CA1161107A - Controlled water application for electromagnetic casting shape control - Google Patents
Controlled water application for electromagnetic casting shape controlInfo
- Publication number
- CA1161107A CA1161107A CA000352198A CA352198A CA1161107A CA 1161107 A CA1161107 A CA 1161107A CA 000352198 A CA000352198 A CA 000352198A CA 352198 A CA352198 A CA 352198A CA 1161107 A CA1161107 A CA 1161107A
- Authority
- CA
- Canada
- Prior art keywords
- coolant
- casting
- adjacent
- impingement
- applying means
- 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.)
- Expired
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
- B22D11/01—Continuous casting of metals, i.e. casting in indefinite lengths without moulds, e.g. on molten surfaces
- B22D11/015—Continuous casting of metals, i.e. casting in indefinite lengths without moulds, e.g. on molten surfaces using magnetic field for conformation, i.e. the metal is not in contact with a mould
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Continuous Casting (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
A method and apparatus is disclosed for electromagnetic casting of metal and alloy ingots of rectangular or other desired shape having corners or portions of small radius of curvature, A coolant application system is provided which lessens the severity of the rounding off of radius of the corners of the electromagnetically cast ingots by contouring the coolant application rate and/or elevation so that the rate and/or elevation is a minimum at the corners of the ingot.
A method and apparatus is disclosed for electromagnetic casting of metal and alloy ingots of rectangular or other desired shape having corners or portions of small radius of curvature, A coolant application system is provided which lessens the severity of the rounding off of radius of the corners of the electromagnetically cast ingots by contouring the coolant application rate and/or elevation so that the rate and/or elevation is a minimum at the corners of the ingot.
Description
1~3~-?~
)7 ' BA'CKGR'O'UNI~ '~F 'l~IE TN~JENTION
This invention relates to an impro~ed process and apparat~s for con~rol of corner shape in continuous or semi-continuous electromagnetic casting of desired shapes, such as for example~ shéet or rectangular ingots of metals and alloys.
The basic electromagnetic casting process has been known and used for many years for continuously or semi-continuously casting metals and alloys.
~ ne of the problems which has been presented by electro-magnetic casting of sheet or rectangular ingots has been the existence of high radius of curvature corners thereon.
Rounding off of corners in electromagnetic cast sheet ingots is a result of higher electromagnetic pressure at a given distance ~rom ~he inductor near the ingot corners~ where two proximate faces of the inductor generate a larger field.
This is in contrast to lower electromagnetic pressure at the same distance from the inductor on the broad face of the ingot remote from the corner where only one inductor face acts.
There is a need to form small radius of curvature corners on sheet ingots so that during rolling cross~sectional changes at the edges of the ingot are minimized. Larger radius of curvature corners accentuate tensile stress at the ingot edges during rolling which causes edge cracking and loss of material.
Thus, by reducing the radius of curvature of the ingot at the corners there is a maximizing in the production of' useful material.
It has been ~ound in accordance with the present inyention that rounding off of corners in electromagnetic casting can be made less severe or of smaller radius by contouring the coolant application rate or elevation (or both) 10022 r~
so that the rate and/or elevation is a minimum at the:'cor~ers of the 'ingot.
PKrO'R ~'~T:STATEME'NT
Known electromagnetic casting apparatus comprises a three part mold consisting of a water cooled inductor, a non-magnetic screen and a manifold for applying cooling water to the ingot being cast. Such an apparatus is exemplified in U.S. Patent No. 3,467,166 to Getselev et al. Con~ainment of the molten metal is achieved without direct contact between lQ the molten metal and any component of the mold. Solidificakion o~ the molten metal is achieYed by direct application of water ~rom the cooling manifold to the forming ingot shell.
In some prior art approaches the inductor is formed as part of the cooling manifold so that the cooling manifold supplies both coolant to solidify the casting and to cool the .~. inductor. ,See U.S Patent 4,004,631.to ,Goodrich et al. , Non-magnetic screens of the,prior art are typically utilized to properly shape the magnetlc ~ield for containing ~ the molten metal as exemplified in U.S. Patent No. 3,605~865 to Getselev. Another approach with respect to use of non-magnetic screens is exemplified as well in U.S. Patent No.
3~985,179 to Goodrich et al. Goodrich e~ al. '179 descri~es the use of a shaped inductor in con~unction with a screen to modify the electromagnetic forming field.
It is generally known that durlng electromagnetic casting the solidification ~ront between the molten metal and the solidifying ingot at the ingok surface should be maintained within the 'zone of high magnetic field strength, i.e. the solidification front should be located within the inductor.
If thé' soldiification front extends abo~e the induckor, cold
)7 ' BA'CKGR'O'UNI~ '~F 'l~IE TN~JENTION
This invention relates to an impro~ed process and apparat~s for con~rol of corner shape in continuous or semi-continuous electromagnetic casting of desired shapes, such as for example~ shéet or rectangular ingots of metals and alloys.
The basic electromagnetic casting process has been known and used for many years for continuously or semi-continuously casting metals and alloys.
~ ne of the problems which has been presented by electro-magnetic casting of sheet or rectangular ingots has been the existence of high radius of curvature corners thereon.
Rounding off of corners in electromagnetic cast sheet ingots is a result of higher electromagnetic pressure at a given distance ~rom ~he inductor near the ingot corners~ where two proximate faces of the inductor generate a larger field.
This is in contrast to lower electromagnetic pressure at the same distance from the inductor on the broad face of the ingot remote from the corner where only one inductor face acts.
There is a need to form small radius of curvature corners on sheet ingots so that during rolling cross~sectional changes at the edges of the ingot are minimized. Larger radius of curvature corners accentuate tensile stress at the ingot edges during rolling which causes edge cracking and loss of material.
Thus, by reducing the radius of curvature of the ingot at the corners there is a maximizing in the production of' useful material.
It has been ~ound in accordance with the present inyention that rounding off of corners in electromagnetic casting can be made less severe or of smaller radius by contouring the coolant application rate or elevation (or both) 10022 r~
so that the rate and/or elevation is a minimum at the:'cor~ers of the 'ingot.
PKrO'R ~'~T:STATEME'NT
Known electromagnetic casting apparatus comprises a three part mold consisting of a water cooled inductor, a non-magnetic screen and a manifold for applying cooling water to the ingot being cast. Such an apparatus is exemplified in U.S. Patent No. 3,467,166 to Getselev et al. Con~ainment of the molten metal is achieved without direct contact between lQ the molten metal and any component of the mold. Solidificakion o~ the molten metal is achieYed by direct application of water ~rom the cooling manifold to the forming ingot shell.
In some prior art approaches the inductor is formed as part of the cooling manifold so that the cooling manifold supplies both coolant to solidify the casting and to cool the .~. inductor. ,See U.S Patent 4,004,631.to ,Goodrich et al. , Non-magnetic screens of the,prior art are typically utilized to properly shape the magnetlc ~ield for containing ~ the molten metal as exemplified in U.S. Patent No. 3,605~865 to Getselev. Another approach with respect to use of non-magnetic screens is exemplified as well in U.S. Patent No.
3~985,179 to Goodrich et al. Goodrich e~ al. '179 descri~es the use of a shaped inductor in con~unction with a screen to modify the electromagnetic forming field.
It is generally known that durlng electromagnetic casting the solidification ~ront between the molten metal and the solidifying ingot at the ingok surface should be maintained within the 'zone of high magnetic field strength, i.e. the solidification front should be located within the inductor.
If thé' soldiification front extends abo~e the induckor, cold
- 2 -~ 1~0~2~
'7 folding is likely to occur. On the other hand, if it reaches to below the inductor, a bleed out or décantation of the liquid metal is likely to result. GetseIev ét al. '166 associate the coolant application manifold with the screen portion of the mold such that they are arranged ~or slmul-taneous movement relative to the inductor. In U.S. Patent No. 4,156,451 to ~etseleY a cooling medium is supplied upon the lateral face of the ingot in several cooling tiers arranged at various levels longitudinally o~ the lngot. Thus~ depending on the pulling veIocity of the ingot, the solidi~ication front can be maintained within the inductor by appropriate selection o~ one of the tiers.
Another approach to improved ingot shape consisted oP
provision of more uniform fields at conductor bus connections (Canadian Patent No. 930,925 to Getselev).
In electromagnetically casting rect~ngular or sheet ingots, the ingots are often cast with high radius o~
curvature ends or corners which is indicative of the need for improved ingot shape control at the corners of such ingots.
Finally, United States Patent 3,502,133 to Carson teaches utilizing a sensor in a continuous or semi-continuous casting mold to sense temperature variations at a particular location in the mold during casting. The sensor controls application of coolant to the mold and ~orming ingot. Use of such a device overcomes instabilities with respect to how much extra coolant is required at ~tart up of the casting operation and ~ust when or at what rate this excess cooling should be reduced. The ultimate purpose of ad~usting the flow of ~ 3 -coolant is to maintain th~ freeze line of the casting at a substantially constant location.
Carson '133 teaches that ingots having a width to thickness ratio on the order of 3 to 1 or more possess an uneven cooling rate during casting when coolant is applied peripherally of the mold in a uniform manner. To overcome this problem, Carson '133 applies coolant to the wide faces of the ingot and/or the mold walls and not at all (or at least at a reduced rate) to the relatively narrow end faces of the ingot and/or the mold walls.
The present invention comprises a process and apparatus for electromagnetic casting of metals and alloys into rectangular or sheet ingots and other desired elements of shape control having small radius of curvature corners or portions by application of controlled static head (through metal head or pres~ure modification). In particular, a method and apparatus utilizing controlled differential static head by control of cooling water application to obtain refine-ment of ingot shape, particularly at the corners of rectan-gular ingots or other desired elements of shape is claimed.
According to the present invention control of ingot shape may be effected by selection of the rate or location of cooling water application to the forming ingot shell within or below the containment inductor. Rounding off of corners in electromagnetic casting can be made less severe or of smaller radius by contouring the water application rate or elevation (or both) 50 that the rate or elevation , :~
, . ~oa ~ 3'~
i5 a minimum at the'corners o~'the ingot. ~eduction o~ the - water application rate or lowering the applicatlon level serves to reduce the local heat extraction rate along an ingot transverse cross section line of co~stant height.
This in turn lowers the position o~ the solidi~ication front at the ingot corner and correspondingly raises the metal static head or pressure at the corner. Thi~ increased pressure results in the liquid metal approaching the inductor more closely at the corner and thus ~illlng the corner to ~orm a smaller radius o~ curvature at the corner be~ore the -increased static pressure Is counter~alanced by an increased electromagnetic force.
In accordance with one embod~ment of this invention a water mani~old or cooling water application device is provided with drilled holes or slots OL a size and/or local hole density which is modified to yield locally reduced rates O ,D
. ~ , . .. . . . ................. . . ................ .. .
water appllca~lon at the ingot or desired shape corners~
In accordance with another preferred embod'iment o~ this invention a water mani~old or coollng water application device is provided wherein the elevatlon of the supply holes is modi~ied so as to apply water at the lowest elevation at the ingot or desired shape corners.
In accordance with yet another preferred embodiment o~
thi's invention the holes or slots in a water manifold or cooling water application devlce are modified such that the angle of the holes or slots around tha corners o~ the ingot cause the ~ater to impinge on the ingot sur~ace at a lower elevation at the Ingot corn,ers.
It Is of cou~se understood that hybrids of local hole cross section, hole angle, and hole elevation can also be _ 5 _ utilized in accordance with the concepts of thig invention.
In accordance with another preferred embodiment of this invention a water manifold or cooling water applic-ation device is provided which produces a water application rate of zero over short distances at the corners o-f the in~ot or desired shape to further accentuate the effects of reduced local cooling.
Accordingly, it is an object of this invention to provide an improved process and apparatus for 01ectromagnetic casting of metals and alloys into sheet ingots, or other desired elements of shape control, characterized by small radius of curvature corners or portions thereon.
In accordance with a particular embodiment there is provided, in an apparatus for electromagnetic forming of molten materials into a casting with a desired transverse cross section having at least one portion of the transverse cross section with a small radius of curvature relative to an adjacent portion of the transverse cross section comprises:
means for generating an electromagnetic force field to form said molten materials into said casting, and means for apply-ing coolant to the peripheral surface of said casting, the improvement comprising: means -for controlling the rate at which said coolant impinges upon said peripheral surface such that the rate of impingement in an area of said at least one portion of small radius of curvature is different as compared to the rate of impingement at peripherally adjacent areas of said casting.
In accordance with a further embodlment there is provided, in an apparatus for electromagnetic forming of molten materials into a casting with a desired transverse cross section having at least one portion of the transverse cross section with a small radius of curvature relative to an adjacent portion of the transverse cross section comprises:
means for generating an electromagnetic force field to form said molten material into said casting, and means for applying coolant to the peripheral surface of said casting, the improvement comprising: means for controlling the rate and elevation at which coolant impinyes upon said peripheral surface such that the rate and elevation of impingement in the area of said at least one portion of small radius of curvature is different as compared to the rate and elevation of impingement at peripherally adjacent areas of said casting.
From a different aspect, and in accordance with the invention, thére is provided, in a process for electro-magnetic forming of molten material into a casting having at least one portion of the transverse cross section with a small radius of curvature relative to an adjacent portion of the transverse cross section comprising: generating an electro-magnetic force field for forming said molten materials into said casting, pouring said molten material into said electro-magnetic force field, and applying a coolant to the peripheral surface of said casting, the improvement comprising: con-trolling the rate at which said coolant impinges upon said peripheral surface such that the rate of impingement in the area of said at least one portion of small radius of cur-vature is different as compared to the rate of impingement at peripherally adjacent areas of s.aid casting.
In accordance with a further aspect of the invention, there is provided, in a process for electromagnetic forming of molten material into a casting having at least one portion of the transverse cross section with a small radius of curvature relative to an adjacent portion of the transverse cross section comprising: generating an electromagnetic force - 6a -field for forming said molten materials into said casting, pouring said molten material into said electromagnetic force field, and applying a coolant to the perip~eral surface of said casting, the improvement comprising: controlling the rate and elevation at which said coolant impinges upon said peripheral surface such that the ra~e and elevation of impinge- -ment in the area of said at least one portion of small radius of curvature is different as compared to the rate and elevation of impingement at peripherally adjacent areas of said casting, In accordance with a further embodiment of the invention there is provided, in an apparatus for electro-magnetic forming of molten materials into a casting with a desired transverse cross section having at least one portion of the transverse cross section with a small radius of cur-vature relative to an adjacent portion of the transverse cross section comprising: means for generating an electromagnetic force field to form said molten materials into said casting, and means for applying coolant to the peripheral surface of said casting, the improvement comprising: said coolant apply-ing means including discharge port means for providing an unbaffled flow of coolant directly against said casting surface, said discharge port means in operation being sub-stantially filled with said coolant.
In accordance with a still further embodiment of the invention there is provided, a coolant discharge apparatus operatively associated with a mean9 for generating an electro-magnetic force field in casting of molten materials comprising:
manifold means formed into a substantially closed loop to enclose the casting having at least one corner for directing a flow of coolant against the casting within the confines of the electromagnetic force field, discharge port means 6b -~ i3'7 associated with said manifold means for ~irecting the flow of coolant against said casting from said at least one corner of said substantially closed loop at a different rate of flow as compared to the flow from adjacent peripheral areas of the mani~old means.
In accordance with a still further embodiment of the invention there is provided, a coolant discharge apparatus operatively associated with a means for degenerating an electromagnetic force field in electromagnetic casting of molten materials comprising: manifold means formed into a substantially closed loop to enclose the casting having at least one corner for directing a flow of coolant against the casting within the confines of the electromagnetic force field, discharge port means associated with said manifold means for directing unbaffled flow of coolant directly against said casting, said discharge port means being substantially full of coolant during operation, said discharge port means con-trolling flow of coolant from said at least one corner of said substantially closed loop at a different elevation as-compared to the elevation of the flow of coolant from adjacentperipheral areas of the manifold means.
This and other objects will become more apparent from the following description and drawings.
BRIEF DESCRIPTIO~ OF THE DRAWINGS
Figure 1 is a schematic cross-sectional represen-tation of a prior art electromagnetic casting apparatus ukil-izing a slot type coolant manifold for discharging water onto the faces of a forming ingot.
Figure 2 is a schematic cross-sectional represent-ation of an electromagnetic casting apparatus showing an in-ductor having drilled holes for supplying water to an ingot - 6c -'7 in accordance wi-th this invention.
Figure 3 is a schematic cross-sectional represen-tation of an electromagnetic casting apparatus showing a modified slot type manifold for supplying water to an ingot in accordance with this invention.
E'igure 4 is a schematic cross-sectional represen-tation of an electromagnetic castlng apparatus showing another embodiment of a modified slot type manifold for supplying coolant to an ingot in accordance with this invention.
- 6d -ao .~"l~
Figure 5 is a partial bottom plan view looking up into the manl~old dlscharge 310t of a manifold showing corners possessing dl~erent slot modi~ications in accordance with this invention.
DETAILED DES'C~IPTION OF PREFERRED EMBODIMENTS
In all drawing Flgures alike parts are designated by alike numerals.
Referring no~ to FIGURE 1 there is shown therein a prior art electromagnetic casting apparatus in accordance with U.S. Patent 4~158~37g.
The electrornagnetic cas~ing mold 10 is comprised of an inductor 11 which ie water cooled; a coolant manifold 12 for appl~Ing cooling water to the peripheral surface''l3 of the metal being cast C; and a non-magnetic screen 14.
Molten metal is continuously introduced into the mold 10 during a casting run, in the normal manner using a trough . . . . . . .. .. .. ..
15 and do~n spout 16 and conventional molten metal head control. The inductor 11 is excited by an alternatin~
, current ~rom a suitable power source (not shown~.
The alternating current in the inductor 11 produces 2 ma~netic ~ield which interacts with the molten metal head 19 to produce edd~ currents therein. These eddy currents in turn interact with the magnetlc ~ield'and produce forces .
which apply a magnetic pressure to the molten metal head 19 to contain it so that it solidifies in a desired ingot cross section.
An air gap exists during casting, between the molten metal head lg and the inductor 11. The molten metal head 19 is ~ormed~or molded into the same general shape as the inductor 11 there~y prot~iding the desired ingot cross section.
._ s ~ 10022-MB
~i~.4~ 7 The inductor may ~ave any desired shape including circular or rectangu~ar as required to obtain the desired ingot C cross section.
The purpose of the non-magnetic screen 14 is to fine tune and balance the magnetic pressure with the hydrostatic pressure of the molten metal head 19 The non-magnetic screen 14 comprises a separate element as shown, and is not a part of the manifold 12 for applying the coolant.
Initiall~, a con~entional ram 21 and bottom block 22 is held in the magnetic contalnment zone of the mold 10 to allow the molten me~al to be poured into the mold at the start o~ the casting run. The ram 21 and bottom block 22 are then uni~orml~ wlthdrawn at a desired casting rate.
Solidificatlon o~ the molten metal which is magnetically contained in the mold 10 is achieved by direct appl~cation of water from the cooling manifold 12 to the ingot surface . . . . .. . . , . .. , . , -- , . . ............. . . .. ... . ...
13. The water is shown applled to the ingot surface~l3 within the con~ines o~ the inductor 11. The water may be applied, however,to the ingot sur~ace 13 ~rom above~
withln or below the inductor 11 as desired.
The solidification front 25 o~ the casting comprises the boundar~ ~etween the molten metal head 19 and the solidi~ied lngot C. The location o~ the solidi~ication front 25 at the ingot sur~ace 13 results ~rom a ~alance o~ the heat input ~rom the superheated liquid metal 19 and the resis~ance heating from the induced currents in the ingot surface layer, with the longitudinal heat extraction ~rom the cooling water applica~ion.
Coolant manifold 12 is arranged above the inductor 11 and includes at least one discharge port 28 at the end of ~ ' ' 10022~M.3 ~4.h'L~ 7 , _ . ,, extended portion 30 for directing the coolant a~ain3t the surface ~3 of the ingot or casting. The discharge port 28 can comprise a slot or a plurallty o~ individual orl~ices ~or directing the coolant against the surface 13 of the ingot C about the entire periphery of that surface.
Coolant manifold 12 is arranged for movement along vertically extending rails 38 and 39 axially of the ingot C
such that extended portion 30 and discharge port 28 can be moved ~etween the non-magnetlc screen 14 and the inductor 11.
Axial ad~ustment o~ the discharge port 28 position is provided ~y means of cranks 40 mounted to screws 41.
The coolant is dlscharged against the surface of the casting in the direction indicated ~y arrows 43 to define the place of coolant application.
Figure 2 is a schematic cross-sectional representation of one embodiment of a system for application o~ a coolant .. - . . ..... ..... . . .. . . . . . . . . .
in accordance with this invention. Line 29 divides Figure 2 into two sides tA) and CB~. Slde ~Al shows a section through a face of rectangular ingot 20 and inductor 11' while side CB) shows a section through the corner of the same .
elements. Coolant, typically ~ater, is supplied to the peripheral surface 13 o~ ingot 20 via holes 17 in inductor Rounding o~f o~ corners in electromagnetic casting results from higher electromagnetic pressure at a given distance ~rom the inductor near the corner Cwhere two proximate ~ces o~ the single turn inductor generate field) and from excess cooling or higher heat extracticn rates a~
the corners because of geometrlc ~nd h~gher heat transfer
'7 folding is likely to occur. On the other hand, if it reaches to below the inductor, a bleed out or décantation of the liquid metal is likely to result. GetseIev ét al. '166 associate the coolant application manifold with the screen portion of the mold such that they are arranged ~or slmul-taneous movement relative to the inductor. In U.S. Patent No. 4,156,451 to ~etseleY a cooling medium is supplied upon the lateral face of the ingot in several cooling tiers arranged at various levels longitudinally o~ the lngot. Thus~ depending on the pulling veIocity of the ingot, the solidi~ication front can be maintained within the inductor by appropriate selection o~ one of the tiers.
Another approach to improved ingot shape consisted oP
provision of more uniform fields at conductor bus connections (Canadian Patent No. 930,925 to Getselev).
In electromagnetically casting rect~ngular or sheet ingots, the ingots are often cast with high radius o~
curvature ends or corners which is indicative of the need for improved ingot shape control at the corners of such ingots.
Finally, United States Patent 3,502,133 to Carson teaches utilizing a sensor in a continuous or semi-continuous casting mold to sense temperature variations at a particular location in the mold during casting. The sensor controls application of coolant to the mold and ~orming ingot. Use of such a device overcomes instabilities with respect to how much extra coolant is required at ~tart up of the casting operation and ~ust when or at what rate this excess cooling should be reduced. The ultimate purpose of ad~usting the flow of ~ 3 -coolant is to maintain th~ freeze line of the casting at a substantially constant location.
Carson '133 teaches that ingots having a width to thickness ratio on the order of 3 to 1 or more possess an uneven cooling rate during casting when coolant is applied peripherally of the mold in a uniform manner. To overcome this problem, Carson '133 applies coolant to the wide faces of the ingot and/or the mold walls and not at all (or at least at a reduced rate) to the relatively narrow end faces of the ingot and/or the mold walls.
The present invention comprises a process and apparatus for electromagnetic casting of metals and alloys into rectangular or sheet ingots and other desired elements of shape control having small radius of curvature corners or portions by application of controlled static head (through metal head or pres~ure modification). In particular, a method and apparatus utilizing controlled differential static head by control of cooling water application to obtain refine-ment of ingot shape, particularly at the corners of rectan-gular ingots or other desired elements of shape is claimed.
According to the present invention control of ingot shape may be effected by selection of the rate or location of cooling water application to the forming ingot shell within or below the containment inductor. Rounding off of corners in electromagnetic casting can be made less severe or of smaller radius by contouring the water application rate or elevation (or both) 50 that the rate or elevation , :~
, . ~oa ~ 3'~
i5 a minimum at the'corners o~'the ingot. ~eduction o~ the - water application rate or lowering the applicatlon level serves to reduce the local heat extraction rate along an ingot transverse cross section line of co~stant height.
This in turn lowers the position o~ the solidi~ication front at the ingot corner and correspondingly raises the metal static head or pressure at the corner. Thi~ increased pressure results in the liquid metal approaching the inductor more closely at the corner and thus ~illlng the corner to ~orm a smaller radius o~ curvature at the corner be~ore the -increased static pressure Is counter~alanced by an increased electromagnetic force.
In accordance with one embod~ment of this invention a water mani~old or cooling water application device is provided with drilled holes or slots OL a size and/or local hole density which is modified to yield locally reduced rates O ,D
. ~ , . .. . . . ................. . . ................ .. .
water appllca~lon at the ingot or desired shape corners~
In accordance with another preferred embod'iment o~ this invention a water mani~old or coollng water application device is provided wherein the elevatlon of the supply holes is modi~ied so as to apply water at the lowest elevation at the ingot or desired shape corners.
In accordance with yet another preferred embodiment o~
thi's invention the holes or slots in a water manifold or cooling water application devlce are modified such that the angle of the holes or slots around tha corners o~ the ingot cause the ~ater to impinge on the ingot sur~ace at a lower elevation at the Ingot corn,ers.
It Is of cou~se understood that hybrids of local hole cross section, hole angle, and hole elevation can also be _ 5 _ utilized in accordance with the concepts of thig invention.
In accordance with another preferred embodiment of this invention a water manifold or cooling water applic-ation device is provided which produces a water application rate of zero over short distances at the corners o-f the in~ot or desired shape to further accentuate the effects of reduced local cooling.
Accordingly, it is an object of this invention to provide an improved process and apparatus for 01ectromagnetic casting of metals and alloys into sheet ingots, or other desired elements of shape control, characterized by small radius of curvature corners or portions thereon.
In accordance with a particular embodiment there is provided, in an apparatus for electromagnetic forming of molten materials into a casting with a desired transverse cross section having at least one portion of the transverse cross section with a small radius of curvature relative to an adjacent portion of the transverse cross section comprises:
means for generating an electromagnetic force field to form said molten materials into said casting, and means for apply-ing coolant to the peripheral surface of said casting, the improvement comprising: means -for controlling the rate at which said coolant impinges upon said peripheral surface such that the rate of impingement in an area of said at least one portion of small radius of curvature is different as compared to the rate of impingement at peripherally adjacent areas of said casting.
In accordance with a further embodlment there is provided, in an apparatus for electromagnetic forming of molten materials into a casting with a desired transverse cross section having at least one portion of the transverse cross section with a small radius of curvature relative to an adjacent portion of the transverse cross section comprises:
means for generating an electromagnetic force field to form said molten material into said casting, and means for applying coolant to the peripheral surface of said casting, the improvement comprising: means for controlling the rate and elevation at which coolant impinyes upon said peripheral surface such that the rate and elevation of impingement in the area of said at least one portion of small radius of curvature is different as compared to the rate and elevation of impingement at peripherally adjacent areas of said casting.
From a different aspect, and in accordance with the invention, thére is provided, in a process for electro-magnetic forming of molten material into a casting having at least one portion of the transverse cross section with a small radius of curvature relative to an adjacent portion of the transverse cross section comprising: generating an electro-magnetic force field for forming said molten materials into said casting, pouring said molten material into said electro-magnetic force field, and applying a coolant to the peripheral surface of said casting, the improvement comprising: con-trolling the rate at which said coolant impinges upon said peripheral surface such that the rate of impingement in the area of said at least one portion of small radius of cur-vature is different as compared to the rate of impingement at peripherally adjacent areas of s.aid casting.
In accordance with a further aspect of the invention, there is provided, in a process for electromagnetic forming of molten material into a casting having at least one portion of the transverse cross section with a small radius of curvature relative to an adjacent portion of the transverse cross section comprising: generating an electromagnetic force - 6a -field for forming said molten materials into said casting, pouring said molten material into said electromagnetic force field, and applying a coolant to the perip~eral surface of said casting, the improvement comprising: controlling the rate and elevation at which said coolant impinges upon said peripheral surface such that the ra~e and elevation of impinge- -ment in the area of said at least one portion of small radius of curvature is different as compared to the rate and elevation of impingement at peripherally adjacent areas of said casting, In accordance with a further embodiment of the invention there is provided, in an apparatus for electro-magnetic forming of molten materials into a casting with a desired transverse cross section having at least one portion of the transverse cross section with a small radius of cur-vature relative to an adjacent portion of the transverse cross section comprising: means for generating an electromagnetic force field to form said molten materials into said casting, and means for applying coolant to the peripheral surface of said casting, the improvement comprising: said coolant apply-ing means including discharge port means for providing an unbaffled flow of coolant directly against said casting surface, said discharge port means in operation being sub-stantially filled with said coolant.
In accordance with a still further embodiment of the invention there is provided, a coolant discharge apparatus operatively associated with a mean9 for generating an electro-magnetic force field in casting of molten materials comprising:
manifold means formed into a substantially closed loop to enclose the casting having at least one corner for directing a flow of coolant against the casting within the confines of the electromagnetic force field, discharge port means 6b -~ i3'7 associated with said manifold means for ~irecting the flow of coolant against said casting from said at least one corner of said substantially closed loop at a different rate of flow as compared to the flow from adjacent peripheral areas of the mani~old means.
In accordance with a still further embodiment of the invention there is provided, a coolant discharge apparatus operatively associated with a means for degenerating an electromagnetic force field in electromagnetic casting of molten materials comprising: manifold means formed into a substantially closed loop to enclose the casting having at least one corner for directing a flow of coolant against the casting within the confines of the electromagnetic force field, discharge port means associated with said manifold means for directing unbaffled flow of coolant directly against said casting, said discharge port means being substantially full of coolant during operation, said discharge port means con-trolling flow of coolant from said at least one corner of said substantially closed loop at a different elevation as-compared to the elevation of the flow of coolant from adjacentperipheral areas of the manifold means.
This and other objects will become more apparent from the following description and drawings.
BRIEF DESCRIPTIO~ OF THE DRAWINGS
Figure 1 is a schematic cross-sectional represen-tation of a prior art electromagnetic casting apparatus ukil-izing a slot type coolant manifold for discharging water onto the faces of a forming ingot.
Figure 2 is a schematic cross-sectional represent-ation of an electromagnetic casting apparatus showing an in-ductor having drilled holes for supplying water to an ingot - 6c -'7 in accordance wi-th this invention.
Figure 3 is a schematic cross-sectional represen-tation of an electromagnetic casting apparatus showing a modified slot type manifold for supplying water to an ingot in accordance with this invention.
E'igure 4 is a schematic cross-sectional represen-tation of an electromagnetic castlng apparatus showing another embodiment of a modified slot type manifold for supplying coolant to an ingot in accordance with this invention.
- 6d -ao .~"l~
Figure 5 is a partial bottom plan view looking up into the manl~old dlscharge 310t of a manifold showing corners possessing dl~erent slot modi~ications in accordance with this invention.
DETAILED DES'C~IPTION OF PREFERRED EMBODIMENTS
In all drawing Flgures alike parts are designated by alike numerals.
Referring no~ to FIGURE 1 there is shown therein a prior art electromagnetic casting apparatus in accordance with U.S. Patent 4~158~37g.
The electrornagnetic cas~ing mold 10 is comprised of an inductor 11 which ie water cooled; a coolant manifold 12 for appl~Ing cooling water to the peripheral surface''l3 of the metal being cast C; and a non-magnetic screen 14.
Molten metal is continuously introduced into the mold 10 during a casting run, in the normal manner using a trough . . . . . . .. .. .. ..
15 and do~n spout 16 and conventional molten metal head control. The inductor 11 is excited by an alternatin~
, current ~rom a suitable power source (not shown~.
The alternating current in the inductor 11 produces 2 ma~netic ~ield which interacts with the molten metal head 19 to produce edd~ currents therein. These eddy currents in turn interact with the magnetlc ~ield'and produce forces .
which apply a magnetic pressure to the molten metal head 19 to contain it so that it solidifies in a desired ingot cross section.
An air gap exists during casting, between the molten metal head lg and the inductor 11. The molten metal head 19 is ~ormed~or molded into the same general shape as the inductor 11 there~y prot~iding the desired ingot cross section.
._ s ~ 10022-MB
~i~.4~ 7 The inductor may ~ave any desired shape including circular or rectangu~ar as required to obtain the desired ingot C cross section.
The purpose of the non-magnetic screen 14 is to fine tune and balance the magnetic pressure with the hydrostatic pressure of the molten metal head 19 The non-magnetic screen 14 comprises a separate element as shown, and is not a part of the manifold 12 for applying the coolant.
Initiall~, a con~entional ram 21 and bottom block 22 is held in the magnetic contalnment zone of the mold 10 to allow the molten me~al to be poured into the mold at the start o~ the casting run. The ram 21 and bottom block 22 are then uni~orml~ wlthdrawn at a desired casting rate.
Solidificatlon o~ the molten metal which is magnetically contained in the mold 10 is achieved by direct appl~cation of water from the cooling manifold 12 to the ingot surface . . . . .. . . , . .. , . , -- , . . ............. . . .. ... . ...
13. The water is shown applled to the ingot surface~l3 within the con~ines o~ the inductor 11. The water may be applied, however,to the ingot sur~ace 13 ~rom above~
withln or below the inductor 11 as desired.
The solidification front 25 o~ the casting comprises the boundar~ ~etween the molten metal head 19 and the solidi~ied lngot C. The location o~ the solidi~ication front 25 at the ingot sur~ace 13 results ~rom a ~alance o~ the heat input ~rom the superheated liquid metal 19 and the resis~ance heating from the induced currents in the ingot surface layer, with the longitudinal heat extraction ~rom the cooling water applica~ion.
Coolant manifold 12 is arranged above the inductor 11 and includes at least one discharge port 28 at the end of ~ ' ' 10022~M.3 ~4.h'L~ 7 , _ . ,, extended portion 30 for directing the coolant a~ain3t the surface ~3 of the ingot or casting. The discharge port 28 can comprise a slot or a plurallty o~ individual orl~ices ~or directing the coolant against the surface 13 of the ingot C about the entire periphery of that surface.
Coolant manifold 12 is arranged for movement along vertically extending rails 38 and 39 axially of the ingot C
such that extended portion 30 and discharge port 28 can be moved ~etween the non-magnetlc screen 14 and the inductor 11.
Axial ad~ustment o~ the discharge port 28 position is provided ~y means of cranks 40 mounted to screws 41.
The coolant is dlscharged against the surface of the casting in the direction indicated ~y arrows 43 to define the place of coolant application.
Figure 2 is a schematic cross-sectional representation of one embodiment of a system for application o~ a coolant .. - . . ..... ..... . . .. . . . . . . . . .
in accordance with this invention. Line 29 divides Figure 2 into two sides tA) and CB~. Slde ~Al shows a section through a face of rectangular ingot 20 and inductor 11' while side CB) shows a section through the corner of the same .
elements. Coolant, typically ~ater, is supplied to the peripheral surface 13 o~ ingot 20 via holes 17 in inductor Rounding o~f o~ corners in electromagnetic casting results from higher electromagnetic pressure at a given distance ~rom the inductor near the corner Cwhere two proximate ~ces o~ the single turn inductor generate field) and from excess cooling or higher heat extracticn rates a~
the corners because of geometrlc ~nd h~gher heat transfer
3 characteristics. Re~erring to Figure 2, dotted line- 23 - . ~ 100~2-~
~ t~
exemplifles the location o~ the solidPicatlon front at khe corner of an ingot Cside CB~ whIch is cooled by known uniform rate and height per~pheral coolant flow directed to the sur~ace 13 of rectangular ingot 20. As can ~e seen, excess cool~ng at the corners of the ingot 20 cause the ~ olidi~ication front to rise in comparison to the elevation o~ the solidi~lcation front along the faces of the ingot 20 tside (A~, denoted by dashed line 24. Thus, b, the height of the solidification front from the point of coolant impingement at the corners of the ingot 20 is greater than a, the height of the solidification front from the point of coolant impingement along the faces of the ingot 20. This combination of higher solidi~ication front (lo~rer head) and increased magnetic pressure at the corners causes the pushing of molten metal a~ay from the corners thereby producing a highly undesirable rounding off of the ingot ..... . ... . . . . . .
corners.
In accordance with this invention coolant appllcation devices are modified to produce controlled differential static head leading to refinement of lngot shapes at the corners, and in particular to form smaller radius of curvatures at lngot corners.
Control o~ ingot shape is effected in accordance with the present lnvention by selection of the rate and/or location of cooling water impingement upon the surface of forming ingot shells. Rounding off of corners in electro-magnetic castlng can be made less severe or of smaller radius ~y contourin~ the water application rate and/or elevation so that the rate and/or ele~ation is a minimum at the corner of the ingot. Reductlon of the ,rater l o ~
application rate and/or lowering of the appllca~ion level serves to reduce the local heat extraction rate along an ingot transverse cross section line of constant height.
This in turn lowers the posi~ion of the ~olidification front at the ingot corners and correspondingly raises the metal static head or pressure at the corners. This increased pressu~e results in the liquid metal-approaching the inductor more closely at the corners and thereby ~illing the corner to form a smaller radius of curvature before the increased static pressure ls counterbalanced by the increased electromagnetic force.
As can be seen ~rom Figure 2, the elevation of the water impingement at the side {B~ Cthe corner o~ ingot 20) in accordance ~ith this invention ls lower than the elevation at side CA) (along the face of the ingot 20) by virtue of the modification in elevation and angle o~ holes 17 in inductor .. . . . . . . . . . . . . . .
11'. The solidi~ication front 25 ~orms as a result at a heigh~ b above the point of water impingement Cpoint 26~
but at a level lower than the point 27 where the solidification front 25 forms along the faces of ingot 20.
As an alternative to alterring the angle and/or elevat on o~ holes 17 in inductor llr it would be possible to obtain a lowering o~ the solidi~ication ~ront at the corners o~ ir.got 20 by reducing the diameter o~ holes 17 and/or by blocking one or more holes locall~ of the corners thereby partially reducing or reducin~ to zero the rate of water applicatlon at the ingot corners. 0~ course hybrids Or hole size, dens~t~J, elevatlon, angle and blocka~e could be devised to obtain the results desired wlth respect to cooling rate at the corne~s 3 in accordance with this invention.
' ~ 100~2-MB
Figure 3 shows a par~ial schematic cross-3ectional representatian of the electromagne~ic caeting apparatus of Figure 1 wlth a modified coolant manifold 12' in accordance with another embodiment of this invention.
Figure 3 shows extended portlon 30 to have a discharge port 28' CSide tB~ having a modlfied slot discharge angle causing implngement of coolan~ water at a lower elevation at the corners of ingot 20. Side CA~ shows a standard or un-modified discharge port 28 whlch impinges water at a hlgher level along the faces of ingot 20. Solidification front 25 is seen to be at a higher level as designated by ~oint 27 along the ~aces of the ingot than at or near the corners of ingot 20, designated ~y point 26.
Figure 4 shows a partial schematic cross-sectional representation of the electromagnetic casting apparatus of Figures 1 and 3 with a modi~ied coolant manifold 12" in - . . .
accordance with yet another embodiment of th~s invention.
ln Figure 4, extended portion 30 o~ modified coolant mani~old 12" is constructed with discharge port 28 completely blocked off at or near the corners of ingot 20 CSide (B~) by portion 3I of coolant manifold 12". Thu~ there is zero local cooling in the immediate corners of ingot 20 causlng solidification front 25 to drop to the point 26 at the corners of ingot 20. Side CA~ shows that the solidification front 25 stays at point 27 along the faces of the ingot~
Where sIot type coolant manifolds such as deplcted in Figures 1, 3 and 4 are used, khe slot cross section can be accurately contoured to produce a smoothly varylng water ~low rate wikh a minimum or zero ~low rate at or near the 3Q ingot corner positions.
oa~2-r~
~ i3~
In additlon to alterring the angle of slot di~charge, it is contemplated to alter the extended portion 30 at the areas o~ the corners of the ingot 20 to modi~y the elevation of the slot discharge ports so as to be lowest at the ingot corners. Thus the elevation o~ the impinging water can be alterred ~y alterring the angle and/or the actual elevation of the discharge slots. Again, hybrids of contoured slot cross section3 ele~ation and angle could be devised to carr~
out the process o~ this invention.
Figure 5 is a bottom plan view looking up lnto an extended portion 30 of a mani~old and shows corners possessing dif~erent slot modifications in accordance with this inventlon.
Extended portion 30 comprises an inner wall 32, an outer wall 34 and a discharge port 28. Corner C shows an unmodified full slot discharge port 28 with a slot width equal to that .
along the four faces of extended portion 30. Corner D shows . - . ; . .
a contoured slot discharge port 28 with zero slot width Cclosed~ at the exact corner 62 o~ extended portion 30.
Corner E shows a contoured slot discharge port 28 with zero slot wldth over about half the corner radius 64 of extended portion 30 and corner F shows zero slot width over about virtually the whole corner radius 66 of extended portion 30.
The aforedescribed variants in coolant applying eauip-ment are typicall~ designed so as to modify the coolant application rate and/or impact psint within about three inches on either side of a corner while the maximum extent o~ the modifications in coolant application is to result in suhstantial absence of coolant application over about one inch or less ol the ingot sur~ace about the corner.
- ~002~
The novel method and apparatus o~ the pre~ent in~ention find applicability ln the electrGmagnetic castin~ o~ any - shapes wherein it is desired to form portions thereon of low radius of curvature.
. It is apparent that there has been provided with this lnvention a novel process and means for utilizlng controlled differential static head by control of coolant application to obtain refinement of ingot shape during electromagnetic casting which fully satis~y the ob~ects, means and advantages set ~or~h herein before. ~ile the invention has been described in combination with speci~ic emhodiments thereo~, it is evident that many alternatives, modifications and variations wlll be apparent to those skilled in the art in light of the ~oregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations as fall within the spirit and broad scope o~
. . . .
the appended claims~
3o
~ t~
exemplifles the location o~ the solidPicatlon front at khe corner of an ingot Cside CB~ whIch is cooled by known uniform rate and height per~pheral coolant flow directed to the sur~ace 13 of rectangular ingot 20. As can ~e seen, excess cool~ng at the corners of the ingot 20 cause the ~ olidi~ication front to rise in comparison to the elevation o~ the solidi~lcation front along the faces of the ingot 20 tside (A~, denoted by dashed line 24. Thus, b, the height of the solidification front from the point of coolant impingement at the corners of the ingot 20 is greater than a, the height of the solidification front from the point of coolant impingement along the faces of the ingot 20. This combination of higher solidi~ication front (lo~rer head) and increased magnetic pressure at the corners causes the pushing of molten metal a~ay from the corners thereby producing a highly undesirable rounding off of the ingot ..... . ... . . . . . .
corners.
In accordance with this invention coolant appllcation devices are modified to produce controlled differential static head leading to refinement of lngot shapes at the corners, and in particular to form smaller radius of curvatures at lngot corners.
Control o~ ingot shape is effected in accordance with the present lnvention by selection of the rate and/or location of cooling water impingement upon the surface of forming ingot shells. Rounding off of corners in electro-magnetic castlng can be made less severe or of smaller radius ~y contourin~ the water application rate and/or elevation so that the rate and/or ele~ation is a minimum at the corner of the ingot. Reductlon of the ,rater l o ~
application rate and/or lowering of the appllca~ion level serves to reduce the local heat extraction rate along an ingot transverse cross section line of constant height.
This in turn lowers the posi~ion of the ~olidification front at the ingot corners and correspondingly raises the metal static head or pressure at the corners. This increased pressu~e results in the liquid metal-approaching the inductor more closely at the corners and thereby ~illing the corner to form a smaller radius of curvature before the increased static pressure ls counterbalanced by the increased electromagnetic force.
As can be seen ~rom Figure 2, the elevation of the water impingement at the side {B~ Cthe corner o~ ingot 20) in accordance ~ith this invention ls lower than the elevation at side CA) (along the face of the ingot 20) by virtue of the modification in elevation and angle o~ holes 17 in inductor .. . . . . . . . . . . . . . .
11'. The solidi~ication front 25 ~orms as a result at a heigh~ b above the point of water impingement Cpoint 26~
but at a level lower than the point 27 where the solidification front 25 forms along the faces of ingot 20.
As an alternative to alterring the angle and/or elevat on o~ holes 17 in inductor llr it would be possible to obtain a lowering o~ the solidi~ication ~ront at the corners o~ ir.got 20 by reducing the diameter o~ holes 17 and/or by blocking one or more holes locall~ of the corners thereby partially reducing or reducin~ to zero the rate of water applicatlon at the ingot corners. 0~ course hybrids Or hole size, dens~t~J, elevatlon, angle and blocka~e could be devised to obtain the results desired wlth respect to cooling rate at the corne~s 3 in accordance with this invention.
' ~ 100~2-MB
Figure 3 shows a par~ial schematic cross-3ectional representatian of the electromagne~ic caeting apparatus of Figure 1 wlth a modified coolant manifold 12' in accordance with another embodiment of this invention.
Figure 3 shows extended portlon 30 to have a discharge port 28' CSide tB~ having a modlfied slot discharge angle causing implngement of coolan~ water at a lower elevation at the corners of ingot 20. Side CA~ shows a standard or un-modified discharge port 28 whlch impinges water at a hlgher level along the faces of ingot 20. Solidification front 25 is seen to be at a higher level as designated by ~oint 27 along the ~aces of the ingot than at or near the corners of ingot 20, designated ~y point 26.
Figure 4 shows a partial schematic cross-sectional representation of the electromagnetic casting apparatus of Figures 1 and 3 with a modi~ied coolant manifold 12" in - . . .
accordance with yet another embodiment of th~s invention.
ln Figure 4, extended portion 30 o~ modified coolant mani~old 12" is constructed with discharge port 28 completely blocked off at or near the corners of ingot 20 CSide (B~) by portion 3I of coolant manifold 12". Thu~ there is zero local cooling in the immediate corners of ingot 20 causlng solidification front 25 to drop to the point 26 at the corners of ingot 20. Side CA~ shows that the solidification front 25 stays at point 27 along the faces of the ingot~
Where sIot type coolant manifolds such as deplcted in Figures 1, 3 and 4 are used, khe slot cross section can be accurately contoured to produce a smoothly varylng water ~low rate wikh a minimum or zero ~low rate at or near the 3Q ingot corner positions.
oa~2-r~
~ i3~
In additlon to alterring the angle of slot di~charge, it is contemplated to alter the extended portion 30 at the areas o~ the corners of the ingot 20 to modi~y the elevation of the slot discharge ports so as to be lowest at the ingot corners. Thus the elevation o~ the impinging water can be alterred ~y alterring the angle and/or the actual elevation of the discharge slots. Again, hybrids of contoured slot cross section3 ele~ation and angle could be devised to carr~
out the process o~ this invention.
Figure 5 is a bottom plan view looking up lnto an extended portion 30 of a mani~old and shows corners possessing dif~erent slot modifications in accordance with this inventlon.
Extended portion 30 comprises an inner wall 32, an outer wall 34 and a discharge port 28. Corner C shows an unmodified full slot discharge port 28 with a slot width equal to that .
along the four faces of extended portion 30. Corner D shows . - . ; . .
a contoured slot discharge port 28 with zero slot width Cclosed~ at the exact corner 62 o~ extended portion 30.
Corner E shows a contoured slot discharge port 28 with zero slot wldth over about half the corner radius 64 of extended portion 30 and corner F shows zero slot width over about virtually the whole corner radius 66 of extended portion 30.
The aforedescribed variants in coolant applying eauip-ment are typicall~ designed so as to modify the coolant application rate and/or impact psint within about three inches on either side of a corner while the maximum extent o~ the modifications in coolant application is to result in suhstantial absence of coolant application over about one inch or less ol the ingot sur~ace about the corner.
- ~002~
The novel method and apparatus o~ the pre~ent in~ention find applicability ln the electrGmagnetic castin~ o~ any - shapes wherein it is desired to form portions thereon of low radius of curvature.
. It is apparent that there has been provided with this lnvention a novel process and means for utilizlng controlled differential static head by control of coolant application to obtain refinement of ingot shape during electromagnetic casting which fully satis~y the ob~ects, means and advantages set ~or~h herein before. ~ile the invention has been described in combination with speci~ic emhodiments thereo~, it is evident that many alternatives, modifications and variations wlll be apparent to those skilled in the art in light of the ~oregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations as fall within the spirit and broad scope o~
. . . .
the appended claims~
3o
Claims (19)
1. In an apparatus for electromagnetic forming of molten material into a casting with a desired transverse cross section having at least one portion of a transverse cross section line at the outer casting surface with a small radius of curvature relative to an adjacent portion of the transverse cross section line at the outer casting surface comprising:
means for generating an electromagnetic force field to form said molten material into said casting; and means for applying coolant to the peripheral surface of said casting, the improvement comprising:
said coolant applying means including discharge port means for providing an unbaffled flow of coolant directly against said casting surface, said discharge port means in ope-ration being substantially filled with said coolant;
means for controlling said coolant applying means for providing a first hydrostatic pressure head of molten material at the liquid-solid interface at the outer casting surface at said one portion and for providing a second hydrostatic pressure head of molten material at the liquid-solid interface at the outer casting surface at said adjacent portion, said first pressure head being greater than said second pressure head, whereby the molten material more closely approaches said elec-tromagnetic generating means at said at least one portion with a small radius of curvature.
means for generating an electromagnetic force field to form said molten material into said casting; and means for applying coolant to the peripheral surface of said casting, the improvement comprising:
said coolant applying means including discharge port means for providing an unbaffled flow of coolant directly against said casting surface, said discharge port means in ope-ration being substantially filled with said coolant;
means for controlling said coolant applying means for providing a first hydrostatic pressure head of molten material at the liquid-solid interface at the outer casting surface at said one portion and for providing a second hydrostatic pressure head of molten material at the liquid-solid interface at the outer casting surface at said adjacent portion, said first pressure head being greater than said second pressure head, whereby the molten material more closely approaches said elec-tromagnetic generating means at said at least one portion with a small radius of curvature.
2. An apparatus as in claim 1 wherein said controlling means further includes means for providing coolant impingement on said peripheral casting surface such that the height of the impingement at said at least one portion is lower as compared to the height of impingement at said adjacent portion of said casting.
3. An apparatus as in claim 1 or 2 wherein said control-ling means further includes means for providing coolant impinge-ment upon said peripheral casting surface such that the rate of impingement on said at least one portion is lower as compared to the rate of impingement at said adjacent portion of said casting.
4. An apparatus as in claim 1 or 2 wherein said control-ling means further includes means for providing coolant impinge-ment upon said peripheral casting surface such that the rate of impingement on said at least one portion is lower as compared to the rate of impingement at said adjacent portion of said casting and wherein said lower rate of impingement on the cas-ting surface is zero.
5. An apparatus as in claim 1 wherein said controlling means comprises a slot in said coolant applying means, said slot being generally directed toward said peripheral surface of said casting.
6. An apparatus as in claim 5 wherein said slot is nar-rower at areas of said coolant applying means adjacent said at least one portion as compared to an adjacent peripheral area of said coolant applying means.
7. An apparatus as in claim 5 wherein said slot has a smaller angle of inclination with respect to a casting axis at areas of said coolant applying means adjacent said at least one portion as compared to an adjacent peripheral area of said coolant applying means.
8. An apparatus as in claim 5 wherein said slot is at a lower elevation at an area of said coolant applying means adjacent said at least one portion as compared to an adjacent peripheral area of said coolant applying means.
9. An apparatus as in claim 1 wherein said controlling means comprises a plurality of orifices in said coolant apply-ing means, said orifices being generally directed toward said peripheral surface of said casting.
10. An apparatus as in claim 9 wherein there are fewer of said orifices at an area of said coolant applying means adjacent said at least one portion as compared to an adjacent peripheral area of said coolant applying means.
11. An apparatus as in claim 9 wherein said orifices are of smaller diameter at an area of said coolant applying means adjacent said at least one portion as compared to an adjacent peripheral area of said coolant applying means.
12. An apparatus as in claim 9 wherein said orifices have axes which are arranged at a smaller angle of inclination with respect to a casting axis at an area of said coolant applying means adjacent said at least one portion as compared to an adjacent peripheral area of said coolant applying means.
13. An apparatus as in claim 9 wherein at least one of said orifices is at a lower elevation at an area of said coo-lant applying means adjacent said at least one portion as compared to an adjacent peripheral area of said coolant apply-ing means.
14. In a process for electromagnetic forming of molten material into a casting with a desired transverse cross section having at least one portion of a transverse cross section line at the outer casting surface with a small radius of curvature relative to an adjacent portion of the transverse cross section line at the outer casting surface comprising the steps of:
providing means for generating an electromagnectic force field for forming said molten material into said casting, pouring said molten material into said electromagnetic force field, the improvement comprising the steps of:
applying an unbaffled flow of coolant from a dis-charge port directly against the peripheral surface of said casting, said discharge port in operation being substantially filled with said coolant, controlling the flow of coolant to a first hydro-static pressure head of molten material at the liquid-solid interface at the outer casting surface at said one portion and to provide a second hydrostatic pressure head of molten mate-rial at the liquid-solid interface at the outer casting surface at said adjacent portion, said first pressure head being greater than said second pressure head, whereby the molten ma-terial more closely approaches said electromagnetic force field generating means at said at least one portion of small radius of curvature.
providing means for generating an electromagnectic force field for forming said molten material into said casting, pouring said molten material into said electromagnetic force field, the improvement comprising the steps of:
applying an unbaffled flow of coolant from a dis-charge port directly against the peripheral surface of said casting, said discharge port in operation being substantially filled with said coolant, controlling the flow of coolant to a first hydro-static pressure head of molten material at the liquid-solid interface at the outer casting surface at said one portion and to provide a second hydrostatic pressure head of molten mate-rial at the liquid-solid interface at the outer casting surface at said adjacent portion, said first pressure head being greater than said second pressure head, whereby the molten ma-terial more closely approaches said electromagnetic force field generating means at said at least one portion of small radius of curvature.
15. The process as in claim 14 wherein said step of controlling the coolant flow further comprises the step of providing coolant impingement on said peripheral casting sur-face such that the height of the impingement at said at least one portion is lower as compared to the height of impingement at said adjacent portion of said casting.
16. The process as in claim 14 wherein said step of controlling the coolant flow further comprises the step of providing coolant impingement upon said peripheral casting surface such that the rate of impingement at said at least one portion is lower as compared to the rate of impingement at said adjacent portion of said casting.
17. An apparatus as in claim 1 wherein said controlling means comprises a slot in said coolant applying means, said slot being generally directed toward said peripheral surface of said casting and wherein said lower rate is zero.
18. A process as in claim 14 wherein said flow of coo-lant is provided through a variable width slot.
19. A process as in claim 14 wherein said flow of coo-lant is provided through a plurality of orifices, said step of applying coolant being carried out by specifically geome-trically arranging and sizing said orifices.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US5677379A | 1979-07-11 | 1979-07-11 | |
| US56,773 | 1979-07-11 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1161107A true CA1161107A (en) | 1984-01-24 |
Family
ID=22006506
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000352198A Expired CA1161107A (en) | 1979-07-11 | 1980-05-16 | Controlled water application for electromagnetic casting shape control |
Country Status (4)
| Country | Link |
|---|---|
| EP (1) | EP0022566B1 (en) |
| JP (1) | JPS5614056A (en) |
| CA (1) | CA1161107A (en) |
| DE (1) | DE3071333D1 (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CA1192372A (en) * | 1981-06-26 | 1985-08-27 | Michael J. Pryor | Prioritized electromagnetic casting control system |
| CN107243609A (en) * | 2017-06-16 | 2017-10-13 | 浙江天宁合金材料有限公司 | A kind of copper and copper alloy casting crystallizer |
Family Cites Families (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3467166A (en) * | 1967-03-01 | 1969-09-16 | Getselev Zinovy N | Method of continuous and semicontinuous casting of metals and a plant for same |
| US3646988A (en) * | 1970-05-20 | 1972-03-07 | Getselev Zinovy N | Induction apparatus for continuous and semicontinuous casting |
| US4014379A (en) * | 1970-06-09 | 1977-03-29 | Getselev Zinovy N | Method of forming ingot in process of continuous and semi-continuous casting of metals |
| AU460318B2 (en) * | 1971-11-10 | 1975-04-24 | Kuibyshevsky Metallurgichesky Zavod Imerti Vi. Lenina | Ingot-producing plant |
| US3985179A (en) * | 1975-07-28 | 1976-10-21 | Kaiser Aluminum & Chemical Corporation | Electromagnetic casting apparatus |
| US4156451A (en) * | 1978-02-07 | 1979-05-29 | Getselev Zinovy N | Continuous or semi-continuous metal casting method |
| US4158379A (en) * | 1978-07-03 | 1979-06-19 | Olin Corporation | Electromagnetic casting method and apparatus |
| FR2429633A1 (en) * | 1979-03-08 | 1980-01-25 | Gi Splavov | Continuous casting of metals in electromagnetic field - where inductor controls shape of cast billet, and metal is under protective partial vacuum or liq. cover |
-
1980
- 1980-05-16 CA CA000352198A patent/CA1161107A/en not_active Expired
- 1980-06-04 JP JP7538980A patent/JPS5614056A/en active Pending
- 1980-07-10 DE DE8080103976T patent/DE3071333D1/en not_active Expired
- 1980-07-10 EP EP80103976A patent/EP0022566B1/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| EP0022566A1 (en) | 1981-01-21 |
| JPS5614056A (en) | 1981-02-10 |
| DE3071333D1 (en) | 1986-02-20 |
| EP0022566B1 (en) | 1986-01-08 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |