Note: Descriptions are shown in the official language in which they were submitted.
CA 02355133 2001-08-16
I
j DIRECT COOLED hIETAL CASTING CONTROL SYSTEM
TECHNICAL FIELD
3
This invention relates to a system for use in a continuous cast mold in
a
which coolant is applied to a castpart emerging from a mold cavity, and
s
discloses a system which controls the flow of coolant back toward the mold
6
cavity. More particularly, this invention relates to the creation of a forced
gas barrier or knife, which prevents coolant from meving against the direction
8
of the movement of the emerging castpart and back toward the mold cavity.
9
I BACKGROUND OF THE Il~'VENTION
II '
Direct cooled metal casting processes and apparatuses have been known
for many years, such as that disclosed in U.S. Patent No. 5,582,230 for a
13
"Direct Cooled Metal Casting Process and Apparatus", which is incorporated
I -t
herein by this reference as though fully set forth herein.
Is
While coolant is generally directed, applied or sprayed in one or more
16
jets onto the emerging castpart, the coolant has a tendency to creep or flow
l .'
back toward the mold cavity. This may be referred to as a capillary action
18
of the coolant, as it moves, flows or creeps toward the mold cavity or mold
!9
cavity inlet.
?o
It is desirable in the industry to control the placement and location of
zl
the coolant and to prevent the coolant from moving, flowing or creeping back
z~
toward the mold cavity.
.3
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r There have beer. prfor uses of discharge jets and other coolant
manipulation techniques to affect the cooling of the emerging ingot and to
3 more precisely control the location and magnitude of cooling, as more fully
a disclosed in U.S. Patent No. 5,82,230. These techniques may also help
control
s the tendency of the coolant to flow back toward the mold cavity. However,
using coolant to avoid having coolant flow back toward the mold cavity is not
as effective as the present invention.
The ability (or inability) to sufficiently control 'the flow of the coolant
9 II back toward the mold cavity has also imposed certain limitations in the
to utilization of other more efficient casting techniques. For example,
applying
ll the coolant at an approximate ninety degree angle to the surface of the
I' emerging castpart may increase the efficiency of the cooling. However most
Ij coolant is applied at an angle substantially less than ninety degrees due
to the
l~ ~~ inability to control or prevent the flow of the coolant back toward the
mold
Is ~~ cavity.
16 ~~ The inability to sufficiently control the flow of the coolant back
toward
I% the mold cavity has also presented limitations on the ability to change the
l~ orientation of the mold without' concern over the coolant working its way
back
19 II toward the mold cavity. For instance in a. vertical mold, the mold
cavity is
1o vertically above the location where coolant is applied to the emerging
castpart
'I and gravity therefore assists in keeping the coolant from flowing back
toward
1' the mold cavity. In horizontal molds gravity does not provide the same
13 assistance and controlling the flow of the coolant becomes more important.
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It is therefore an ohject of this invention to provide a direct cooled
metal casting control system which better controls and prevents the coolant
3 from flowing, creeping or moving back toward the mold cavity. This invention
a utilizes a fluid, preferably a gas, even more preferably, air, to create
pressure,
s force, and/or a barrier, baffle or knife which prevents the coolant from
flowing, creeping or moving back toward the mold cavity inlet. This invention
is not however limited to the fluid being a gas, but instead it may be other
types of fluids such as ethylyn glycol (a non-explosive fluid).
The control system provided by this invention will allow for an angle
to between the coolant stream and the metal surface of up to ninety degrees or
II more, including up to one hundred twenty degrees. This will allow for more
I1 efficient and effective direct-cooled metal casting.
13
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IS
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BRIEF DESCRIPTION OF -THE DR4'i/INGS
z Preferred
embodiments
of the
invention
are described
below with
3 reference to the accompanying drawings, which are briefly described
below.
Figure 1 is a part schematic, part cross-sectional view of a
prior art mold
s portion as disclosed in U.S. Patent No. x,582,230,
illustrating two
coolant discharge apertures contacting the emerging
castpart;
Figure 2 is a perspective view of an example of a typical ingot
shaped
mold framework and mold cavity;
9 Figure 3 is a bottom view of the example of the typical ingot
shaped
m mold framework and mold cavity illustrated in Figure
2;
m Figure 4 is an exemplary elevation part schematic, part cross-sectional
view
I' of a mold for casting billets, and illustrates one
alternative
I3 environment for the use of the invention;
laFigure S is a part schematic, part cross-sectional view of one
~' embodiment
Is of a mold utilizing the system provided by this invention,
16 illustrating two coolant discharge apertures contacting
the
l' emerging metal_ castpart, and further illustrates a
gas control
system and aperture imparting a force on the coolant
away from
19 the mold cavity; .
2oFigure 6 is a perspective view of an exemplary short section
of an
'I embodiment of a mold framework, illustrating the relative
'z configuration of the multiple coolant apertures and
of the
13
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I i apertures for introducing gas to keep the coolant
from moving
back toward the mold cavity;
3 I Figure is a side view of the portion of the mold shown
7 in Figure 6
and illustrates an embodiment of this invention
with
the gas
s I discharge apertures;
I
Figure 8 is a part cross-sectional and part schematic view
of an
embodiment of this invention wherein the coolant
is discharged
at an angle of approximately ninety degrees relative
to the outer
perimeter surface of the emerging castpart;
to Figure 9 is the detail view from Figure 8 and illustrates
~ th
a forced gas
11 imparting a force on the coolant and preventing
it from moving
5
I= back toward the mold cavity;
I
Ij Figure 10 is an elevation view schematic of an embodiment
~ of this
la ~ invention wherein the gas is introduced beriveen
; the target zones
Is of adjacent coolant aperture discharges;
16 Figure 11 is an elevation schematic view of one embodiment
of this
l~ invention wherein the gas is introduced at or near
the target
la zones for the coolant discharged on the emerging
metal;
l~ Figure 12 is a perspective schematic illustrating the coolant
as discharged
zo and the introduction of gas at or near the coolant
target zone;
11 Figure 13 is a perspective schematic view of the embodiment
of this
11 invention wherein the gas is introduced between
target zones of
13 adjacent coolant discharges; and
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Figure 14 is a perspective. view of a section of a mold framework which
1 has an air slit aperture instead of individual apertures.
a
7
8
9
!0
ll
11
l3
1.1 '
IS
l6
l7
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1I
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Many of the fastening, connection, manufacturing and other means and
components utilized in this invention are widely known and used in the field
a ~ of the invention described, and their exact nature or type is not
necessary for
s an understanding and use of the invention by a person skilled in the art or
science; therefore, they will not be discussed in significant detail.
Furthermore, the various components shown or described herein for any
a specific application of this invention can be varied or altered as
anticipated
by this invention and the practice of a specific application or embodiment of
!o ~ any element may already be widely known or used in the art or by persons
r! skilled in the art or science; therefore, each will not be discussed in
significant detail.
m II The terms "a", "an", and "the" as used in the claims herein are used
!a in confonrnance with long-standing claim drafting practice and not in a
Is limiting way. Unless specifically set forth herein, the terms "a", "an",
and
16 "the" are not limited to one of such elements, but instead mean "at least
I~ II one".
l8 II This invention has numerous different embodiments within direct cooled
I9 II metal casting processes and apparatuses, with only a few being described
herein, including the preferred embodiment, as required. One such
=1 environment, which is incorporated by reference herein, is U.S. Patent
No. 5,582,230, which describes, discloses and illustrates a system for cooling
?3 i an emerging castpart; and which would help control the backflow of the
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I coolant with a second coolant discharge directed at portions of the coolant
from the first coolant discharge.
I
3 Although the references herein are generally to the continuous casting
a if ingot-shaped and billet-shaped castparts, this invention is certainly not
limited to any particular shape or configuration of castpart, but instead
applies
to all such shapes, including~exotic and unique shapes in addition to the more
. traditional billets and ingots.
It will further be appreciated that this invention may be applied in
9 different embodiments to differently configured continuous casting molds and
to ' devices, including vertical molds, horizontal molds, and molds at any
other
1I ~ possible angle. This invention is articularI we
p y 11 sorted to allow continuous
I' f casting and the utilization of coolant at numerous different angles for
the
Ij ~ casting, as the invention better provides for the control and/or
prevention of
la the movement of the fluid back toward the mold cavity. This invention will
I~ be important in allowing other directional castings to be utilized without
fear
I6 of the coolant moving, creeping, or flowing back toward or into the mold
I- cavity.
I8 Figure 1 is similar to Figure 10 from U.S. Patent No. 5,582,230 and
19 i illustrates a typical cross-section and schematic of the interface
between the
2~ coolant discharge and the emerging castpart in a continuous casting mold.
21 Figure 1 illustrates emerging castpart 1, mold ring 2 supported within
22 framework 3, first coolant discharge aperture 4, and second coolant
discharge
=3 aperture 5.
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/ The coolant discharged from first coolant discharge aperture 4 contacts
the emerging castpart at or about target zone 6. The coolant then typically
moves in the direction the emerging castpart is moving, and also splashes as
a ~~ additional coolant is discharged.
s When it is referred to herein that a force is imparted on coolant away
from the mold inlet, this not only includes imparting a force on the coolant,
but may also include imparting a force only on a coolant vapor and/or on the
coolant. .
It will be appreciated by those of ordinary skill in the art that while
to this invention may be used with one or two coolant discharge apertures,
there
11 is no particular number which needs to be used in order to practice the
f' embodiments of this invention. The examples and illustrations shown herein
m are for illustrative purposes and not in any way to limit the environment or
la scope of the invention.
IS Figure 1 further illustrates first coolant reservoir 8 and second coolant
16 reservoir 9 which supply the coolant for first coolant discharge aperture 4
and
second coolant discharge aperture 5, respectively.
l8 There are numerous general and specific configurations for continuous
19 casting molds, which are generally known by those of ordinary skill in the
art,
and each one will not be described in any significant detail herein.
11 II Figure 2 is a perspective view of one example of a mold framework 20
shaped to produce rectangular or ingot-shaped castparts or cast formats. The
=3 mold outlet cavity side 21 and the mold intlet cavity side 22 of the
framework
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1 are shown, and molten metal would generally be provided or made available
through mold inlet cavity 21, and would exit through mold outlet cavity 22.
3 It is generally at the mold outlet cavity 22 where coolant is sprayed on or
a directed to the emerging castpart. The general manufacture and use of such
s a mold framework 20 is well known by those of ordinary skill in the art and
will not be described in further detail. Furthermore_ a mn,-P r~Pra;tP~
description of such a framework is provided in U.S. Patent No. x,582,230,
which has previously been incorporated herein by reference.
Figure 3 is a bottom view of the example of the typical ingot-shaped
to mold framework as illustrated in Figure 2, and is a view from the outlet
11 cavity side of the mold framework 20. The inner perimeter 24 of the mold
1? framework is also shown in Figure 3, and generally defining what is
referred
I3 to as an ingot shape.
1~ Figure 4 is an exemplary elevation view, part schematic, part cross-
Is sectional, of a continuous casting mold which casts round or billet shaped
l6 castparts or cast formats. Figure 4 illustrates one of the several other
I% possible environments for the utilization of the invention described
herein.
Is Figure 4 illustrates mold distribution trough 30 which is generally
composed of refractory material and which is a distribution trough through
?~ which molten metal is provided to mold or mold framework 31. Mold inlet
?/ or mold inlet cavity 32 is where molten metal is received within and by
mold
z1 II ring 34, and mold outlet cavity 35 is where the emerging billet or
emerging
?3
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/ castpart exits the mold or mold cavity. Outline 36 illustrates a billet-
shaped
2 castpart as it would otherwise exit the mold.
The terms mold inlet or mold inlet cavity as used in the claims are
a intended to be used as a direction towards which it is desired to prevent
the
s coolant from flowing, which is generally in the opposite direction of the
flow
of the molten metal. This invention is not limited to a vertical or horizontal
application, but would apply to situations where the mold is upside down
a from the current typical mold orientation so that the 'cast part is emerging
in
9 an upward direction.
to Coolant discharge apertures 38 are also illustrated and show a relative
l/ location of the coolant discharge relative to the mold cavity 39 and mold
m outlet cavity 35. Figure 4 illustrates a general configuration of how molten
I3 metal would be fed into the mold inlet cavity 32, proceed to mold cavity 39
m surrounded by mold rings 34, and then emerging through mold outlet cavity
3~, while coolant is sprayed or discharged thereon.
l6 Figure 5 is an illustration of one embodiment of this invention wherein
the system for preventing the flow of the coolant back toward the mold cavity
is combined with a first coolant discharge aperture 50 and a second coolant
discharge aperture ~l. The first coolant .discharge aperture 50 discharges
2~ coolant 52 to contact the emerging castpart 53 on or about the target zone
2/ 54. Also illustrated in Figure S are mold ring 55, first coolant reservoir
56,
and second coolant reservoir 57.
23
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r This invention provides a baffle fluid which is preferably a gas, and
- more particularly, preferably air, to impart a force on a coolant adjacent a
castpart surface in a direction away from the mold inlet. This creates a
a baffle of sort between the mold inlet and the target zone for the coolant.
s Although the term gas is used throughout, it is to be understood that a gas
s is just one of the baffle fluids which may used in an embodiment of this
invention, with others being equally usable within the contemplation of the
a invention (such as momentum bearing fluids, fluids which have an affinity to
water vapor).
m It will also be appreciated by those of ordinary skill in the art that the
m baffle fluid apertures may be located in any one of a number of different
r' positions or components within the contemplation of the various embodiments
l3 of this invention, such as in the bottom block, in the graphite, or in a
~a separate'baffle body structure.
h I Figure 5 illustrates gas feed aperture 60 which feeds the one or more
r6 gas discharge apertures 61. As can be seen in Figure 5, the discharged gas
j% 62 (preferably air) imparts _a force on the coolant and on the outer
perimeter
/8 surface 53a of the emerging ~castpart 53 to prevent the coolant 52 from
moving back toward the mold cavity. It. will be appreciated by those of
ordinary skill in the art that there are numerous different configurations for
2l gas discharge apertures which would create such a gas force on the coolant
z' S2 around the outer perimeter 53a of the castpart 53, to prevent the
coolant
zj 52 from traveling back toward the mold cavity.
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Figure 6 is a perspective view of a short portion of an embodiment of
a mold framework 70 of this invention and illustrates a plurality of gas
3 discharge apertures 71, a plurality of first coolant discharge apertures 72,
and
a a plurality of second coolant discharge apertures 73. Figure 6 would be
s representative of an embodiment similar to that shown in Figure 5 and
further illustrates gas discharge feed aperture 75, first coolant feed
discharge
aperture 76, and second coolant feed discharge aperture 77.
It is contemplated by this invention that there will be embodiments
wherein this coolant control system will be used to effectively mold exotic
and
to I non-symmetrical castparts, and the particular controls provided by this
system
ll ~ will allow unique castpart outer perimeter shapes (and casting angles
through
b
I' ~ the placement of gas discharge apertures around the castpart outer
perimeter,
Ij to prevent the coolant from traveling or flowing back toward the mold
cavity.
la Figure 7 is a cross-sectional view of the mold framework 70 shown in
Is Figure 6 and illustrates gas discharge feed aperture 7~, first coolant feed
16 ~ discharge aperture 76 and second coolant feed discharge aperture 77. The
I% gas discharge aperture 71, the first coolant discharge aperture 72, and the
second coolant discharge aperture 73 are also illustrated in Figure 6.
I9 Figure 7 also illustrates a few examples of angles at which the various
discharge apertures may be with respect to the interior perimeter of the mold
sl framework 70, which is the same approximate angle to the outer perimeter
1' surface of the emerging castpart (which will approximately abut against the
13 interior perimeter surface of mold framework 70).
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I Angle 78 is the angle between the gas discharge aperture 71 and the
mold framework interior perimeter surface 70, and is._intended to represent
3 the angle at which the gas is discharged relative to the outer perimeter
surface of the emerging castpart. As will be appreciated by those of ordinary
s ~ skill in the art, angle 78 'need not be any particular magnitude within
the
contemplation of this invention, but instead may range from zero degrees to
eighty or ninety degrees, with approximately fifteen to twenty degrees being
a preferred.
9 li Angle 79 represents the angle between the second coolant discharge
la aperture 73 and the outer surface of the emerging castpart, and angle 80
ll I represents the angle between the first coolant discharge apertures 72 and
the
I' ; outer perimeter surface of the emerging castpart.
i
13 ~ Figure 8 is another embodiment or illustration, part cross-sectional and
m ~ part schematic view, of an embodiment of th'
is invention m which the coolant
If discharge aperture is at an approximate ninety (90) degree angle relative
to
l6 ' the interior perimeter surface of the mold framework and with respect to
the
I outer perimeter surface of the emerging castpart. Figure 8 illustrates mold
Is framework 80, coolant discharge aperture 81 approximately perpendicular to
I9 I the outer perimeter surface 86 of the emerging castpart 85, gas discharge
feed
o aperture 82, gas discharge aperture 83, coolant 84, and emerging castpart
8~.
ZI This invention is particularly well suited to allow the use of this more
effective cooling angle (i.e. to approximately ninety (90) degrees or even one
hundred five (10~) degrees or beyond), and configuration to be utilized, since
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this invention provides for ..the more effective prevention of the coolant 84
moving or flowing back toward mold cavity 86.
The discharged gas 93 is shown preventing the coolant 84 from moving
back toward the mold cavity 86 by imparting a force or creating a gas barrier
s or gas knife between the mold cavity 86 and the coolant. The gas barrier is
generally created around the outer perimeter surface 86 of the emerging
castpart 8~.
Figure 9 is a close-up detail of the target zone 90 where coolant stream
84 contacts emerging castpart 8~. Gas discharge aperture 83 discharges a
to I stream of forced gas 93 which imparts a force on emerging castpart 86 and
on the coolant 84 to prevent the coolant from creeping or flowing back
i
m ~ toward the mold cavity. Emerging castpart 8~ is moving in the direction
I
shown by arrow 87.
It will be appreciated by those of ordinary skill in the art that the gas
Is discharge apertures may be positioned in a number of different ways, and
l6 Figures 10 and 11 illustrate two of the many possible configurations which
may be used within the contemplation of this invention. Figure 10 shows a
schematic view of mold framework 100, emerging castpart 105, coolant
r9 discharge apertures 101 providing coolant discharge streams 108 which
impact
ao or contact emerging castpart 10~ approximately at target zones 103.
Typically
between target zones 103 the coolant will tend to creep or move back toward
1= mold framework 100, and in this embodiment, gas discharge apertures 102 are
provided between coolant discharge apertures 101 to more effectively impart
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a force on the coolant between the target zones 103. This is the preferred
method of imparting a gas force on the coolant to control it and prevent it
from moving back toward the mold cavity. Coolant lOb is shown on emerging
a castpart 10~ in Figure 10.
s Figure 11 illustrates ,another embodiment of this invention, only wherein
s the gas discharge apertures t I2 in the mold framework 100 provide the force
or discharge gas approximately at the target zones 113. Coolant 116 is also
shown on emerging castpart 115. While this is not a' preferred embodiment,
it is an optional one contemplated by this invention.
to ( It will also be seen in Figure 11 that gas discharge apertures 112 may
I
ll ~ be extended or more precisely placed by using hollow pin type apertures
l~ ~ extending from the mold framework 110.
l3 ~ . Figure 12 is a perspective schematic view of the embodiment of the
I-~ I mventionv illustrated in Figure 11 and shows mold framework 120, coolant
Is streams 121 being discharged through coolant apertures (not shown) in mold
l6 framework 120. Gas discharge apertures 123 are configured to impart the gas
I% force at approximately the target zones 122. Coolant 125 is also shown on
l~ emerging castpart 126.
l9 Figure 13 is a schematic of the configuration shown in Figure 10 of
'o discharge coolant streams 108 being discharged from mold framework 100 and
zl gas discharge apertures 102 being positioned between the target zones which
== coolant streams 108 are hitting. Coolant 106 is shown on emerging castpart
1j U 105.
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Figure 14 illustrates ..mold framework 1~0, gas discharge slit aperture
l~ 1, first coolant discharge apertures 1~2, second coolant discharge
apertures
3 1JJ, first coolant feed discharge aperture 1~6, second coolant feed
discharge
a aperture 157, and gas discharge feed aperture I~~.
s Figure 14 shows an embodiment wherein a slit is used to form an air
curtain or to impart the gas force instead of a plurality of individual
elliptical
. or circular-shaped apertures (as shown in prior embodiments).
In another embodiment of the invention, the invention may be
9 considered a baffle for use in a continuous cast mold with a mold inlet, a
mold outlet and a mold outlet perimeter, the mold further providing for a
1l i coolant to be applied to a castpart emerging from the mold, the baffle
!' ~ preventing the flow of the coolant back toward a mold inlet, the baffle
I
!j comprising: a baffle body structure; one or more baffle fluid apertures in
l~ the baffle body structure and around the mold outlet perimeter, the one or
Is more baffle fluid apertures disposed to impart forced baffle fluid on
coolant
l6 which is on or adjacent a castpart surface emerging from the mold, and in
l~ a direction away from the mold inlet.
!8 The baffle body structure may be considered the graphite around the
19 mold outlet perimeter, the bottom cover or. any other structure which
wholly
or partially covers the mold outlet perimeter sufficiently to create the
baffle.
21
In compliance with the statute, the invention has been described in
Z3 language more or less specific as to structural and methodical features. It
is
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to be understood, howeve-r, that the invention is not limited to the specific
features shown and described, since the means herein disclosed com rise
P
3 preferred forms of putting the invention into effect. The invention is,
therefore, claimed in any of its forms or modifications within the proper
scope
s of the appended claims appropriately interpreted in accordance with the
doctrine of equivalents.
s
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