Belt casting path control

Patent metadata

Field	Value
Publication number	US-10906093-B2
Application number	US-201815999068-A
Country	US
Kind code	B2
Filing date	Aug 16, 2018
Priority date	Aug 16, 2017
Publication date	Feb 2, 2021
Grant date	Feb 2, 2021

Abstract

A continuous casting device having multi-stage convergence control is disclosed. Cooling surfaces of the continuous casting device can be articulated in stages, providing individual convergence control to longitudinally spaced-apart regions of the casting cavity. In a proximal region, during which the molten metal exhibits solidification shrinkage, a first convergence profile can be used to optimally account for the solidification shrinkage. In a subsequent distal region, a second convergence profile can be used, such as to provide optimal control of exit temperature of the continuously cast article. Multi-stage convergence control can be achieved through individually articulatable cooling pads or other supports positioned opposite the cooling surfaces from the casting cavity to displace the cooling surfaces and thereby adjust the convergence profile of the casting cavity. Actuation of the individually articulatable cooling pads can effect different convergence profiles along the length of the continuous casting device.

First claim

What is claimed is:

1. A continuous casting apparatus comprising:
an opposing pair of cooling assemblies defining a casting cavity therebetween, the casting cavity extending longitudinally between a proximal end for accepting molten metal via a nozzle at the proximal end and a distal end for outputting solidified metal, wherein each of the opposing pair of cooling assemblies comprises a cooling surface made of a thermally conductive material for extracting heat from the molten metal to form the solidified metal, and wherein each of the opposing pair of cooling assemblies comprises:
at least one proximal support positioned opposite the cooling surface from the casting cavity for displacing the cooling surface, wherein the at least one proximal support is longitudinally positioned adjacent to the proximal end of the casting cavity, and wherein the at least one proximal support is pivotable about a fulcrum to adjust a convergence profile of the casting cavity in a proximal zone of the casting cavity; and
at least one distal support positioned opposite the cooling surface from the casting cavity for displacing the cooling surface, wherein the at least one distal support is longitudinally positioned between the at least one proximal support and the distal end of the casting cavity.

2. The continuous casting apparatus of claim 1 , wherein the at least one distal support is movable to adjust a convergence profile of the casting cavity in a distal zone of the casting cavity between the proximal zone and a distal end of the casting cavity.

3. The continuous casting apparatus of claim 1 , wherein the at least one proximal support is pivotable to adjust the convergence profile of the casting cavity.

4. The continuous casting apparatus of claim 1 , wherein the at least one proximal support is coupled to at least one actuator for adjusting the convergence profile of the casting cavity during a casting process.

5. The continuous casting apparatus of claim 1 , wherein at least one of the at least one proximal support and the at least one distal support includes a cooling pad for extracting heat from the cooling surface.

6. The continuous casting apparatus of claim 1 , wherein each of the cooling surfaces is a continuous metal belt.

7. A metal casting system comprising:
an opposing pair of cooling assemblies defining a casting cavity therebetween, the casting cavity extending longitudinally between a proximal end and a distal end; and
a nozzle positioned at the proximal end of the casting cavity for feeding molten metal into the casting cavity, wherein the opposing pair of cooling assemblies each comprise a cooling surface made of a thermally conductive material for extracting heat from the molten metal within the casting cavity to solidify the molten metal as the molten metal travels towards the distal end of the casting cavity;
wherein each of the opposing pair of cooling assemblies includes:
at least one proximal cooling pad positioned opposite the cooling surface from the casting cavity for displacing the cooling surface, wherein the at least one proximal cooling pad is longitudinally positioned adjacent to the proximal end of the casting cavity, and wherein the at least one proximal cooling pad is pivotable about a fulcrum to adjust a convergence profile of the casting cavity in a proximal zone of the casting cavity; and
at least one distal cooling pad positioned opposite the cooling surface from the casting cavity for displacing the cooling surface, wherein the at least one distal cooling pad is longitudinally positioned between the at least one proximal cooling pad and the distal end of the casting cavity.

8. The metal casting system of claim 7 , wherein the at least one distal cooling pad is movable to adjust a convergence profile of the casting cavity in a distal zone of the casting cavity between the proximal zone and the distal end of the casting cavity.

9. The metal casting system of claim 7 , wherein the at least one proximal cooling pad is coupled to at least one actuator for adjusting the convergence profile of the casting cavity during a casting process.

10. The metal casting system of claim 7 , wherein the at least one proximal cooling pad includes a plurality of linear nozzles extending laterally across a width of the cooling surface.

11. The metal casting system of claim 7 , wherein each of the cooling surfaces is a continuous metal belt.

12. The metal casting system of claim 7 , wherein the at least one distal cooling pad is longitudinally spaced apart from the proximal end of the casting cavity by at least a distance at which the molten metal has solidified.

13. A method of continuous casting comprising:
providing, using a nozzle at a proximal end of a casting cavity, molten metal to the casting cavity between an opposing pair of cooling assemblies at the proximal end of the casting cavity;
extracting, using a cooling surface made of thermally conductive material at each of the opposing pair of cooling assemblies, heat from the molten metal to solidify the molten metal into a solidified metal exiting at a distal end of the casting cavity;
adjusting a convergence profile of the casting cavity at a proximal region, wherein the proximal region is adjacent the proximal end of the casting cavity, and wherein adjusting the convergence profile of the casting cavity at the proximal region includes pivoting at least one proximal support about a fulcrum, wherein pivoting the at least one proximal support displaces a cooling surface of the cooling assembly to adjust the convergence profile of the casting cavity at the proximal region; and
adjusting the convergence profile of the casting cavity at a distal region, wherein the distal region is located between the proximal region and a distal end of the casting cavity, and wherein at least one distal support at the distal region displaces the cooling surface of the cooling assembly to adjust the convergence profile of the casting cavity at the distal region.

14. The method of claim 13 , wherein:
adjusting the convergence profile of the casting cavity at the proximal region includes adjusting, for each of the opposing pair of cooling assemblies, a proximal angle of attack of a cooling surface of the cooling assembly, wherein the proximal angle of attack defines an orientation of the cooling surface with respect to a centerline of the casting cavity at the proximal region; and
adjusting the convergence profile of the casting cavity at the distal region includes adjusting, for each of the opposing pair of cooling assemblies, a distal angle of attack of the cooling surface of the cooling assembly, wherein the distal angle of attack defines an orientation of the cooling surface with respect to a centerline of the casting cavity at the distal region.

15. The method of claim 13 , wherein:
adjusting the convergence profile of the casting cavity at the distal region includes, for each of the opposing pair of cooling assemblies, moving the at least one distal support, wherein moving the at least one distal support displaces the cooling surface of the cooling assembly to adjust the convergence profile of the casting cavity at the distal region.

16. The method of claim 13 , further comprising determining a desired casting profile, wherein determining the desired casting profile is based on at least one casting parameter, and wherein adjusting the convergence profile of the casting cavity at the proximal region includes using the desired casting profile.

17. The method of claim 13 , wherein adjusting the convergence profile of the casting cavi

Assignees

• Novelis Inc

Inventors

• Barker Simon William

Classifications

• B22D11/0677

  for guiding, supporting or tensioning the casting belts · CPC title

• B22D11/168

  for adjusting the mould size or mould taper · CPC title

• B22D11/1246

  Nozzles; Spray heads · CPC title

• B22D11/1206

  for plastic shaping of strands (rolling mills B21B1/46) · CPC title

• B22D11/0685

  by cooling the casting belts (B22D11/0677 takes precedence) · CPC title