WO2009118751A2 - Techniques de coulée continue à la verticale - Google Patents

Techniques de coulée continue à la verticale Download PDF

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Publication number
WO2009118751A2
WO2009118751A2 PCT/IN2009/000151 IN2009000151W WO2009118751A2 WO 2009118751 A2 WO2009118751 A2 WO 2009118751A2 IN 2009000151 W IN2009000151 W IN 2009000151W WO 2009118751 A2 WO2009118751 A2 WO 2009118751A2
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WO
WIPO (PCT)
Prior art keywords
metal
internal passage
molten metal
cooling
casting
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Ceased
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PCT/IN2009/000151
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English (en)
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WO2009118751A3 (fr
Inventor
Pradeep Navale
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Individual
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Individual
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Publication of WO2009118751A2 publication Critical patent/WO2009118751A2/fr
Anticipated expiration legal-status Critical
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Ceased legal-status Critical Current

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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
    • B22D11/14—Plants for continuous casting
    • B22D11/145—Plants for continuous casting for upward casting

Definitions

  • This invention relates to vertical continuous casting techniques.
  • this invention relates to a method of vertically upward continuous casting of a strip.
  • casting generally refers to individual articles or components made by the solidification of hot liquid metal in a die or a mould.
  • the process for making such components is generally referred to as casting process.
  • the casting process is carried out by allowing hot liquid material to enter into a mould or die in order to obtain solidified individual components by cooling. Casting is used for making complex shapes that would be otherwise difficult or uneconomical to manufacture by other methods or for manufacturing single components.
  • the various methods of casting include sand casting, investment casting, high pressure die casting, low pressure die casting and the like.
  • Sand casting is carried out by applying sand mixed with binders and water around wood or metal pattern having two parts to produce a sand mould.
  • the mould is removed from the wood or metal pattern and metal is poured into the mould through cavities. After cooling, moulds are broken to remove the castings.
  • Investment casting is carried out by injecting wax into a metal mould to make patterns, which are connected to a common sprue.
  • the patterns are repeatedly dipped in ceramic slurry and dried which is followed by heating to remove the wax to form ceramic shells.
  • the ceramic shells are heated and filled with molten metal.
  • the ceramic shell containing the molten metal is cooled to solidify the molten metal to form casting.
  • Low pressure die casting is a method of casting wherein a die or mould is mounted above a sealed furnace containing a molten metal.
  • a riser tube connects the bottom of the die to the molten metal furnace.
  • the furnace containing the molten metal is pressurized (typically 20-10OkPa), and the metal is forced up into the mould.
  • the pressure is released and the molten metal falls back into the furnace. The casting is then taken out of the die for further processing.
  • High pressure die casting is a method wherein molten metal is poured into the mould or die through a shroud on the top of the mould or die. When the molten metal solidifies in the die the casting is then taken out of the die for further processing.
  • Continuous Casting is a process whereby molten metal passing through a die is solidified to form various cast sections of substantial lengths.
  • the process of continuous casting is initiated by causing the molten metal to enter into a die containing a starter device.
  • the molten metal is allowed to attach to the starter device to initiate the casting of continuous lengths of metal.
  • the continuous casting process is carried out either vertically or horizontally.
  • the liquid metal is made to continuously enter into a cooled mould or die which is placed such that the molten metal enters the die or mould in the horizontal direction from an inlet pipe.
  • the liquid metal is made to solidify in the mould and is continuously withdrawn in a horizontal direction from the mould or die in order to form a continuous length of metal casting.
  • the liquid metal is made to continuously enter into a cooled mould or die which is placed such that the molten metal enters the die or mould, either in the vertically upward direction or the vertically downward direction, from an inlet pipe.
  • the liquid metal is made to solidify in the mould and is continuously withdrawn from the mould or die in order to form a continuous length of metal casting.
  • the process of continuous casting allows lower-cost production of metal sections having better quality, allows manufacturing of continuous lengths of metals and provides increased control over the process through automation.
  • the continuous casting processes described above is suitable for manufacturing wires, rods, blooms, billet and slabs.
  • the methods of continuous casting mentioned above are not suitable for manufacturing continuous strips of metal.
  • the continuous strips of metal are used for making car bodies, airplane wings, medical tables, roofs for building, transformers etc.
  • the continuous strips of metal are at present produced typically by hot drawing which is an expensive process and cannot be used to produce oxygen free strips. Therefore, there is a need for a process for making a continuously cast strips of metal and metal alloy.
  • US Patent 3872913 discloses the continuous method for upward casting of metal wherein the melt is continuously drawn upwards from a supply of the melt by suction through a vertical graphite nozzle the upper portion of which is cooled to solidify the melt enough in the nozzle to endure pulling the solidified product upwards through a cooler having a cross-section which is somewhat greater than that of the product.
  • the innermost tube of the cooler through which the product is pulled is of somewhat greater diameter than the product and has an opening at the upper part thereof to create suction inside the apparatus.
  • a continuous casting furnace for manufacturing an elongated cast product for example, of copper or its alloy includes a housing defining a chamber.
  • a crucible is accommodated within the chamber for holding a casting material.
  • a heater is mounted on the crucible for melting the casting material.
  • a generally vertically-disposed elongated casting nozzle hermetically extends into the chamber.
  • One of the casting nozzle and the crucible is movable toward the other for immersing a lower end of the casting nozzle in the molten casting material in the crucible.
  • the housing is connected to an inert gas source for introducing inert gas into the chamber when the casting material in the crucible is melted.
  • US Patent 4719961 discloses a vertical or bow-type continuous casting machine for steel.
  • Continuous casting apparatus having a highly conductive, cooled flow-through mold, a feeder for the mold having an upstream and a downstream section with the downstream section in abutment with the mold, a heater associated with the upstream section for maintaining metal in contact therewith above liquids temperature, the feeder sections being made of refractory material and dimensioned such that the heat from the upstream section is not bled off so rapidly into the cooling elements of the adjacent mold as to start the strand shell development in the upstream section, but sufficiently to let it start in the downstream section of the feeder.
  • the major disadvantage of the vertical casting process of US Patent 4719961 arises due to the vertically downward casting of molten metal. The process of vertically downward casting causes the problem of melt run-outs which accounts for heavy damages during the production process. Another disadvantage of the process disclosed in US Patent 4719961 is that it results in long intervals production shutdown.
  • US Patent 5273103 discloses continuous casting machines for vertically thin-bodies.
  • continuous casting machines in which the liquid metal is cast in a mold formed by a pair of counter-rotating rolls with parallel longitudinal axes lying in the same horizontal plane and by a pair of containment plates facing onto the flat ends of the rolls, an electromagnetic device is introduced which produces a field of electromagnetic forces in a desired and given space formed between the plates and roll ends, the orientation and intensity of the forces being such as to impede leakage of liquid metal between the plates and the rolls.
  • the use of electromagnetic device increases the cost of installation.
  • Another disadvantage of US Patent 5273103 is that the electronic device has to be set to produce the desired intensity and direction of the electromagnetic forces.
  • An object of the present invention is to provide a method for directly casting continuous strips of metal instead of obtaining strips by forging or rolling of slabs.
  • Further object of the invention is to provide a method of vertically upward continuous casting of strips, which is efficient, economical and less time consuming.
  • the expression "vertically” used in this specification would mean in a direction between 30 degrees to 150 degrees although preferably the direction should be 85 degrees to 95 degrees and still more preferably 90 degrees.
  • Still further object of the invention is to provide a method of vertically upward continuous casting of strips, which consumes less electricity.
  • Yet further object of the invention is to provide a method of vertically upward continuous casting of strips, which is simple and safe to use.
  • Still further object of the invention is to provide a method of vertically upward continuous casting of strips, wherein furnace mouth repair is not required.
  • Yet a further object of the invention is to provide a method of vertically upward continuous casting of strips, wherein there is no leakage of molten metal or metal run-outs during casting process.
  • Further object of the invention is to provide oxygen free strips which have better ductility, malleability, high electrical and thermal conductivity.
  • Still further object of the invention is to provide a method of vertically upward continuous casting of strips which is carried out in an air free environment.
  • a method of vertically upward continuous casting of a strip of a metal/metal alloy comprising the following steps: a) making a graphite die defining a passage conforming to the dimension of the strip; b) holding a molten metal in a casting chamber in an air free environment and maintaining the temperature in the casting chamber in the range of about 1000 0 C to 1400 0 C; c) immersing vertically the lower end of said graphite die partially in the molten metal, said graphite die having a nozzle at its operational lower end and a first internal passage leading from said nozzle to the operative outer face of the die; d) providing a cooling arrangement on the outer face of said die, said cooling arrangement defining a second internal passage contiguous with said first internal passage; e) lowering a dummy bar having slots at its operative lower end through said second and first internal passages to contact the surface of the molten metal; f) allowing the molten metal to rise and
  • the step of transferring said molten metal from a melting chamber to said casting chamber through an air-tight passageway is typically performed by the step of transferring said molten metal from a melting chamber to said casting chamber through an air-tight passageway.
  • the step of the air free environment of the molten metal in the casting chamber is achieved by spreading at least one layer of graphite flakes on the surface of the molten metal in the casting chamber and the melting chamber.
  • the molten metal is allowed to rise under positive pressure.
  • the step of cooling the said second internal passage is in the range of 8°C to 20 0 C by means of a cooling fluid to cool the metal strip inside the second internal passage to about 200 0 C.
  • drawing includes providing withdrawal rollers and the step of raising and lowering of the solidified metal strip is achieved by angularly displacing said withdrawal rollers in an anti-clockwise and a clockwise direction.
  • the displacement in the anti-clockwise direction is greater then the displacement in the clockwise direction.
  • the step of raising and lowering of the metal strip includes providing stop and rest between the anti-clockwise and clockwise displacement.
  • the method includes a step of cooling the metal strip emerging from said second passage and entering the withdrawal roller.
  • the cooling is achieved by providing cooled idle rollers, cooled to a temperature of 8 0 C to 20 0 C, between the outlet of the second internal passage and the inlet to the withdrawal rollers to cool the metal strip to about 100 0 C.
  • an apparatus of vertically upward continuous casting of a metal strip comprising:
  • a furnace partitioned into a melting chamber and a casting chamber partitioned into a melting chamber and a casting chamber; b) a graphite die defining a first internal passage; c) an insulating protection tube surrounding the graphite die and the first cooling means. d) a first cooling means for cooling the die; e) a second internal passage contiguous with the first internal passage in said die; f) a second cooling means for cooling the second passage; and g) a drawing means for drawing cast strips through said first and second internal passages.
  • a nozzle is provided at the entrance of the first internal passage.
  • a venturi is provided at the entrance of said nozzle.
  • the protection tube is refractory lined.
  • the graphite die is spaced apart from the protection tube and the defining space is packed with insulating material typically of glass wool, ceramic wool and the like.
  • fitting means are provided to rigidly fit the second cooling means to said graphite die.
  • a support means in the form of an M. S. plate is provided to support the first cooling means in the protection tube.
  • the venturi is formed in said protection tube.
  • idle rollers are provided between the secondary cooling means and the drawing means.
  • a third cooling means is provided to cool said idle rollers.
  • the first cooling means, the second cooling means and the third cooling means are continuous.
  • a servomotor is provided to the drawing means for raising and lowering the metal strip incrementally, alternatively and repetitively during casting.
  • a dummy bar is provided for leading the strip during casting through the first passage, the second passage and the drawing rolls.
  • At least one layer of graphite flakes is provided in said casting chamber to isolate said molten metal to come in contact with air.
  • Figure 1 shows a front cross-sectional view of an apparatus according to the invention for continuous vertical casting of strips
  • Figure 2 shows the cross-sectional view of a die along with a first cooling means in a protection tube
  • Figure 3 shows a side cross-sectional view of an apparatus according to the invention for continuous vertical casting of strips without the strip;
  • Figure 4 shows a side cross-sectional view of figure 3 showing the strip being produced
  • Figure 5 shows a front view of a dummy bar provided with slots for acting as starter
  • Figure 6 shows a side view of withdrawal rollers along with the dummy bar.
  • an apparatus for a method of vertical continuous casting of strip in accordance with this invention is generally indicated by reference numeral (10) and is particularly shown in figure 1.
  • Figure 1 show a furnace (12) used in the vertically upward continuous casting of a strip (52).
  • the melting chamber (14) and the casting chamber (18) are interconnected by means of an air-tight passageway (16).
  • a metal/metal alloy is melted in the melting chamber (14) and the molten metal/metal alloy (20) is maintained at a temperature of about 1000 0 C to 1400 0 C.
  • the molten metal/metal alloy (20) enters the casting chamber (18) through the passageway (16) from the melting chamber (14).
  • the surface of the molten metal/metal alloy (20) in the furnace (12) is covered by graphite flakes (24) to prevent the molten metal/metal alloy (20) from reaction with the atmospheric oxygen and thus maintaining an air free environment.
  • FIG 2 shows a protection tube (36) housing a die (46), a first cooling means (44), an M.S. back up plate (42) and an insulating material (38).
  • the protection tube (36) is provided with a lining typically of a refractory material (40).
  • the protection tube (36) is provided with a venturi (21).
  • the die (46) used for casting the strip (52) defines a first internal passage (22), shown in figure 2, open at both ends.
  • One end of the first internal passage (22) of the die (46) is provided with a nozzle (23) while the other end leads into a second internal passage (33) of a second cooling means (32) as shown in figure 3.
  • the dimension of the first internal passage (22) of the die (46) is slightly greater than the required dimension of the strip (52).
  • the die (46) is typically made of graphite and provides a non- wetting surface for the molten metal (20).
  • the die (46) typically has a length of 300mm.
  • the venturi (21) of the protection tube (36) cooperates with the nozzle (23) of the die (46).
  • the die (46) is surrounded by the first cooling means (44) which is further supported by the M.S. back up plate (42).
  • the die (46) and the first cooling means (44) are spaced apart from the protection tube (36) to define a space which is packed with insulating material (38).
  • the insulating material (38) is typically glass wool.
  • the first cooling means (44) is provided with an inlet (28) and an outlet (30) for circulating water, in the temperature range of 15°C to 35°C, which acts as a coolant.
  • the first cooling means (44) is typically of copper.
  • the coolant in the first cooling means (44) helps in cooling the die (46) and maintains the temperature of the molten material in the range of 1000 0 C to 500 0 C.
  • the molten metal (20) in the die (46) solidifies as a result of cooling after a traverse of 150 mm, that is, half the lengths of the passage in the die (46).
  • the second cooling means (32) is provided with a second internal passage (33), open at both ends.
  • the dimension of the second internal passage (33) is made to conform to the dimension of the first internal passage (22) of the die (46).
  • the second cooling means (32) causes the cooling of the second internal passage (33) with the help of water or a fluid in the range of 8°C to 20 0 C and maintains the second internal passage (33) such that the strip emanating from the second internal passage (33) has a temperature of about 200 0 C.
  • the second cooling means (32) has a length of 500 mm.
  • a rail and rail guide assembly (51), shown schematically in figure 3, is provided to lower and raise the die (46) enclosed in the protection tube (36) and the second cooling means (32) in the molten metal (20).
  • the operation of the rail and rail guide assembly (51) in order to precisely control the movement of the die (46) and the second cooling means (32) is controlled by a motor (not shown in figure).
  • a plurality of withdrawal rollers (50) acts as a means for drawing the strip out of the process.
  • At least one idle roller (48) is provided between the secondary cooling means (32) and the withdrawal rollers (50).
  • a third cooling means (not shown in figure) is provided to cool the idle rollers (48) to a temperature typically in the range of 8°C to 20 0 C.
  • the idle rollers (48) helps in cooling as well as guiding the formed strip (52) coming out of the second cooling means (32) towards the set of withdrawal rollers (50).
  • the withdrawal rollers (50) are operated with the help of a servomotor (not shown in figure).
  • a dummy bar (34), shown in figure 5 and figure 6, is used as a start-up device for attaching the molten metal.
  • the dummy bar (34) consists of a metal attaching portion (56) having the same dimension as the desired dimension of the formed metal strip (52) and a withdrawal portion (58) provided to allow the dummy bar (34) to extend the dummy bar (34) upto the withdrawal rollers (50).
  • the metal attaching portion (56) is provided with slots (54) for allowing the solidified molten metal fix to the dummy bar (34).
  • Figure 4 shows the casting of the molten metal (20) to form the strip (52).
  • the second cooling means (32) is fitted using bolts on the side opposite to the nozzle (23) of the die (46).
  • the first internal passage (22) of the die (46) is aligned with the second internal passage (33) of the second cooling means (32), so as to form a single contiguous passage.
  • the gap between the bolted ends of the die (46) and the second cooling means (32) is sealed with a sealing material to further enhance the continuity of the aligned first internal passage (22) and the second internal passage (33).
  • the casting metal (20) is made to melt in the melting chamber (14) by heating the casting metal to a temperature of about 1000 0 C to 1400 0 C.
  • the molten metal /metal alloy (20) is transferred to the casting chamber (18) through the passageway (16). At least one layer of graphite flakes (24) is provided on the top surface of the molten metal.
  • the graphite flakes (24) being lighter in weight than the molten metal (20), floats on the surface of the molten metal (20) thus preventing the molten metal to come in contact with air.
  • the dummy bar (34), shown in figure 5 and figure 6, is inserted into the first internal passage (22) of the die (46) through the second internal passage (33) of the second cooling means (32).
  • the dummy bar (34) is inserted in the first internal passage (22) of the die (46) such that the dummy bar (34) lies just above the nozzle (21) of the die (46).
  • the assembly of the die (46) and the second cooling means (32) is immersed in the molten metal (20) in the casting chamber (18) such that the die (46) is partially immersed in the molten metal (20).
  • the assembly of the die (46), the first cooling means (44), the insulating material (38) housed in the protection tube (36) is partially immersed in the molten metal (20) in the casting chamber (18).
  • the nozzle (23) of the die (46) in co-operation with the venturi (21) of the protection tube (36) enables in causing a positive displacement of the molten metal (20) into the first internal passage (22) of the die (46).
  • the molten metal (20) in the first internal passage (22) of the die (46) is attached to the metal attaching portion (56) of the dummy bar (34).
  • the withdrawal rollers (50) are operated with the help of servomotor (not shown in figure).
  • the withdrawal rollers (50) are provided with an angular displacement in the anti-clockwise and clockwise direction so as to continuously raise and lower the attached molten metal (20).
  • the angular displacement of the withdrawal rollers (50) is provided in an incremental, alternative and repetitive cycle.
  • the incremental, alternative and repetitive cycle of the withdrawal rollers (50) causes the dummy bar (34) to rise along with the attached molten metal (20) away from the casting chamber (18) typically by 7 mm.
  • the raised dummy bar (34) along with the attached molten metal (20) is held in position typically for 1 second.
  • the raised dummy bar (34) along with the attached molten metal (20) is then lowered towards the casting chamber (18) along with the attached and partially solidified molten metal strip through a distance typically of 1.3 mm.
  • the lowered dummy bar (34) along with the attached partially solidified molten metal (20) is held in the lowered position typically for 1 second so that a thin layer of the molten metal (20) attaches itself to the molten metal strip attached to the dummy bar (34).
  • the incremental, alternative and repetitive cycle is continued till the desired length of the strip (52) is obtained.
  • the metal strip (52) typically forms/ solidifies after passing through 150 mm.
  • the metal strip (52) coming out of the first internal passage (22) to the second internal passage (33), is at a temperature of about 500 0 C as it enters the second internal passage (33) and is about 200 0 C on coming out of the second cooling means.
  • the formed metal strip (52) is further cooled to a temperature of 100 0 C after passing through the internally cooled idle rollers (48).
  • the relative temperature are a matter of design optimization and the final temperatures of the strip (52) in the first internal passage (22) and the second internal passage (33) is dependent upon the length of the passage and the resident times of the strip in the respective passages.
  • Idle rollers (48) may be provided between the exit of the second internal passage (33) and the withdrawal rollers (50) which may be cooled to further reduce the temperature of the metal strip (52) to a manageable temperature of 100 0 C.
  • the solidified and formed strip (52) coming out of the draw roller assembly (47) is made to form coiled rolls of metal strip (52).
  • the metal strip obtained by the present invention has a thickness typically in the range of 8 mm to 25 mm and has a width typically in the range of 125 mm to 400 mm.
  • the strips formed can be further rolled to obtain strips of thickness as low as about 2 mm to 3.5 mm in the casting line itself and by further processing the strip (52) can be rolled to a thickness of 0.04 mm.
  • the strips formed in accordance with this invention by the above method were tested for ductility (40%), conductivity (97%), malleability, X-ray diffraction for cracks and holes and the product passed all test standards. It was also found to be oxygen free and could be used as such or after annealing for various applications.
  • the cost of making the strip in accordance with this invention was also calculated to be almost 200% less than the cost of making the strip according to vacuum process. The apparatus is also comparatively less expensive.
  • the product as described herein above offers several advancements over similar products disclosed in the prior art.
  • the vertically upward continuous casting process in accordance with the present invention helps in directly producing continuous lengths of metal strips.
  • the vertically upward continuous casting process in accordance with the present invention is simple in construction.
  • the vertically upward continuous casting process in accordance with the present invention helps in reducing the losses.
  • the vertically upward continuous casting process in accordance with the present invention also helps in reducing electricity consumption.
  • the vertically upward continuous casting process in accordance with the present invention is safe to handle and require minimum manual work.

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

Abstract

L'invention concerne un procédé et un appareil de coulée continue verticale vers le haut pour la production de rubans continus de métal, dans lesquels un métal fondu est amené à monter à la verticale vers le haut à travers une filière entourée par un moyen de refroidissement. Le ruban métallique est amené à traverser un autre moyen de refroidissement et est extrait au moyen de galets de traction. Le ruban métallique formé est exempt d'oxygène et présente une haute conductivité.
PCT/IN2009/000151 2008-03-07 2009-03-05 Techniques de coulée continue à la verticale Ceased WO2009118751A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN472/MUM/2008 2008-03-07
IN472MU2008 2008-03-07

Publications (2)

Publication Number Publication Date
WO2009118751A2 true WO2009118751A2 (fr) 2009-10-01
WO2009118751A3 WO2009118751A3 (fr) 2011-01-20

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PCT/IN2009/000151 Ceased WO2009118751A2 (fr) 2008-03-07 2009-03-05 Techniques de coulée continue à la verticale

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Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FI46693C (fi) * 1970-05-19 1973-06-11 Outokumpu Oy Laitesovitelma putkien, tankojen, levyjen ym. ylöspäin suuntautuvaa ja tkuvaa valua varten.
GB8703231D0 (en) * 1987-02-12 1987-03-18 Wilson R Casting furnaces
KR20050000165A (ko) * 2003-06-23 2005-01-03 주식회사 포스코 박 슬라브용 더미바

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