such as alumina powder, is useful where carbidization is undesirable.
  • FIGURE 12 shows an ingot formed with cores of the type in FIGURE 7, the relative width dimensions being exaggerated for clearness.
  • This ingot B has five core channels aligned along the median plane M of its thickness.
  • the central channel is the widest, being 6.122 inches in an illustrative example above: the next outwar channels 71 are each 6.102 inches wide; and the laterally outermost channels 72 are each 6.082 inches Wide.
  • the cast metal has bonded with the spacers and the edge or end pieces; so that only the inter-spacer antiwelding layers 61 are present at the ingot ends.
  • the ingot can be formed with the longitudinal external grooves '73 which can he of v section and arranged in pairs at the regions of the layers 6.1: such can be produced by the ribs 2%, FlIGURE 2, and then dressed to the desired final size and shape; and preferably receive on one or both walls of each groove a coating of anti-wclding material.
  • suitable resist materials are organic substances such as polysiloxanes, polyvalent metal stearates such as the ferric or aluminum soaps, epoxy resins, hydrocarbon polymers such as polyethylene and polypropylene.
  • organic materials have been found to endure temperatures of 900 to 1,000 degrees F. without losing ability to prevent welding of the metal when employed as set out herein. Such materials can liquefy below such temperatures but maintain the desired antiwelding property when air is excluded.
  • the ingot can be heated for homogenization, the resist introduced, and the hot rolling begun at once so that the How of the metal with closure of the core channel walls upon the resist quickly effects expulsion of air and prevents its re-entry: or the ingot may be brought to a temperature of 300 to 500 degrees, at which the resist liquefies, the resist introduced and the other ingot end sealed, and the ingot raised to the hot-rolling temperature.
  • Refractory resist materials such as particles of alumina, zirconia, silica and silicates, talc, and graphite, in sizes of a few microns downward, can be introduced into the channels of ingots formed in the present fashion, for example, by vibrating the ingot while the powder is being introduced into the channels, and thereby attaining a substantially uniform packing with uniform density of the resist. The ingot is then raised to the hot-rolling temperature.
  • an ingot 8 to 12 inches thick can be reduced to a slab or billet 4 to 6 inches thick, having the longitudinal core channels therein and each filled with resist material from edge to edge and end to end.
  • the billet can be reheated to 900 degrees, for an aluminum or aluminum alloy billet; and further hot-rolled to a hot band 0.090 to 0.150 inch thick, which can be heat-treated, and then cold-rolled to the desired final gage, e.g., 0.010 to 0.020 inch, with intermediate annealings if desired.
  • the final intermediate annealing during cold-rolling can be performed at a thickness at which the finished strip will have the hardness desired, such as quarter-hard, half-hard, or fullhard.
  • Some alloys can advantageously be heat-treated after cold-rolling to final gage.
  • 5052 aluminum alloy may be heated for l to 4 hours at 350 to 500 degrees (F. to relieve stresses: and 6061 aluminum alloy may be heated for an hour at 980 degrees F. to remove work hardening effects and cause precipitation components such as magnesium silicide to re-dissol-ve; with quenching in cold water so that age-hardening can later occur at room temperature or be accelerated by heating to 300 to 400 degrees F. to attain the hardest temper effect.
  • the strip can be annealed and quenched as a coil: it is prefered to pass the strip through a rollerleveler after quenching, to eliminate warpage effects which have arisen.
  • the surfaces 75, FIGURE 12, originally in contact with the rolls, and later the upper and lower surfaces of the partly rolled billet, have essentially no lateral spread, but the spreading effect occurs between such surfaces, for example, adjacent the median plane M. This is compensated by the tilting of the grooves, and by the lateral displacement of the roots of these grooves relative to the adjacent spacer pieces.
  • the channels 71 are initially of differentiated widths, so that the rolled strip S, FIGURE 13, has the resist residues 76 of the same widths by reason of the compensation due to lateral spreading, and the residues '77 of the coatings applied in the grooves 73 extend at right angles from the rolled surfaces and normally are invisible in the rolled strip, but reveal themselves when the strip is bent about longitudinal axes.
  • FIGURE 14 It is preferred to shape and locate the external longitudinal grooves 73 of FIGURE 12 as shown by FIGURE 14, in which one lateral half of a five-channel ingot B is shown at theleft of the upright central plane C.
  • the ingot is symmetrical about the median plane M.
  • the spacers 25 are outlined, with hatched lines to indicate that they have become integrated into the billet.
  • the successive external grooves 75a, 75b, 75c from the central plane are shown as having successively greater tilts; that is, the bisector planes 30a, 30b, c, have successively greater angles from the upright planes 81a, 81b, 81c which pass through the roots of the respective pairs of grooves.
  • Such grooves may have root angles of 10 to 70 degrees: the depths of the grooves, from the respective ingot surfaces 82 such that the total of the two grooves and the upright dimension of the interspacer parting material 61 does not exceed half of the total ingot thickness between the surfaces 82.
  • the upright plane 81a defined by the roots of the grooves 75a passes laterally outside the coating 61 of the associated spacers 26 by a small distance, corresponding to the limited lateral spreading of the channel 70 during rolling: while the planes 81b defined by the roots of the grooves 75b and the planes 81c defined by the roots of the grooves 75c are at successively greater distances from the respective coatings 61.
  • the differential lateral spreading of the core channels 70, 71, 72 during rolling brings the groove roots and the coatings 61 into alignment at the end of rolling.
  • Coatings 85, FIGURE 15, of anti-welding material such as a polysiloxane grease, a bonded inorganic powder, or soot, is applied to one or both walls of each groove, to prevent later welding between the Wall surfaces and to establish longitudinal weakening or notching effects in the rolled strip.
  • anti-welding material such as a polysiloxane grease, a bonded inorganic powder, or soot
  • FIGURE 15 The effects during rolling are illustrated in FIGURE 15.
  • the ingot is reduced in thickness to establish the surfaces 87, and the anti-'weld residues of coatings 85 have become films 88 extending from these surfaces: noting that the metal flow has not yet shifted the films so that the films of a pair of grooves lie in a common upright plane, but are still relatively tilted.
  • the thickness of the channels 70, '71, 72 and the spacers 26 of FIGURE 14 are likewise reduced as shown by the dotted lines in FIGURE 15, noting that such reductions are usually not linearly proportionate to the total thickness reduction from lines 32-432 to lines 87-87.
  • the metal between the inner edges of the films 88 spreads laterally away from the center plane C, and therewith the coating 61 moves outward.
  • the films 88 have become erect, and lie in a plane which passes through the respective coating 61: and there are three weakness areas at each such plane, two being provided by the films 88 which extend from the outer surfaces, and the third by the respective coating 61.
  • the thickness of the ingot is successively reduced by the rolling, until the strip of FIGURE 13 is produced; and therewith, the dimensions of the films 88 and coatings 61 are likewise reduced in essentially the same proportion.
  • the resist material in the core channels 70, 7'1, 72 is liquid during the hot rolling, the thicknes of these channels is reduced during the course of the rolling, usually with expulsion of some of the resist material at the initial hotpass, so that the final thickness of the core channel resist residue may be a few ten-thousandths of an inch or less.
  • the strip of FIGURE 13 is 0.020 inch thick, the combined dimensions of the Weakenings can occupy 0.008 or 0.009 inch, and the remainder of the thickness is composed of rolled metal.
  • the greater travel of metal, in the lateral spreading, at points nearer the median plane M than the inner edges of the films 88 is indicated by the longer arrows 8?.
  • the channel 70 at the center plane C is broadened less than the lateral channels 71 and 72.
  • the grooves 75c nearest the margins of the billet provide aligned residues which are at essentially uniform spacing from the edges of the residues 76 in the outermost channels 72.
  • the strip may receive camber, that is, its lateral edges are curved rather than straight lines.
  • the marginal portions 94), FIG- URE 16 may be torn away, with the severance following the lines of the residues 77, so that the edges of the residual central portion of the strip now lie at essentially uniform distances from the edges of the outermost channel resist residues 76 and can be employed as reference lines in cutting the strip into sheets along lines at right angles to these reference edges, even though camber is present.
  • the rolled strip S with five channel resist residues extending along its length, may be severed at lines 91 to form panels or sections P of multihigh, m-ulti-wide individual blanks, which can receive lithographic coating, embossing, and other treatments as multiple units.
  • Such sheets can then be separated into individual blanks, by bending the sections about longitudinal axes, that is, axes parallel to the weakenings 77, thereby over-stressing the .metal along the planes of the resist residues 88, 61, and causing the sheet to break along these planes, without intrusion of the break into the channel resist residue regions.
  • the edges of the cores may be spaced /8 inch from one another: but when such an ingot is rolled to a strip 0.20 inch thick, the distance between a pair of surface resist residues 88 is far less than the spacing between the cores.
  • Such a piece may have the length of one or more individual blanks, and it may now be trimmed and severed as desired, to provide a single blank 1%, FIGURE 18.
  • An individual blank 100, FIGURE 18, may be opened or expanded, as by a mandrel 191, into a desired tubular section, FIGURE 19.
  • a ductile metal has been employed for the spacers
  • the bending at the edges of the channel resist residue 7 6 occurs in such metal as indicated by the dotted limit lines 101:: for the portions 102 of the soft metal: and the lamination portions 193, 104 of harder metal are bent apart to curves of greater radii.
  • the outwardly projecting fins 105 are of soft metal, of double the thickness of the laminations 103, 104, and present re-entrant angles 1% at the inner surface.
  • the fins After trimming the fins, if desired, they may be reduced in distance of projection as shown in FIGURE 20 by the illustrative use of a hammer tool 108, while the expanded tube is supported internally by an anvil 109 of appropriate section, so that the inner and out-er surfaces of the tube are smoothed, with essential disappearance of the re-entrant angle, as shown in FIGURE 20.
  • An ingot competent of rolling to produce a laminate strip having a multiplicity of longitudinally extending non-welded internal regions of uniform width and spaced laterally from one another and from the edges of the strip comprising a metal body having essentially parallel external surfaces to be engaged by the reduction rolls, and having between said surfaces and spaced from one another and the lateral edges of the body a multiplicity of hollow longitudinally extending internal channels located substantially in a plane, the channels having successively lesser widths from the center of width of the body toward its lateral edges whereby differential lateral spreading of the channels during rolling will bring the channels to a uniform width in producing the strip, the metal between each two adjacent channels having metallurgically a wrought structure and integratedly bonded to the cast metal structure of other parts of the ingot.
  • a mold and core structure for casting ingots having a multiplicity of hollow internal longitudinal channels therein, said channels having differing widths comprising a mold body having a mold cavity therein, a plurality of core structures each having side and center members with interengaging parts at their abutting edges, the center member being tapered at its said edges from end to end of its mold-received portion and the side members each having the abutting edges thereof tapered oppositely to mate with the taper of the center member, said members having mating ribs and grooves along their abutting edges and being adjustable longitudinally relative to one another, each said core structure presenting surfaces extending across the central and side members thereof for forming the surfaces of a channel in the ingot and means for holding the members in the mold cavity and in edgeabutting relation whereby the distance between the outer edges of the side members and thereby of the respective widths of the channels being formed is determined by the prevailing relative longitudinal positions of the members and the mating ribs and grooves maintain the ingot-metal exposed surfaces in
  • An apparatus for making ingots having a plurality of hollow internal longitudinal fiat channels extending from end to end thereof, said channels being of controllably differing individual widths between their lateral edges, which comprises a mold member having an upright mold cavity extending therethrough, with the sides of the horizontal cross-section of the mold cavity closer together than the ends of the said cross-section of said cavity, a plurality of core structures each having abutting and inter-engaged side and center members of mating inverse edge tapers and having surfaces resistant to bonding by the molten ingot metal, said side members presenting lateral edges for forming the said lateral edges of the respective channel, said members being located in the said mold cavity in a row essentially parallel to the sides thereof and being longer than the ingot to be made so that they extend below the bottom of the ingot mold and above its top, means for closing the bottom of the mold member and having apertures through which the core structures can be introduced, holding means located below the bottom of the mold member and including individual parts for engaging and supporting the side and center members of the core structures with the
  • An apparatus as in claim 4 including means for withdrawing said mold bottom closing means and said individual core member holding parts downward at a concurrent rate.
  • the mold bottom closing means has openings located between the said apertures for the core structures for the passage of preformed spacer pieces to be integrated into the ingot being formed
  • said holding means include parts for holding such spacer pieces between and in contact with and immovable relative to said core structures
  • said holding means located above the mold member includes parts for holding said spacer pieces and core members in abutment with one another.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Metal Rolling (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
US37266A 1960-06-20 1960-06-20 Ingot and the mold and core structure for casting the same Expired - Lifetime US3116121A (en)

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US37266A US3116121A (en) 1960-06-20 1960-06-20 Ingot and the mold and core structure for casting the same
GB35982/60A GB953436A (en) 1960-06-20 1960-10-20 Improvements in or relating to methods and apparatus for making hollow ingots, laminate stock, hollow tubular bodies and to ingots and hollow tubular bodies
FR846805A FR1281487A (fr) 1960-06-20 1960-12-13 Procédé de coulée de lingots et bandes stratifiées pour corps creux à paroi mince
CH1417060A CH370200A (fr) 1960-06-20 1960-12-19 Procédé de coulée d'un lingot comportant des canaux longitudinaux intérieurs

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3570713A (en) * 1969-04-14 1971-03-16 Schloemann Ag Pouring of melts

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0005951B1 (fr) * 1978-05-26 1982-08-04 Potterton International Limited Echangeur de chaleur en fonte

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1984186A (en) * 1933-01-19 1934-12-11 David W Haber Permanent mold
US2286994A (en) * 1941-02-27 1942-06-16 Permold Co Molding apparatus
US2818618A (en) * 1955-09-07 1958-01-07 Bohn Aluminium & Brass Corp Four-part core pin
US2845695A (en) * 1953-05-21 1958-08-05 Gen Motors Corp Method of making refrigerating tubing
US2950512A (en) * 1957-04-02 1960-08-30 Revere Copper & Brass Inc Casting apparatus and method
US2957234A (en) * 1957-03-12 1960-10-25 Emery I Valyi Method of making pressure vessel
US2986810A (en) * 1959-02-11 1961-06-06 Continental Can Co Production of composite metal stock having internal channels
US3016587A (en) * 1959-07-08 1962-01-16 Continental Can Co Art of producing hollow ingots

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1984186A (en) * 1933-01-19 1934-12-11 David W Haber Permanent mold
US2286994A (en) * 1941-02-27 1942-06-16 Permold Co Molding apparatus
US2845695A (en) * 1953-05-21 1958-08-05 Gen Motors Corp Method of making refrigerating tubing
US2818618A (en) * 1955-09-07 1958-01-07 Bohn Aluminium & Brass Corp Four-part core pin
US2957234A (en) * 1957-03-12 1960-10-25 Emery I Valyi Method of making pressure vessel
US2950512A (en) * 1957-04-02 1960-08-30 Revere Copper & Brass Inc Casting apparatus and method
US2986810A (en) * 1959-02-11 1961-06-06 Continental Can Co Production of composite metal stock having internal channels
US3016587A (en) * 1959-07-08 1962-01-16 Continental Can Co Art of producing hollow ingots

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3570713A (en) * 1969-04-14 1971-03-16 Schloemann Ag Pouring of melts

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FR1281487A (fr) 1962-01-12
CH370200A (fr) 1963-06-30
GB953436A (en) 1964-03-25

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