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WO1991019578A1 - Appareil et procede de coulage direct en lingotiere de lingots de metal - Google Patents

Appareil et procede de coulage direct en lingotiere de lingots de metal Download PDF

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Publication number
WO1991019578A1
WO1991019578A1 PCT/CA1991/000216 CA9100216W WO9119578A1 WO 1991019578 A1 WO1991019578 A1 WO 1991019578A1 CA 9100216 W CA9100216 W CA 9100216W WO 9119578 A1 WO9119578 A1 WO 9119578A1
Authority
WO
WIPO (PCT)
Prior art keywords
ingot
molten metal
liquid sump
casting
sump
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/CA1991/000216
Other languages
English (en)
Inventor
Neil Burton Bryson
John Gordon Mccubbin
Charles Mark Read
Philip Graham Enright
Stephen C. Flood
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rio Tinto Alcan International Ltd
Original Assignee
Alcan International Ltd Canada
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Alcan International Ltd Canada filed Critical Alcan International Ltd Canada
Priority to JP91510015A priority Critical patent/JPH05507882A/ja
Publication of WO1991019578A1 publication Critical patent/WO1991019578A1/fr
Priority to NO92924809A priority patent/NO924809L/no
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/10—Supplying or treating molten metal
    • B22D11/103—Distributing the molten metal, e.g. using runners, floats, distributors

Definitions

  • This invention relates to an apparatus and process for improving internal macro and microstructures and homogeneity of metal ingots and, more particularly, to reducing macrosegregation in the central region of aluminum ingots produced by direct chill casting.
  • Background Art The primary technique used today for producing aluminum ingots is direct chill (D.C.) casting. Direct chill casting is effected in an axially vertical mould which is initially closed at its lower end by a downwardly movable platen. Molten aluminum is introduced to the upper end of the mould, which is chilled by continuous supply of coolant fluid to its external surface, and as the molten metal solidifies in the region adjacent to the periphery of the mould, the platen is moved downwardly.
  • D.C. direct chill
  • Macrosegregation is one parameter used to measure the properties of a finished ingot so as to determine its future usefulness. Changes in macrosegregation across commercial size castings, particularly aluminum alloy ingots produced by direct chill casting, make it difficult to maintain a particular concentration of alloying elements within specification throughout the entire cross- section or thickness of a casting. The degree of macrosegregation in a casting is determined to a large extent by the casting thickness, casting speed, the alloying elements and their concentration, and by the procedure used in casting the ingots. However, the most influential parameter affecting macrosegregation is the thickness or diameter of the ingot being cast, and as the thickness or diameter increases beyond 18", macrosegre ⁇ gation becomes an extremely serious problem.
  • the macrosegregation is a direct result of unavoidable variations in the solidification brought about by varying heat extraction rates from location to location within the ingot cross-section and by convective forces in the liquid and mushy zones of the ingot.
  • U.S. Patent No. 4,709,747, Yu et al describes the use of a mechanical damper positioned within the liquid zone which is intended to control the magnitude of the flow currents within the liquid zone. It was hoped that this would reduce macrosegregation in the solidified casting.
  • U.S. Patent 3,672,431, Bryson describes the use of a baffle structure placed beneath the metal delivery tube to a mould, this baffle being adapted to direct a major flow of molten aluminum laterally and a minor portion of the molten flow downwardly. Another attempt at solving the problem can be found in U.S.
  • Patent 3,506,059, Burkhart et al in which a core member or displacer is positioned within the mould cavity vertically downwards to a location within the liquid zone after casting has commenced. Again in this case the displacer is intended to direct the incoming hot liquid metal to the periphery of the mould cavity.
  • This invention relates to an apparatus and process for reducing macrosegregation and generally improving the uniformity of an ingot formed by direct chill casting of metals, such as aluminum alloys. It has been found according to the present invention that very significant improvements can be achieved if a flow directing means is provided which directs a major portion of a molten metal feed centrally downwardly and into substantially the bottom of a liquid sump within the forming ingot, then preferably outwardly and upwardly along an interface between the liquid sump and surrounding solidified metal.
  • This system works by ensuring that the hottest feed metal is fed to the central core of the ingot, and generally contrary to existing practices which result in the hottest metal being fed to the surface region of the ingot and dispersed laterally.
  • the system of the present invention opposes the naturally occurring buoyancy driven flows which would normally occur in the direct chill casting of large ingots, and inhibits the transport of alloy depleted dendrites to the central core of the ingot. Additionally, hot fluid is supplied to those regions of the ingot where there is the greatest thickness of mushy zone, and thus is believed to steepen the local temperature gradient and decrease the mushy zone thickness.
  • the apparatus of the present invention in its broadest aspect includes:
  • the inventive feature comprises flow directing means for directing a major portion of the molten metal feed centrally downwardly and into substantially the bottom of the liquid sump.
  • a baffle or vertically movable dip tube for directing the molten metal feed to substantially the bottom of the liquid sump, or means may be provided for increasing the velocity of the molten metal feed sufficiently to force a major portion of the molten metal feed centrally downwardly through the liquid sump to substantially the bottom-thereof.
  • the molten metal feed is also preferably directed from the bottom of the sump outwardly and upwardly along an interface between the liquid sump and surrounding solidified metal.
  • this baffle When the baffle is used, it is positioned within the upper region of the casting zone and adapted to project downwardly into the liquid sump, this baffle means having substantially closed side walls and at least one bottom opening for directing a major portion of the molten metal feed centrally downwardly through the bottom opening and into substantially the bottom of the liquid sump and then outwardly and upwardly along an interface between the liquid sump and the surrounding solidified metal.
  • the interface between the liquid sump and solidified metal generally extends in a downward and inward direction within the forming ingot and the baffle is preferably shaped to generally conform to the shape of the liquid sump. Accordingly, the baffle is preferably downwardly and inwardly tapered. It may be in the form of a fixed baffle, or an array of baffles, the position of which may be independently adjusted during casting to impose a preferred interface profile, dynamically.
  • the baffle may be a solid metal, e.g. alloy steel, structure, but is preferably designed as a disposable unit with walls formed of glass cloth. This glass cloth may typically be woven glass fibre fabric screen which is impermeable to liquid metal passage in the present application in the absence of a pressure differential across the screen.
  • the baffle can be accordion folded and then deployed downwardly stagewise as the liquid sump forms in the start up of a direct chill casting procedure.
  • the liquid sump may be in the order of two to three feet deep and the baffle-preferably extends down into a bottom region of the sump.
  • the top of the baffle typically has a width approximately 75% of the width of the ingot, with the walls tapering inwardly generally parallel to the side of the liquid sump. It may be used with any of the usual shapes of casting moulds, including rectangular, square, oblong, round, etc.
  • the baffle device of the invention may be pushed deeper and deeper into the ingot head during casting and in some instances it may be pushed to a position below the original solidus position.
  • the liquidus and solidus isotherms dynamically adjust themselves to fit an imposed profile.
  • Holes or slots may be provided in the side walls of the baffle and the bottom openings and side wall openings are preferably configured to ensure that flow through them is fast enough to reduce greatly the diffusive penetration of the sub-baffle cooling into the hotter liquid maintained above the baffle.
  • the baffle enables metal to be supplied close to the solidification front at temperatures much hotter, e.g. more than 20 ⁇ K hotter, than would normally occur. This has the effect of increasing or steepening the local temperature gradient ahead of and within the mushy (solid and liquid) region thereby decreasing the local solidification time. It is well known that the scale of the microstructure (secondary dendrite arm spacing and size of second phase particles) depends on local solidification time and the baffle arrangement of the present invention has profound effects on the structure. The baffle functions well whether it is made of heat conductive or insulating material.
  • a vertically movable trough and down spout or manifold preferably having a changing cross-section, for directing a major portion of the molten metal feed centrally downwardly and into substantially the bottom of the liquid sump.
  • the formation of the ingot is commenced with the bottom end of the down spout in an upper position in the upper portion of a DC mould.
  • the lower end of the down spout is lowered down into and immersed in the liquid sump whereby the molten metal feed is directed to substantially the bottom of the liquid sump.
  • the flow rate of the metal and the positioning of the down spout can dynamically adjust the liquidus and solidus isotherms to fit an imposed profile.
  • the vertically movable down spout enables the feed metal to be supplied close to the solidification front at temperatures much hotter than would normally occur.
  • Another way of directing the molten metal feed to substantially the bottom of the liquid sump is to increase the velocity of the molten metal feed sufficiently to force a major portion of the molten metal feed centrally downwardly through the liquid sump to substantially the bottom thereof.
  • One convenient way of achieving this is to provide an electromagnetic device surrounding a portion of the down spout. With this arrangement, the outlet of the down spout is positioned in an upper region of the DC casting mould. The electromagnetic device is not turned on until the casting has reached a steady state with a liquid sump fully formed. At that point, the device is turned on and is adjusted such that the liquid metal feed travels to substantially- the bottom of the liquid sump.
  • the velocity of the liquid metal can be adjusted to maintain the liquidus and solidus isotherms within an imposed profile. While an electromagnetic velocity increasing means is particularly desirable, the velocity can be increased by other means such as hydraulic or pneumatic systems.
  • the invention also relates to a novel product, namely an aluminum-magnesium alloy ingot of improved homogeneity.
  • a direct chill cast aluminum-magnesium alloy ingot is obtained having a maximum variation in magnesium content across a section of the cast ingot between +5% and -5% of the mean magnesium content of the alloy.
  • Figure 1 is a simplified sectional elevational view of a direct chill casting apparatus embodying the present invention in a particular form
  • FIG. 2 is a top plan view of the baffle of the invention shown in Figure 1;
  • Figure 3 is a simplified sectional elevational view of a direct chill casting apparatus embodying a tilting baffle unit according to the invention
  • Figure 4 is a perspective view of one half of the baffle shown in Figure 3;
  • Figure 5 is a simplified sectional elevational view of a direct chill casting apparatus embodying a folding baffle according to the invention with the baffle fully folded;
  • Figure 6 is a simplified sectional view of the arrangement of Figure 5 with the baffle partly unfolded;
  • Figure 7 is a simplified sectional elevational view showing the baffle fully unfolded
  • Figure 8 is a simplified sectional elevational view of a casting apparatus with a vertically movable down spout
  • Figure 9 is the same view as Figure 8 with the down spout lowered;
  • Figure 10 is a simplified section view of a casting apparatus with an electromagnetic velocity accelerator; and Figure 11 is a graph showing variations in magnesium content across the thickness of an ingot. Best Mode For Carrying Out the Invention
  • a direct chill ingot casting mould 10 is shown for forming an elongated rectangular ingot 17.
  • this moulding device can be any type of continuous or semi-continuous casting mould for producing elongated ingots having circular, oblong, square or rectangular cross-section.
  • the mould includes a water cooling chamber 11, a mould face 12 and a cooling water discharge outlet 18.
  • Molten aluminum feed 13 is fed from a launder 14 fed into the mould 10 via dip tube 15 and controlled by stopper rod 23.
  • the lower end of the casting zone between the mould faces 12 is closed by a platen 19 supported by a hydraulic ram.
  • the platform 19 is drawn slowly vertically downward by operation of the hydraulic ram and the solidifying base of the ingot being cast, resting on the platform, then begins to emerge from the lower end of the casting zone.
  • Water spray from the outlets 18 is sprayed onto the emerging solidified ingot surface immediately below the moulding faces 12. This spray of water, striking the ingot surface, acts to enhance the cooling and consequent solidification of the ingot 17 as it moves downwardly away from the mould.
  • a feature of the present invention is the baffle arrangement 25 which is designed to direct the molten metal flowing out of dip tube 15 downwardly in an axial direction and through bottom outlet 27 such that it travels to the lower end of the liquid sump 16 and then travels upwardly outside the baffle and adjacent the interface 21.
  • This baffle has inwardly sloping sidewalls 26 which are generally parallel to the interface 21 and end walls 28. It is preferably fabricated as a disposable unit having a steel frame with sidewalls 26 and end walls 28 formed of glass cloth. At the end of each cast, the baffle is pulled out of the liquid sump, e.g. by a winch, and the glass cloth portions are removed and replaced by fresh fabric.
  • FIGS 3 and 4 show an alternate form of baffle device in which the baffle 30 comprises two half sections 30a and 30b. Each of these sections 30a and 30b is pivotally mounted by arms 34 pivotally suspended from brackets 35. Each baffle half section includes a pair of sidewalls 31 and an end wall 32. The bottom is open and the walls are preferably tapered.
  • the baffle sections 30a and 30b are swung up into the position shown by the dotted lines in Figure 3 and as a depth of molten sump begins to form, the baffles can gradually be tilted downwardly such that they eventually assume the position shown by the solid lines in Figure 3. In this position, the baffle is fully functional for the remainder of the casting of the ingot.
  • This baffle can also be made disposable by building the sections with steel frames and glass cloth walls. Another form of baffle arrangement is shown in
  • the baffle 40 has flexible glass cloth fabric walls 41 connected by support rods 42 such that the entire baffle can be accordion folded within a container 43 as shown in Figure 5. Sections of the baffle can then be deployed as shown in Figures 6 and 7 as the liquid sump builds up to its maximum depth as shown in Figure 7.
  • the deployment of the baffle in this manner can be fully automated by the use of solenoids to lower the baffle sections and controlling the solenoids by a computer.
  • FIG. 8 Another flow directing embodiment of the invention is shown in Figures 8 and 9.
  • a down spout or manifold 15 of substantial length is used and this distribution arrangement and launder 14 are vertically movable as indicated.
  • Figure 8 shows the beginning of a casting with a liquid sump 16 beginning to form.
  • the platform 19 is moved slowly vertically downward with the solidifying base of the ingot being cast resting on the platform.
  • a steady state is reached as shown in Figure 9 with a relatively deep sump or pool 16 of molten metal surrounded by solidified metal 20.
  • the interface 21 between the solidified metal 20 and the molten sump 16 tapers downwardly and inwardly because of the cooling action of the mould faces 12 and water spray. Below the region of the liquid sump 16 is the fully formed ingot 17.
  • FIG. 10 An example of a casting device of the invention with a flow accelerator is shown in Figure 10.
  • This utilizes the same basic casting system as shown in Figures 8 and 9 with a down spout 15 and launder 14.
  • the down spout 15 is surrounded by an electromagnetic device 50 adapted to increase the velocity of the flow of molten metal downwardly through down spout 15.
  • the casting operation with the electromagnetic device is commenced in the same manner as in Figure 8 with the outlet of the down spout 15 located in an upper region within the direct chill mould 10. With the electromagnetic device turned off, the casting operation is commenced with the platform 19 being lowered.
  • the device When the casting operation has reached a steady state with a sump fully formed as shown in Figure 10, the device is turned on and the metal emerging from the down spout is given a sufficient velocity to force the molten metal feed downwardly through the liquid sump 16 to substantially the bottom thereof as shown in Figure 10.
  • Example 1 An actual plant trial was conducted using a direct chill caster and baffle as shown in Figures 1 and 2.
  • the mould was rectangular and was dimensioned to cast an ingot 635 mm by 1350 mm.
  • the metal which was cast was an aluminum alloy AA3004 containing a nominal 1.15% Mg and typically used for beverage can bodies. Casting procedures were carried out both with and without the baffle and the results were compared as shown in Figure 11. It will be seen that without the baffle, the magnesium variation was sufficient to exceed the Aluminum Association limits for 3004 alloy. The measured variation was about +4% to -11% about the nominal 1.15% Mg.
  • Figures 1 to 10 are all based upon a rectangular mould with a corresponding rectangular shaped baffle.
  • the invention functions equally well with moulds of square, circular etc. cross-sections.
  • the baffle has a corresponding truncated conical shape.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)
  • Physical Vapour Deposition (AREA)
  • Physical Deposition Of Substances That Are Components Of Semiconductor Devices (AREA)
  • Manufacturing Of Electric Cables (AREA)
  • Electroluminescent Light Sources (AREA)
  • Manufacture And Refinement Of Metals (AREA)

Abstract

Dans le coulage direct en lingotière d'alliages d'aluminium, et en particulier de lingots à large coupe transversale, la macroségrégation est sensiblement réduite et l'uniformité de la composition hautement améliorée dans tout le lingot formé si le coulage est effectué au moyen d'un dispositif à direction d'écoulement, tel qu'un déflecteur (25), ou un accélérateur de vitesse d'écoulement (50) destiné à diriger une majeure partie du métal en fusion vers le bas, de manière centrale, pratiquement jusqu'au fond d'une zone de liquide ou d'un fond (16) formé au cours du coulage, puis vers l'extérieur et vers le haut le long d'une ligne de jonction (21) entre le fond du liquide (16) et le métal solidifié environnant (20). Ceci fait en sorte que le métal le plus chaud est alimenté vers le bas jusqu'au c÷ur du lingot au fond de la zone de liquide.
PCT/CA1991/000216 1990-06-13 1991-06-13 Appareil et procede de coulage direct en lingotiere de lingots de metal Ceased WO1991019578A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
JP91510015A JPH05507882A (ja) 1990-06-13 1991-06-13 金属インゴットのダイレクトチルキャスティングのための装置及び方法
NO92924809A NO924809L (no) 1990-06-13 1992-12-11 Apparat og fremgangsmaate for vannstoeping av metallblokker

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB909013199A GB9013199D0 (en) 1990-06-13 1990-06-13 Apparatus and process for direct chill casting of metal ingots
GB9013199.6 1990-06-13

Publications (1)

Publication Number Publication Date
WO1991019578A1 true WO1991019578A1 (fr) 1991-12-26

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Application Number Title Priority Date Filing Date
PCT/CA1991/000216 Ceased WO1991019578A1 (fr) 1990-06-13 1991-06-13 Appareil et procede de coulage direct en lingotiere de lingots de metal

Country Status (7)

Country Link
EP (1) EP0533769A1 (fr)
JP (1) JPH05507882A (fr)
CN (1) CN1059484A (fr)
AU (1) AU7976291A (fr)
CA (1) CA2083844A1 (fr)
GB (1) GB9013199D0 (fr)
WO (1) WO1991019578A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102211165A (zh) * 2011-05-10 2011-10-12 山东省科学院新材料研究所 一种镁合金导流罩的压铸方法
WO2017165758A1 (fr) * 2016-03-25 2017-09-28 Novelis Inc. Optimisation de jet de métal liquide en coulée semi-continue

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2327702B (en) 1996-07-26 1999-06-02 Ultraframe Uk Ltd Roof beams
US8365808B1 (en) * 2012-05-17 2013-02-05 Almex USA, Inc. Process and apparatus for minimizing the potential for explosions in the direct chill casting of aluminum lithium alloys
IN2014DN10497A (fr) * 2013-02-04 2015-08-21 Almex Usa Inc
US9936541B2 (en) 2013-11-23 2018-04-03 Almex USA, Inc. Alloy melting and holding furnace
FR3051698B1 (fr) * 2016-05-30 2020-12-25 Constellium Issoire Procede de fabrication de lingots de laminage par coulee verticale d'un alliage d'aluminium
CN107127312B (zh) * 2017-06-07 2022-11-22 山东钢铁股份有限公司 一种生产复合连铸坯的设备及方法
CN118002767B (zh) * 2024-04-10 2024-08-20 东北大学 一种振动激冷形核的装置及工艺方法

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1090234A (fr) * 1952-11-18 1955-03-29 Aluminium Lab Ltd Perfectionnements au traitement de l'aluminium en fusion et aux appareils pour effectuer ce traitement
FR1570056A (fr) * 1968-04-26 1969-06-06
US3672431A (en) * 1970-09-25 1972-06-27 Alcan Res & Dev Apparatus and procedures for continuous casting of metal ingots
US3779389A (en) * 1972-09-05 1973-12-18 Fibrous Glass Products Inc Molten metal filter
DE2340291A1 (de) * 1972-08-10 1974-02-21 Voest Ag Verfahren zum kontinuierlichen giessen von breiten, insbesondere ueber 1000 mm breiten brammen
EP0155575A1 (fr) * 1984-03-07 1985-09-25 Concast Standard Ag Procédé pour le réglage d'écoulement d'un liquide conductible à l'électricité spécialement d'un bain de métal de la coulée continue et dispositif pour la mise en oeuvre du procédé

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1090234A (fr) * 1952-11-18 1955-03-29 Aluminium Lab Ltd Perfectionnements au traitement de l'aluminium en fusion et aux appareils pour effectuer ce traitement
FR1570056A (fr) * 1968-04-26 1969-06-06
US3672431A (en) * 1970-09-25 1972-06-27 Alcan Res & Dev Apparatus and procedures for continuous casting of metal ingots
DE2340291A1 (de) * 1972-08-10 1974-02-21 Voest Ag Verfahren zum kontinuierlichen giessen von breiten, insbesondere ueber 1000 mm breiten brammen
US3779389A (en) * 1972-09-05 1973-12-18 Fibrous Glass Products Inc Molten metal filter
EP0155575A1 (fr) * 1984-03-07 1985-09-25 Concast Standard Ag Procédé pour le réglage d'écoulement d'un liquide conductible à l'électricité spécialement d'un bain de métal de la coulée continue et dispositif pour la mise en oeuvre du procédé

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
SOVIET INVENTIONS ILLUSTRATED SECTION CH,WEEK 9043, 5 DEC 1990 DERWENT PUBLICATIONS LTD, LONDON GB *

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102211165A (zh) * 2011-05-10 2011-10-12 山东省科学院新材料研究所 一种镁合金导流罩的压铸方法
WO2017165758A1 (fr) * 2016-03-25 2017-09-28 Novelis Inc. Optimisation de jet de métal liquide en coulée semi-continue
CN108883462A (zh) * 2016-03-25 2018-11-23 诺维尔里斯公司 直接激冷铸造中的液态金属射流优化
RU2720414C2 (ru) * 2016-03-25 2020-04-29 Новелис Инк. Оптимизация струи жидкого металла в процессе литья в кристаллизатор прямым охлаждением

Also Published As

Publication number Publication date
CA2083844A1 (fr) 1991-12-14
CN1059484A (zh) 1992-03-18
AU7976291A (en) 1992-01-07
JPH05507882A (ja) 1993-11-11
EP0533769A1 (fr) 1993-03-31
GB9013199D0 (en) 1990-08-01

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