CA2264890A1 - Improved mold surface for continuous casting and process for making - Google Patents

Improved mold surface for continuous casting and process for making Download PDF

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Publication number
CA2264890A1
CA2264890A1 CA002264890A CA2264890A CA2264890A1 CA 2264890 A1 CA2264890 A1 CA 2264890A1 CA 002264890 A CA002264890 A CA 002264890A CA 2264890 A CA2264890 A CA 2264890A CA 2264890 A1 CA2264890 A1 CA 2264890A1
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CA
Canada
Prior art keywords
mold
coating
liner
compressively stressed
shot peening
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.)
Abandoned
Application number
CA002264890A
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French (fr)
Inventor
James B. Sears, Jr.
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AG Industries Inc Pennsylvania
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Individual
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Filing date
Publication date
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Publication of CA2264890A1 publication Critical patent/CA2264890A1/en
Abandoned legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/04Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
    • B22D11/059Mould materials or platings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/04Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
    • B22D11/057Manufacturing or calibrating the moulds

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

Abstract

A method of preparing a mold surface for a continuous casting machine includes steps of machining the mold surface to a substantially smooth surface, and work hardening the machine surface substantially throughout to impart a compressive stress to the surface. In the preferred embodiment, this work hardening is performed by applying a controlled shot peening process to the mold surface. The surface may then be buffed to a smooth finish, or coated with a material such as nickel or chromium. The residual compressive stress that is created by the work hardening stops cracks from forming or spreading in the moldface wall. This increases the life of the moldface, and makes the casting machine safer and more efficient to operate.

Description

101520CA 02264890 1999-03-03WO 98/09750 PCT/U S97/ 14847IMPROVED MOLD SURFACE FOR CONTINUOUS CASTINGAND PROCESS FOR MAKINGBACKGROUND OF THE INVENTION1. Field of the InventionThis invention relates broadly to the field of metal production,solidification and casting. More specifically, this invention relates to an improved moldfor a continuous casting system that has a longer useful life, is safer and more reliable,improves the uniformity of heat removal, is more stable dimensionally and turns out abetter product having enhanced surface quality and decreased stresses than conventionalcontinuous casting molds do.2. Description of the Related TechnologyMetals such as steel are continuously cast into strands by pouring hot,molten metal into the upper end of a mold and continuously withdrawing a metal strandfrom the mold’s bottom. As the molten metal passes through the mold, the surfaces ofthe metal that are next to the mold walls are cooled, solidified and hardened to form acasing or shell of solidified metal around the molten metal in the strand. After leavingthe bottom of the mold, the metal continues to cool and the casing or shell of solidifiedmetal around the molten core thickens until the whole strand section is solidified.A conventional continuous casting mold includes a number of liner plates,usually made of copper or copper alloy, and outer support walls surrounding the linerplates. The liner plates define a portion of the mold that contacts the molten metal duringthe casting process. Parallel vertically extending water circulation slots or passageways1015202530CA 02264890 1999-03-03WO 98/09750 PCTIU S97/ 14847-2-are provided between the outer walls and the liner plates to cool the liner plates. Duringoperation, water is introduced to these slots, usually at the bottom end of the mold, from awater supply via an inlet plenum that is in communication with all of the slots in a linerplate. The cooling effect so achieved causes an outer skin of the molten metal to solidifyas it passes through the mold. The solidification is then completed after the semi-solidified casting leaves the mold by spraying additional coolant, typically water, directlyonto the casting. This method of metal production is highly efficient, and is in wide use inthe United States and throughout the world.In order ensure consistent product quality and to prevent avoidable failureof the casting machine, steelmakers must arrange for periodic maintenance to beperformed on the casting mold, and in particular on the liner plates, which are susceptibleto wear and cracking during the casting process. AG Industries Inc., the assignee of thisinvention, is the leading provider of mold maintenance services in the United States.In order to recondition and prepare the outer, steel contacting coppersurface of the liner plate for service, it is typically machined and then finished smooth bysanding or buffing. Sometimes, the outer surface is further plated -with a material such asalloys of nickel or chrome to provide additional protection from the extreme heat that istransmitted to the copper from the hot metal being cast and the corrosive effect of the moldfluxes that are used in the casting process. A chrome plating is very porous on themicroscopic level, and it has a tendency to deteriorate and come off of the copper duringservice as a result of corrosion, particularly in the in the meniscus region of the mold liner.A nickel coating is more resistant to corrosion, but is very crack sensitive at the elevatedtemperatures that the mold surface is operated at. Even a thin nickel coating has atendency to crack in the meniscus region of the mold liner, where the heat is the greatest.These cracks can penetrate through the plating interface and into the base copper materialof the mold liner. This lessens the life of the mold liner, because the copper must bemachined when reconditioned to a depth that is sufficient to remove all of the cracks. Inaddition, cracking presents a safety concern during operation. If a crack propagatesthrough the mold liner into a coolant passage, water from the coolant passage can leak intocontact with the molten metal, which can be catastrophic. It is clear that there areanumber of important reasons why crack formation in the mold liner and/or in the coatingthat is applied to the mold liner should be prevented. To this date, however, the industry1015202530.-........................_................,......a..._,,s ..CA 02264890 1999-03-03WO 98/09750 PCT/US97/14847-3-has not developed a satisfactory way to suppress formation of such cracking during highspeed mold operation, and it continues to pose a problem to mold operators and to thecompanies that recondition and maintain the molds.SUMMARY OF THE INVENTIONIt is an object of this invention to provide an improved mold liner for acontinuous casting machine, and/or a coating that is applied to an outer surface of such amold liner, that is more resistant to cracking during operation.It is further an object of the invention to provide a process for making acrack resistant mold face of the type referred to above.In order to achieve the above and other objects of the invention, animproved mold liner for use in a continuous casting machine includes, according to a firstaspect of this invention, an inner surface that is constructed and arranged to be connectedto structure for conducting heat away from the mold liner during operation; and an outersurface that forms a casting surface of the mold, said outer surface being compressivelystressed substantially throughout so that cracks are unlikely to initiate or propagate at saidouter surface, whereby the mold liner will exhibit increased lifespan and improved safetywith respect to mold liners heretofore known.According to a second aspect of the invention, a mold for a continuouscasting machine includes a plurality of mold surfaces for guiding and cooling a strand ofmolten metal as it hardens and emerges from the mold as a casting, each of said moldsurfaces having an outer surface, and wherein said outer surface is compressively stressedsubstantially throughout so that cracks are unlikely to initiate or propagate at said outersurface, whereby the mold will exhibit increased lifespan and improved safety with respectto molds heretofore known.According to a third aspect of the invention, a method of making a strand ofcontinuously cast material includes steps of introducing molten metal into a mold thatincludes a plurality of mold surfaces, each of the mold surfaces having an outer surfacethat is compressively stressed substantially throughout to suppress and prevent cracking ofthe outer surface; cooling the molten metal by conducting heat away from the moltenmetal through the mold surfaces; and moving the cast strand out of the mold.1015202530CA 02264890 1999-03-03WO 98/09750 PCT/U S97/ 14847-4-A method of preparing a mold surface for a continuous casting machineincludes, according to a fourth aspect of the invention steps of: machining the moldsurface to a substantially smooth surface; and work hardening the machined surfacesubstantially throughout to impart a residual compressive stress to said surface.A method of preparing a mold surface for a continuous casting machineaccording to a fifth aspect of the invention includes steps of machining the mold surface toa substantially smooth surface; and applying a controlled shot peening process to themachined surface to impart a residual compressive stress to said surface.These and various other advantages and features of novelty whichcharacterize the invention are pointed out with particularity in the claims armexed heretoand forming a part hereof. However, for a better understanding of the invention, itsadvantages, and the objects obtained by its use, reference should be made to the drawingswhich form a further part hereof, and to the accompanying descriptive matter, in whichthere is illustrated and described a preferred embodiment of the invention.BRIEF DESCRIPTION OF THE DRAWINGSFIGURE 1 is a diagrammatical cross sectional view taken through acontinuous casting mold that is constructed according to a preferred embodiment of theinvention;FIGURE 2 is a diagrammatical cross sectional view taken through acomponent of the mold that is depicted in FIGURE 1;FIGURE 3 is a diagrammatical cross sectional view, similar to FIGURE 2,depicting a mold that is constructed according to a second preferred embodiment of theinvention;FIGURE 4 is a diagrammatical cross sectional view, similar to FIGURES 2and 3, depicting a mold that is made according to a third embodiment of the invention;FIGURE 5 is a graphical depiction of the compressive-tinsel strength of ametallic material that has been treated by a controlled shot peening process; andFIGURES 6A—6E diagrammatically depict a process that is preformedaccording to a preferred embodiment of the invention.DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT§S[1015202530CA 02264890 1999-03-03WO 98/09750 PCT/US97/ 14847-5-Referring now to the drawings, wherein like reference numerals designatecorresponding structure throughout the views, and referring in particular to FIGURE 1, amold assembly 10 for a continuous casting machine typically includes a plurality of moldliners 12, of which four are illustrated, each of which has an outer surface 14 that togetherdefine the mold’s casting surface 16. Each of the mold liners 12 further has an innersurface 18 that is mounted to an outer wall 20 of the continuous casting mold 10 forconducting heat away from the mold liner 12 during operation. To further help to conductheat away from the molten metal/casting during operation, each of the mold liners 12 has aplurality of interior coolant slots 22 defined therein, which are supplied a coolant, usuallywater, via a coolant supply pipe 24, which is also depicted in FIGURE 1.One particularly advantageous feature of the invention is that the outersurface 14 of the mold liner 12 is compressively stressed substantially throughout so thatcracks are unlikely to initiate or propagate at the outer surface 14. Referring to FIGURE2, it will be seen that the outer surface 14 includes a layer 26 of such compressivelystressed material. Ordinarily, the mold liner 12 is fabricated from a thermally conductivematerial, most often copper or a copper alloy, which can be coated with a corrosionresistant material such as nickel or chromium, alloys thereof, or other material, such asdiamond or a refractory material. In a mold liner 32 that is constructed according to asecond embodiment of the invention, shown in FIGURE 3, such a coating 30 is appliedover the layer 26 of compressively stressed material. In a third embodiment of theinvention shown in FIGURE 4, the coating 30 is again applied over the layer 26 ofcompressively stressed material, and than an outer layer of the coating 30 is itselfcompressively stressed so as to deter cracks in the coating 30 itself, and stop them fromspreading if in fact they do occur.The layer 26 of compressively stressed material shown in FIGURE 2, andthe layer 36 of compressively stressed coating material shown in FIGURE 4 are preferablygiven their residual compressive stress by a working hardening process, which ispreferably a controlled shot peening process that is applied to the outer surface 14 of themold liner 34, and the outer surface of the coating 30, respectively. FIGURE 5 is agraphical representation of the compressive stress that is created in a surface by the shotpeening process, such as the outer surface 14 of the mold liner 12. It will be seen that shotpeening produces a significant amount of residual compressive stress immediately beneath1015202530CA 02264890 1999-03-03wo 98/09750 PCTIUS97/14847-5-the surface, which is reduced, and actually transitions to a net tensile stress at a significantdepth beneath the surface.Shot peening is a cold working process in which the surface of a part isbombarded with small spherical media called shot. Each piece of shot striking thematerial acts a tiny peening hammer, imparting to the surface a small indentation ordimple. In order for the dimple to be created, the surface fibers of the material must beyielded in tension. Beneath the surface, the fibers try to restore the surface to its originalshape, thereby producing below the dimple a hemisphere of cold worked material that ishighly stressed in compression. Overlapping dimples develop an even layer of metal inresidual compressive stress. In other industries, such as aircraft manufacturing, it is wellknown that cracks will not initiate or propagate in a shot peened zone. However, to theinventors knowledge, this technique has never been utilized in the manufacture orrefurbishing of continuous casting mold parts.Referring now to FIGURES 6A through 6E, a process for reconditioning amoldface of a continuous casting mold will now be discussed. Typically, a number ofcracks 38 and or imperfections will be found in the moldface surface after it has been inuse for some time. The moldface must be machined to a depth that is sufficient to removethose cracks and imperfections, exposing a fresh relatively smooth surface of copper 40, asis shown FIGURE 6B. In the preferred embodiment of the invention shown in FIGURE6C, this surface 40 of a main body 28 is then work hardened by bombarding it with smallspherical particles at a controlled velocity as described above in a shot peening process,which creates the layer 26 of compressively stressed material that is shown in FIGURE 6Cand is discussed above. Some molds might be buffed and polished to smooth out the outersurface of the compressively stress layer 26 at this point, and put back into service. Othermolds, however, where additional coating is desired, will be coated with a layer 30 of amaterial such as nickel or chromium, or with a nonmetallic material such as refractory ordiamond. In some molds, this material will be polished and the mold can be put into.service. In other molds, where the coating 30 is metallic, it may be desirable to again usea shot peening process to form a work hardened compressively stressed layer on the outersurface of the metallic coating 30, as is shown in FIGURE 6E. As discussed above, thisadditional layer 36 of compressively stressed material will act as a further deterrent to theCA 02264890 1999-03-03WO 98/09750 PCT/US97/14847- 7 -initiation and propagate of cracks that might otherwise begin in the layer 30 of metallicmaterial.It is to be understood, however, that even though numerous characteristicsand advantages of the present invention have been set forth in the foregoing description,5 together with details of the structure and function of the invention, the disclosure isillustrative only, and changes may be made in detail, especially in matters of shape, sizeand arrangement of parts within the principles of the invention to the full extent indicatedby the broad general meaning of the terms in which the appended claims are expressed.

Claims (31)

WHAT IS CLAIMED IS:
1. An improved mold liner for use in a continuous casting machine, comprising:
an inner surface that is constructed and arranged to be connected to structure for conducting heat away from the mold liner during operation; and an outer surface that forms a casting surface of the mold, said outer surface being compressively stressed substantially throughout so that cracks are unlikely to initiate or propagate at said outer surface, whereby the mold liner will exhibit increased lifespan and improved safety with respect to mold liners heretofore known.
2. A mold liner according to claim 1, wherein said outer surface comprises a material containing copper.
3. A mold liner according to claim 1, wherein said mold liner comprises a body that is formed of a material comprising copper, and said outer surface comprises a coating that is attached to mold liner body.
4. A mold liner according to claim 3, wherein said coating comprises nickel.
5. A mold liner according to claim 3, wherein said coating comprises chromium.
6. A mold liner according to claim 3, wherein said coating comprises diamond.
7. A mold liner according to claim 1, wherein said outer surface is compressively stressed by cold working the outer surface.
8. A mold liner according to claim 7, wherein said outer surface is compressively stressed by application of a controlled shot peening process to said outer surface.
9. A mold for a continuous casting machine comprising:
a plurality of mold surfaces for guiding and cooling a strand of molten metal as it hardens and emerges from the mold as a casting, each of said mold surfaces having an outer surface, and wherein said outer surface is compressively stressed substantially throughout so that cracks are unlikely to initiate or propagate at said outer surface, whereby the mold will exhibit increased lifespan and improved safety with respect to molds heretofore known.
10. A mold according to claim 8, wherein said mold comprises a body that is formed of a material comprising copper, and said outer surface comprises a coating that is attached to mold body.
11. A mold according to claim 10, wherein said coating comprises nickel.
12. A mold according to claim 10, wherein said coating comprises chromium.
13. A mold according to claim 10, wherein said surface comprises diamond.
14. A mold according to claim 10, wherein said outer surface is compressively stressed by cold working the outer surface.
15. A mold according to claim 14, wherein said outer surface is compressively stressed by application of a controlled shot peening process to said outer surface.
16. A method of making a strand of continuously cast material, comprising steps of:
(a) introducing molten metal into a mold that includes a plurality of mold surfaces, each of the mold surfaces having an outer surface that is compressively stressed to suppress and prevent cracking of the outer surface;
(b) cooling the molten metal by conducting heat away from the molten metal through the mold surfaces; and (c) moving the cast strand out of the mold.
17. A method according to claim 16, wherein the outer surface is compressively stressed substantially throughout its entire surface.
18. A method of preparing a mold surface for a continuous casting machine, comprising steps of:
(a) machining the mold surface to a substantially smooth surface; and (b) work hardening the machined surface to impart a residual compressive stress to said surface.
19. A method according to claim 18, wherein the surface is compressively stressed substantially throughout its entire surface.
20. A method according to claim 18, further comprising a step of (c) buffing the surface to a smooth finish after step (b).
21. A method according to claim 18, further comprising a step of applying a metallic coating that is selected from a group of materials comprising nickel and chromium to the mold surface after step (b).
22. A method according to claim 21, further comprising an additional step of work hardening the metallic coating after it has been applied, whereby both the coating and the underlying material have been work hardened.
23. A method according to claim 18, wherein step (b) is performed by applying a controlled shot peening process to the mold surface.
24. A method according to claim 18, wherein said additional work hardening step is performed by applying a controlled shot peening process to the outer surface of the coating.
25. A mold surface that has been prepared according to the method that is set forth in claim 18.
26. A method of preparing a mold surface for a continuous casting machine, comprising steps of:
(a) machining the mold surface to a substantially smooth surface; and (b) applying a controlled shot peening process to the machined surface to impart a residual compressive stress to said surface.
27. A method according to claim 26, further comprising a step of (c) buffing the surface to a smooth finish after step (b).
28. A method according to claim 26, further comprising a step of applying a metallic coating that is selected from a group of materials comprising nickel and chromium to the mold surface after step (b).
29. A method according to claim 28, further comprising an additional step of work hardening the metallic coating after it has been applied, whereby both the coating and the underlying material have been work hardened.
30. A method according to claim 29, wherein said additional work hardening step is performed by applying a controlled shot peening process to the outer surface of the coating.
31. A mold surface that has been prepared according to the method that is set forth in claim 26.
CA002264890A 1996-09-03 1997-08-22 Improved mold surface for continuous casting and process for making Abandoned CA2264890A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US70684196A 1996-09-03 1996-09-03
US08/706,841 1996-09-03
PCT/US1997/014847 WO1998009750A1 (en) 1996-09-03 1997-08-22 Improved mold surface for continuous casting and process for making

Publications (1)

Publication Number Publication Date
CA2264890A1 true CA2264890A1 (en) 1998-03-12

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CA002264890A Abandoned CA2264890A1 (en) 1996-09-03 1997-08-22 Improved mold surface for continuous casting and process for making

Country Status (7)

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JP (1) JP2000517246A (en)
AU (1) AU4084497A (en)
BR (1) BR9711826A (en)
CA (1) CA2264890A1 (en)
DE (2) DE19781990B4 (en)
GB (1) GB2332635B (en)
WO (1) WO1998009750A1 (en)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10116416A1 (en) * 2001-04-02 2002-10-17 Thyssenkrupp Stahl Ag Mold for the continuous casting of a molten metal and method for adjusting such a mold
US7192501B2 (en) 2002-10-29 2007-03-20 The Boeing Company Method for improving crack resistance in fiber-metal-laminate structures
JP4845697B2 (en) * 2006-12-05 2011-12-28 三島光産株式会社 Continuous casting mold

Family Cites Families (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2634633C2 (en) * 1976-07-31 1984-07-05 Kabel- und Metallwerke Gutehoffnungshütte AG, 3000 Hannover Continuous casting mold made of a copper material, especially for continuous casting of steel
JPS6039455B2 (en) * 1980-10-15 1985-09-06 日立造船株式会社 Mold for continuous casting equipment
JPS58218351A (en) * 1982-06-12 1983-12-19 Mishima Kosan Co Ltd Casting mold for continuous casting and its production
US4753050A (en) * 1986-06-02 1988-06-28 Penn Lehigh Crane Systems, Inc. Apparatus for cleaning and peening ingot molds
FI75748C (en) * 1986-08-15 1988-08-08 Outokumpu Oy A mold.
EP0498296B2 (en) * 1991-02-06 2000-12-06 Concast Standard Ag Mould for continuous casting of metals, especially of steel
GEP19991523B (en) * 1992-03-05 1999-03-05 Concast Standard Ag Method for Continuous Casting of Metal, in Particular Steel
DE4208446A1 (en) * 1992-03-17 1993-09-23 Schloemann Siemag Ag Producing elongated edge on wide sidewall of a concasting mould - by shot blasting the plate when it is clamped along three sides
FR2708940B1 (en) * 1993-08-12 1995-09-22 Snecma Method of hardening metal parts.
US5499672A (en) * 1994-06-01 1996-03-19 Chuetsu Metal Works Co., Ltd. Mold for continuous casting which comprises a flame sprayed coating layer of a tungsten carbide-based wear-resistant material

Also Published As

Publication number Publication date
GB2332635A (en) 1999-06-30
DE19781990T1 (en) 1999-08-12
GB2332635B (en) 2000-07-05
DE19781990B4 (en) 2009-01-02
JP2000517246A (en) 2000-12-26
BR9711826A (en) 1999-08-31
AU4084497A (en) 1998-03-26
WO1998009750A1 (en) 1998-03-12
GB9904231D0 (en) 1999-04-21

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